VW Tdi injectors, check yours!

Trevorleach · Aug 3, 2023

Seat cutters are a good idea as well, not to actually cut the seta, more to help clean them up.
Annealed washers (new and old) also help a lot.

Colin Barron · Aug 3, 2023

armalites said:
I doubt they can guarantee that, whilst their service may well be good they claim to be AA prices but when you dig deeper they don't cover vehicles over a certain age and they won't recover a big trailer.

I have been with them for over twenty years and used their recovery three times, once with the caravan . At one time they guaranteed the hour with a cash back for missing the hour point, i don't think they do that anymore. One advantage over rip off AA is that they don't inflate the premiums year after year, only an inflation level increase. Also it is the person who is insured, so if you were in someone else's car when they broke down they would recover it. our premium for both my wife and i is just over £100 pa, recovery but not home start. It is the Caravan and motorhome rate.

Monkey Harris · 2025-10-21T14:59:22+0100

hi guys thread revisited ..

i had a snapped injector bolt,

i've drilled and got it out...

rebuilt every thing new washers seals etc,
not expensive,

now I'm at the point of tightening the stretch bolts ..

and need advice

there are various settings out there ,
8nm and 180 deg
8nm and 270 deg...
these bolts are 6mm and look delicate ...

Monkey Harris · 2025-10-21T16:59:36+0100

Monkey Harris said:
hi guys thread revisited ..

i had a snapped injector bolt,

i've drilled and got it out...

rebuilt every thing new washers seals etc,
not expensive,

now I'm at the point of tightening the stretch bolts ..

and need advice

there are various settings out there ,
8nm and 180 deg
8nm and 270 deg...
these bolts are 6mm and look delicate ...

This kit is great for extracting snapped bolts in side parts...

OJCar · 2025-10-21T19:00:11+0100

Monkey Harris said:
This kit is great for extracting snapped bolts in side parts...

Link to a supplier please.

Dutch Welder · 2025-10-21T20:25:33+0100

Not the same kit, but has the same function.
Facom part 885

I did 8nm and 180 ish on mine, did not dare any more.
No problems with leaking or such things for 60k miles

Monkey Harris · 2025-10-21T20:42:34+0100

OJCar said:
Link to a supplier please.

Blue spot..
Local..
Machine mart

Monkey Harris · 2025-10-21T20:44:06+0100

Dutch Welder said:
Not the same kit, but has the same function.
Facom part 885

I did 8nm and 180 ish on mine, did not dare any more.
No problems with leaking or such things for 60k miles

Sounds good...
Thanx..

T5 TDI · 2025-10-21T21:14:16+0100

I fitted a new head to my 2.5 PD van (AXE engine code) a few months ago and the injector clamping bolt in the VW manual was listed as -

5 - Clamping block 6 - Bolt ❑ Renew after removal ❑ 12 Nm + 270°

I never got it to 270° in fact I stopped at 180°. The size of bolt and application made every one of my 'don't do it' senses jangle all the way down to my right arm which refused the instruction to turn the already creaking bolt further! Have you aligned the injectors on yours? I didn't have VW tool T10210 so I made a similar but crude tool taken from the original positions of the injectors. I see that on some vehicles a measurement from the edge of the head is used for this using a giant pair of calliper's. I found that two of my (original) injectors had turned quite a bit in the old (original) head and it had been running fine and VCDS was showing no differences in the live data for the injectors. Mine is the fun but notorious gear driven 2.5 174ps engine so I couldn't vouch for the spec's on another PD.

Ubique · 2025-10-21T22:22:59+0100

Just to correct my earlier 'from memory' tightening sequence, the VW 1.6 TDI is:-
8Nm + 270 degrees
VW 2.0 TDI is:-
8Nm + 180 degrees

These are from the WIS on ELSA Pro this time, not memory!

Dutch Welder · 2025-10-21T23:20:44+0100

T5 TDI said:
I fitted a new head to my 2.5 PD van (AXE engine code) a few months ago and the injector clamping bolt in the VW manual was listed as -

5 - Clamping block 6 - Bolt ❑ Renew after removal ❑ 12 Nm + 270°

I never got it to 270° in fact I stopped at 180°. The size of bolt and application made every one of my 'don't do it' senses jangle all the way down to my right arm which refused the instruction to turn the already creaking bolt further! Have you aligned the injectors on yours? I didn't have VW tool T10210 so I made a similar but crude tool taken from the original positions of the injectors. I see that on some vehicles a measurement from the edge of the head is used for this using a giant pair of calliper's. I found that two of my (original) injectors had turned quite a bit in the old (original) head and it had been running fine and VCDS was showing no differences in the live data for the injectors. Mine is the fun but notorious gear driven 2.5 174ps engine so I couldn't vouch for the spec's on another PD.

