Club 80-90 Forums

Me again, had the van towed to garage for a knock in engine and found injector was stuck open.

Garage have just rang to say it happened again on test drive and they dissembled the injector and found "a big chunk of metal" in it.

They rebuilt the injector and took it out again only for knock to return and another different injector to be stuck open again with metal on the inside. They have took apart the fuel pump and inspected it and found no issues however they have found metal in the fuel filter.

Has this happened to anyone before? The garage thinks the metal in the injectors should be too big to go through the fuel filter and so don't think it's the fuel tank. They think it may be the injection lines but these were changed to new ones less than a month ago.

The garage don't know what to do and to be honest neither do I so any help or suggestions would be much appreciated

Poor quality new injection lines perhaps

I bought them from bw and when I looked all the people who sell them seem to get them from same manufacturer.

I would hate to buy another new set just for the same issue to arise but I guess its either that or fuel filter if pump has been ruled out

Fragments from broken injector pipes ?

Looks like I will just have to fire the parts cannon and see what works! New injector lines and fuel filter here we come

You had a problem with the thread on one of the injectors maybe that’s the source of the metal debris,maybe the leak off pipes allowed debris to spread to the other injector.

Good thinking, I will pass it on to the to the diesel specialist and see what he says cheers

Just spoke with garage and he said he's taken all the injectors out and found metal in 3 of them, said its new looking metal not rust so looks like it must be coming from the new pipes. all injectors look good and doesn't think its coming from the injectors themselves

Going to order a new set of pipes and hopefully that will solve the issue

Followed your other thread with interest.

Does your garage really have the kit to strip down and rebuild IDI injectors and the pump?? Any pics of the metal fragments?

mrhutch wrote: ↑01 Jun 2022, 09:22 Followed your other thread with interest.

Does your garage really have the kit to strip down and rebuild IDI injectors and the pump?? Any pics of the metal fragments?

Injectors are easy to strip , the testing equipment is very simple too, fuel pumps aren’t all that complicated either but the testing equipment is a little more complicated

davidoft1 wrote: ↑01 Jun 2022, 09:49 Injectors are easy to strip , the testing equipment is very simple too, fuel pumps aren’t all that complicated either but the testing equipment is a little more complicated

Agreed chap - just wondered if they have the kit to set the pop pressure on the injectors, and are willing to open up an old IDI pump then they must be pretty clued up on older diesels. would love to see the metal fragments from inside the injectors - they must be tiny.

OP did you fit the metal-rubber support bars on the injection pipes when you fitted them?? Maybe fragments of the inner walls of the pipes are coming away if the pipes are still vibrating ?

Not sure what equipment would be needed but he is a bosh diesel specialist with a garage attached so I would hope he knows what's what.

I don't have pictures of the metal fragments but he said you can see them with the naked eye which is a bit concerning as usually need magnifying glass to see whats blocking injectors. Said has found the same fragments in the fuel filter so must be recirculating.

He definitely thinks it's not coming from fuel tank as is bright silver said when they used to make the pipes themselves they had to be flushed out as metal did get into them during manufacture so reckons this might be what caused it. He is currently stripping all injectors and bench testing the pump again.

VW told him pipes obsolete and pointed him heritage parts who are out of stock with no date of new stock. Have ordered myself through bw again and just getting them sent to him.

On another note my engine timing was spot on but my pump timing was set at 80 when the dial gauge said 90 when I set it so need to get to the bottom of that one if ever have to do it again (hopefully not)

Garage sounds spot on.

Did you fit the pipe supports in the end?

The support clamps were on for my ill fated 300m test drive but were removed when re checked the timing after the noise appeared.

It has only idled and drove 300m by me and whatever distance the garage took it on test drive so you wouldn't think it wasnt enough time to degrade the pipes

Update, had new injector lines fitted after being flushed, pump rechecked injectors checked and new fuel filter fitted.

The garage have took it on along test drive and said it ran great but the noise briefly returned but went away again. (more metal in a injector? )

They have said it should be fine but suggest dropping the fuel tank and cleaning it out when I get it home to get rid of any metal fragments that have returned to the tank.

I'm bit wary of driving home only for the same issue to reappear but I can't think of anything else to check? Any ideas?