Passat B6 Injector Replacement

[DieselMonster]

If you can check it then check it. Do the small tests first before jumping on replacing the injector.

[KeithSAFC]

Thank you. Will let you know how I get on. Power relay and injector test tomorrow morning!

[DMitch16]

Thank you. Will let you know how I get on. Power relay and injector test tomorrow morning!

Will be keeping an eye out as I have removed injectors many a time and with no special tools. Some rope, a long bar and a foot long 2 x 4 wood block are handy. Injector seals can tear easily on installation so a proper tool or careful approach is necessary. I use a bit of oil and some insulting tape to form a cone to install them over any rough edges of the injectors.

[KeithSAFC]

Thanks Mad Mitch, I’ll keep you posted

[Lizard821000]

Crasher I need some advise on an old 2.5tdi v6 motor mate if I can message you about it? I can’t seem to pm you

[KeithSAFC]

Ok. Power supply relay bought and fitted. Battery flat and so it my booster pack 😢
So can’t see if it has made any difference. Booster pack on charge and waiting for a friend to drop off a battery charger so I can get the battery charged overnight then go for round 2 in the morning! Not the start I wanted it needed!

[KeithSAFC]

Another update.
Battery was charged overnight on Saturday, fitted and she still failed to start with the new relay. Got her towed back home so I’m not backwards and forwards all the time. Rocker cover removed and tried to remove the injector loom. As Diesel Monster correctly said, the loom plugs started breaking as soon as I looked at them. New loom bought today (£119) as I needed it anyway. On removing the first plug from injector 1 (I think, nearest driver side) I tried to start it and she fired straight up on 3 cylinder which leads me to believe that this is faulty injector. Would that be right? Next step is to remove the injector and replace.

[KeithSAFC]

Okay, to remove injectors, valve/cam cover needs removing. Then rocker shafts need removing. Then the injectors can be removed. You need a special VW tool or a home made slide hammer. They don't come out easily. The injector harness is very prone to failure too so that may need replacing if you damage it when removing it off the injector. Then when installing the injector, you need new injector seals, bolts, rocker bolts and adjust the injector position/lash and torque all bolts down with torque wrench following proper bolt sequence. For a first timer, it isn't straight forward, I haven't had the pleasure of doing it but there are many steps.

If you need a proper guide on doing it I can provide it, that is if you choose to do the job yourself.

Check your DM too.

ive tried to DM you but not sure if they’ve sent as not appearing in my sent items. A proper guide would be great if you don’t mind. Thank you

[Crasher]

That is THE sure way to prove an injector is faulty, what is the part number on the body?

[KeithSAFC]

That is THE sure way to prove an injector is faulty, what is the part number on the body?

I’m not sure. Will check in the morning and let you know