That's on a different engine.
The 1.6 tdi uses 1 clamp to hold 2 injectors (something to do with the upwards momentum of the injectors cancelling out each other) and I do not think you can rotate the injectors at all, maybe 1 or 2 degrees, the slot in the clamp is a tight fit over the 2 flat sides on each injector. (You can probably fit the injectors 180 degrees off, but that way the diesel return pipe will never fit, as the hard pipes are bent in a certain way to reach the run off fitting on the injector) and as one would usually fit new copper burn rings on an injector I don't think mounting them in exactly the same position is adamant.

Monkey Harris · 2025-10-21T23:47:37+0100

Dutch Welder said:
That's on a different engine.
The 1.6 tdi uses 1 clamp to hold 2 injectors (something to do with the upwards momentum of the injectors cancelling out each other) and I do not think you can rotate the injectors at all, maybe 1 or 2 degrees, the slot in the clamp is a tight fit over the 2 flat sides on each injector. (You can probably fit the injectors 180 degrees off, but that way the diesel return pipe will never fit, as the hard pipes are bent in a certain way to reach the run off fitting on the injector) and as one would usually fit new copper burn rings on an injector I don't think mounting them in exactly the same position is adamant.

Yea that's mine..

premmington · 2025-10-22T01:55:27+0100

Ubique said:
Just to correct my earlier 'from memory' tightening sequence, the VW 1.6 TDI is:-
8Nm + 270 degrees
VW 2.0 TDI is:-
8Nm + 180 degrees

These are from the WIS on ELSA Pro this time, not memory!

I did a 66plate 2.0 TDi passat today.

AD said and Haynes E3 both said.

Use new bolts.
Tighten bolts in the following stages:

Install injectors and clamps and finger-tighten bolts.
Finger-tighten injector pipe unions and align injectors.
8 Nm + 270°

T5 TDI · 2025-10-22T10:17:07+0100

Dutch Welder said:
That's on a different engine.
The 1.6 tdi uses 1 clamp to hold 2 injectors (something to do with the upwards momentum of the injectors cancelling out each other) and I do not think you can rotate the injectors at all, maybe 1 or 2 degrees, the slot in the clamp is a tight fit over the 2 flat sides on each injector.

Yes, mine only has a single bolt. it can move about 30 degrees in the slot. Just in case anyone comes across this, it has this tool to align it. The fuel goes through a gallery in the head direcly into the injectors.
If you get a 100-150k miler example of this engine with poor starting when left overnight with no fault codes and all live data normal, suspect injector bores in the head worn by uneven pressure from the single bolt.

pedrobedro · 2025-10-22T11:39:28+0100

OJCar said:
Link to a supplier please.

Blue Spot Bolt Extractor Kit

For those who think it's easier to annoy you than to Google 'Blue spot bolt extractor kit' themselves.

letmegooglethat.com

Here's the one I found

Blue Spot Tools Stud and Bolt Extractor 25pc Set 22311 Bluespot | Sealants and Tools Direct

Discover the Blue Spot Tools Stud & Bolt Extractor 25pc Set at Sealants & Tools Direct. Find reliable solutions for your projects.

www.sealantsandtoolsdirect.co.uk

Monkey Harris · 2025-10-22T12:31:09+0100

That's the one... :thumbup:

Monkey Harris · 2025-10-22T12:34:22+0100

Dutch Welder said:
Not the same kit, but has the same function.
Facom part 885

I did 8nm and 180 ish on mine, did not dare any more.
No problems with leaking or such things for 60k miles

I've done mine.. Today :thumbup:

Borrowed an expensive digital torque wrench,

and tightened it
8nm and 200 deg
Seemed tight for a 6 mm

Woody.v8 · 2025-10-22T19:05:23+0100

Just done my om651 sprinter ones,
Noticed some black death on a service so cleaned it all up and recut seats , installed new seals and clamp bolts and it's as good as new up to now.

Monkey Harris · 2025-10-22T19:22:09+0100

Woody.v8 said:
Just done my om651 sprinter ones,
Noticed some black death on a service so cleaned it all up and recut seats , installed new seals and clamp bolts and it's as good as new up to now.

A messy one..

Monkey Harris · 2025-10-22T19:27:23+0100

I've done my repair..
Snapped bolt
Put it all back together.. And it won't start..

Opened each injector pipe fuel there's fuel at each,
flowing back in leak off pipes..

Arista obd says low fuel rail pressure...

Any ideas....?

VW Tdi injectors, check yours!

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