Pd Injector Seals

[davey_boy]

Pd Injector Seals Part No: 038 198 051 C Are £15.16 + Vat From ********

Phone Morris On 01257 239200, Quoting The Bosch Part Number:
1 417 010 999 And Get The Same Seal Kit For £4.25 +vat

Hope This Helps Someone

[Crasher]

When replacing the injector seals they MUST be fitted using VW tool set T10056 or the seals may be damaged. When refitting the injectors they MUST be aligned to the correct measurement to a tolerance of +/- 0.8-mm using a very large set of vernier calipers and also the injector hold down bolts MUST be replaced. Failure to follow the last two steps may result in four wrecked injectors and a ruined cylinder head, just like the one I am working on at the moment. A new head and injectors is £2.4K plus fitting.

[davey_boy]

Crasher, is it also necessary to replace the 8x rocker arm shaft bolts?

[Crasher]

Yes, they are torqued to 20Nm + 90°. They must be removed outer first and then inner and refitted inner first and then outer.

[davey_boy]

part numbers for bolts required

(8) x Rocker arm bolt: 038 103 714 A £4.15 + vat each

(4) x Injector clamp bolt: 038 103 385 A £1.70 + vat each

Around £47.00 for the lot with vat, these must be made of solid gold!!!!

[davey_boy]

Link for write up on changing the injectors with pics and video:

http://forums.tdiclub.com/showthread.php?t=138041

Hope this helps someone

[Crasher]

That write up doesn’t mention the critical alignment as pointed out by a subsequent poster, the necessary replacement of the bolts or the fact that replacement injectors must have their basic setting carried out which is quite involved to do.

[davey_boy]

Fair comment Crasher, I am going to do the job this weekend if my seals and bolts arrive in time, I will endeavour to compile a more thorough write up detailing all the finer points of the job. Hopefully will be of assisstance to someone.
Interestingly enough, I was advised by a ******* technician to re-use the rocker-arm and injector retaining bolts, apparently he re-uses them routinely at the ********. Just goes to show you don't always get what you think you are paying for.

[Crasher]

When I get time, and before it goes back for exchange, I will take pics of the one I am doing to show what happens when the bolts are re-used. These so called “Master Techs” that completely ignore the workshop info really annoy me. They put themselves on a pedestal as being something special and then do as they please, completely unacceptable. Independents like myself have to work themselves to death to maintain a good reputation and keep a living coming through the door, the dealers (please don’t call them ********) have it handed to them on a plate and that just breeds arrogance and complacency. I know a few who have broken away and gone indi and to a man they tell me it is such a shock, some end up going back.

[davey_boy]

Sounds like you have a true engineers mentallity Crasher, could do with more people like you at our place. Just out of interest, as an independant, where do you obtain the VW workshop tools you mention?