Wednesday,21-December-2016
Touran TDI injector seals replace
ENHello,
this topic will be dedicated to Touran 1.9TDI engine type: AVQ. It belong to mate of mine and has some issues with idle and some stall when driving. Some advice are for replacing the injectors loom but also is possible to be some combustion gasses entering in the fuel line due problem with the copper seals.
- First you need to remove the valve cover. Maybe that is time for considering it seal replaced. In that case, have been undone all 10mm screws keepint the cover on place.
- Removed all preheating plugs(for that one later)
- Removed one 10mm screw from the EGR that keep pipe bracket(if you still have)
All that done, take the cover out and you should see something like that:
In all manuals I`ve seen, the main advice is to replace both bolt types(injector locker and injectors rocker arm shaft) with new one. In that case, we didn`t but if you do same is only you`r fault if something goes wrong after.
To reduce the tension over the screws I undo one by one them on half turns. Here you`ll need that VW triple torx bits(Mxx type)
When all removed you`ve get:
Now remove the injector locker. And here come the hard part. How to pull the injector out. Redneck way - crawbar. But that is joke of course. The VW tool is looking like that:
You can try with some belt, but what I have done was: use thick screw driver and side rib as base. Then gently push over the injector hexagon nut(over the wire plug).One side, back one side , back.. The idea is to rotate it around the injector valve axis. After few moves and really small pull it goes out:
Once that is done, replace all O-rings. The set used here, was one copper shim(in the set will be some small steel spring ring, that keep the copper shim on place.Put it on the nozzle after the shim), and three O-rings. To be easy for you find some thick paper and roll it as cylinder around the nozzle and put the O-ring over it. In that way you place them easy. Or use something similar to OEM kit:
And finally:
In the refit set was also the metal pusher situated over the top of the injector. That is kind of pain in the ass to replace and in my case was not necessary, but if you have it and wish give it a try.
Now fitting back:
- use some suitable for rubber O-rings grease to be easy to fit them back without issue
- by hand push the injector back on place and keep it position almost as it should be(coil on 90° against camshaft)
- is not such good idea to hummer on that area, but I use soft brass stick, touching the injector “base” behind the coil, on the right side. The little hit with something heavy fit it to the bottom.
- adjust the injector position based on that table:
- tight all injector lockers on place with right torque:
- fit on place the rocker arm shaft, and again tight on right Nm(based on the upper info)
Now the injector piston adjustment. Put the car on 4th or 5th gear, rise one wheel(is easy in that way to rotate the engine by hand) and use that diagram:
Refit the injector plugs, head cover and so on..
Good luck!
Extra info:
Injector numbers for reference if needed:
And here how the injector bed and injector itself get wear because the way it been pushed by the rocker arm.
