Injector Deviation Readings - 1.6 TDi CAYC

[Overdose]

It looks like T10402 is the number and I've found an alternative from Sealey. I've also dismantled one of the failed injectors to see how it all goes together and I think I can make a puller using the solenoid ring nut.

[Crasher]

T10055A slide hammer with T10402/1 and 2 attachments.

[Overdose]

So, now I find that the slide hammer is too long to fit under the bulkhead panel. Presumably this needs to come out too?

This car is a nightmare of crap engineering design...

[Crasher]

The VW slide hammer is very short and fits in the space. Modern cars are extremely hard to work on.

[mickeybo]

On your vehicle you have 2 fuel trims neg & pos. pos fuel trim causes a too lean a mixture & neg fuel trim causes a too rich a mixture. Both the 2 trims can be checked out

[Overdose]

I've finally manage to remove the last injector with a combination of the removal tool body, some 8mm studding, penny washers and a 2Kg dumbbell weight!
It would definitely appear that someone else has been at these injectors in the past. Injectors 1 and 2 have different washers to 3 and 4 and the are not even the same thickness. 1 and 2 also don't appear to have had an O-ring on the body, so a bit of a lash up really.
I have also noticed that 1 and 2 injector bores look ovalised, as if the injectors have been rattling around, possibly due to ineffective clamping caused by fitting the wrong sized washers?

Anyway, aside from being given the wrong shape of rocker cover gasket, I'm ready to put this all back together. I'll update when done, I'm really hoping this cures the fault...
IMG_3033.jpg

[Overdose]

I've finally got the injectors back in and the deviation figures are much better, but I'm sure that there is blow back through No.1 and possibly 2, as the figures are not low enough. This is possibly because of the ovalised injector nozzle bores and is possibly why different washers were used. I'll need to investigate a slightly large size to accommodate the wear.

Edit: I've just fitted two larger washers and things have improved, but No.2 still must have a small leak. A still larger washer might be needed or presumably a reseat?

[Crasher]

You can get a cutting tool but if the locations are worn I would be looking at a new AMC head.

[Overdose]

I'm going to consider this fixed for now. The injectors were definitely the issue, but ideally the seats could be better.

At around the time I decided to replace the injectors, I got a low oil pressure warning, investigation revealed a blocked pick up, with carbon deposits, tissue paper and small aluminium chips being the culprits.

The crank bearings appear to be ok and there was not much in the way of chips in the oil, so quite possibly residual from whatever work had gone on before. The sump had been off at some point in the past and the previous owner had the turbo replaced due to a blocked oil supply. There are currently no fault codes, the engine seems to run smoothly and the mpg is back to where it should be. To say that I am relieved, is an understatement.

To Crasher, thank you very much for your help and input.