Club 80-90 Forums

Hello!

I’d like to share my experience removing diesel injectors from a 1.7KY diesel engine.

Parts used:

• Laser 6851 Diesel Injection Line Wrench 17mm
  
• Halfords 27mm 1/2 deep socket (requires modification)
  
• WD40 specialist Penetration fluid
  
• Breaker bar
  
• Paperclip
  

Steps taken:

• Soak injection pipe in penetration fluid. Leave for 30-60 minutes.
  
• Using 6851 wrench (equivalent to VAG 3035) remove injection pipes. This was really easy with this tool. For all the cost of it I’m glad it was bought as there was no slipping or damage to any parts.
  
• Trying to use the 27mm socket on the now exposed injectors without modification did not work - the socket wasn't deep enough to sit on the nut and was sitting on the threads of the injector. Due to this only the top quarter of the nut was contacted and would slip when trying to untighten the injector.
  
• More penetrating fluid was used on the injectors where they met the Alu head - this was left for 24h
  
• A 13mm drill bit was used to enlarge the hole in the socket - this allowed the socket to slip over the threads at the top of the injectors.   
  
• You can see the result of this modification in this video.
  
• 
  
• Electrical tape was used on each of the threads at the top of the injector to stop them getting damaged.
  
• A breaker bar was used and eventually all 4 injectors were removed. They were very stiff, I do not think this would have been possible without a breaker bar in our case.
  
• A paperclip was fashioned into a tool to remove the fire seal washers.
  

Hope you find this useful.

brilliant..  post more!
 

whats the plans with the 1.7?  upgrade/refurbish?

Great descriptiin. It needs to be arvhived and put into wiki.

Glad you found it useful. We have found this forum helpful so we want to continue where we can.

Plans are to keep the 1.7 working.
It’s had a new timing belt, oil, fillers so we were a little dismayed when it started rattling, cutting out and belching smoke 5mins from the MOT centre.

We have read the 1.7 is very reliable and I think that’s the case. We have been driving around with dirty fuel, no air box and bad injectors - so it needs saved!

Hopefully the injectors are the source of the issues.

ZsZ wrote: ↑19 Mar 2023, 04:48 Great descriptiin. It needs to be arvhived and put into wiki.

Handy tip, web pages can be saved as a pdf on an iOS device into the books app, use the share button at the bottom of the screen. Handy for those things you know you’re going to need in due course, but also know you’ll spend ages thinking “Now where did I see something about this??”

I have a folder (or Collection) in my books app for such things.

There are proper injector sockets available, 27mm stock sockets aren’t usually machined with enough clearance as you’ve found, instead of just changing the injector have them tested by a fuel injection specialist or buy an injector tester, can be found used quite regularly or new aren’t crazy expensive, have you checked valve clearances?

davidoft1 wrote: ↑19 Mar 2023, 17:10 There are proper injector sockets available, 27mm stock sockets aren’t usually machined with enough clearance as you’ve found, instead of just changing the injector have them tested by a fuel injection specialist or buy an injector tester, can be found used quite regularly or new aren’t crazy expensive, have you checked valve clearances?

We are sending them away for testing to a local company. No plans to replace unless required. The company’s pricing seems reasonable also even for refurbishment it’s less than half the cost of what I see online for an exchange service.

Not checked valve clearances - would you recommend we do so?

Sans wrote: ↑19 Mar 2023, 17:15

davidoft1 wrote: ↑19 Mar 2023, 17:10 There are proper injector sockets available, 27mm stock sockets aren’t usually machined with enough clearance as you’ve found, instead of just changing the injector have them tested by a fuel injection specialist or buy an injector tester, can be found used quite regularly or new aren’t crazy expensive, have you checked valve clearances?

We are sending them away for testing to a local company. No plans to replace unless required. The company’s pricing seems reasonable also even for refurbishment it’s less than half the cost of what I see online for an exchange service.

Not checked valve clearances - would you recommend we do so?

As they’re old school type injectors test and rebuild is pretty cheap , my modern vw are £500 each new

I would do a compression test as the injectors are out , new heater plugs , definitely worth checking valve clearances too

+1

and obvs new flame traps

Long time since I updated this.

The injectors were sent away for testing and all were reported to be within spec. That’s good news and bad news…

Next we went onto compression testing. I have photos to upload but I’m on my phone at the minute and it always times out, causing me to lose everything. I’ll get to that later

With regards compression testing;

We removed the wire coming from the fuel cut off solenoid but we still have fuel coming out of the main delivery feed when cranking the engine.

Does anyone know why this might be?

The manual only makes reference to the solenoid spade connector so that’s all we have removed (and that’s the only other connector I can see on the pump!)

So far I had to make do with holding a rag to the fuel line while my partner cranked the engine.

Sadly the results are not looking great - suggesting the piston rings are worn out.

We will attempt another dry test with new fire seals soon.