VW TD leaking past injector

[hsmidy]

I know not a toyota but hey i know there are a few diesel savy guys here so i thought id give it a shot.

so its a 2.5l turbo vw engine.

bit of back ground the ecu is telling the pump at idle to inject .56 mg per stroke(it varrys a little bit ) more into 1 cyl and has cut the rest right back.

So its trying to up the power on that cyl (also theres alot of unburnt fuel coming out the exhaust)
so I changed out the injector on that cyl thinking it might be a bad injector...no luck still injecting the same amount to that cyl.

right so here is my problem , doing a soapy water test around the injector and glow plug on that cyl there is some air leaking past the injector, only thing sealing the injector from the chamber is a cooper washer.

the injector is only held in by a fork like bracket that goes either side of the injector and a single bolt holds it down in place. when tightened to factory specs air pisses out, a bit more pain on it and it and air still leaks past, the head is alloy so i dont want to tighten it too much.

soooooo long story short any ideas on how to get this injector to seal in the head?

oh and yes a new cooper washer was used.

[DVSMOTORSPORT]

Not sure about VW motors, but usually there is more than just the copper washer. Generally from memory there is a small crush washer at the tip of the injector, then the copper washer and then an Oring as you head up the rest of the injector.

But DO NOT over tighten that injector

[hsmidy]

sorry the cooper washer i was talking about is the cooper crush washer around the tip of the injector.

but yeah thats it nothing else in there to seal it.

[DVSMOTORSPORT]

Any chance of some pics of the injector, and maybe the hole it goes in?

[Phothog]

sorry the cooper washer i was talking about is the cooper crush washer around the tip of the injector.

but yeah thats it nothing else in there to seal it.

Sounds like you have a VW CRi system there, Whats the vehicle model/engine?

Have you put a new injector in or just swapped it over from another cyl?
Whats the numbers off the injector?

Did you resurface/recut the washer sealing surface?

Chris.

[hsmidy]

No its running a bosch vp37 pump and two stage direct injection

might be able to get some pics up come tuesday.

Yes it is a new injector,again the numbers will have to wait till tuesday.
and no the washer sealing surface hasnt been touched.

[DVSMOTORSPORT]

Did you resurface/recut the washer sealing surface?

This interests me, Ive never heard of recutting the sealing surface before. Im used to Jap/denso systems.

[Phothog]

This interests me, Ive never heard of recutting the sealing surface before. Im used to Jap/denso systems.

We havent recut any toyota/nissan seats yet.
but we have done heaps of euro ones...
using something like this....

http://www.taiwantrade.com.tw/MAIN/en_front/searchserv.do?method=listProductProductDetail&locale=2&MEMBER_TYPE=4&WEB_OPEN=0&DOMAIN_NAME=tienchien&DOMAIN_NAME_FLAG=0&company_id=3779&catalog_id=255997&come_soon=0

Chris.

[DVSMOTORSPORT]

Hmmmm very interesting. Cheers mate.

[hsmidy]

The engine is a BBR 80kw engine.

injectors have this on them
074 130 203B BPX 220/300
0432193 511 FRANCE 937 48213C5

might have to look into one of those kits

[AE82 FXGT]

Wouldn't you need to space the injector out or use a thicker washer or something after cutting the seats?

As there will be more clearance?

[Phothog]

Wouldn't you need to space the injector out or use a thicker washer or something after cutting the seats?

As there will be more clearance?

The amount you take off is minimal, just enough to clean the seat up.

Chris.