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If anybody can offer any useful info or similar experiences I'd be very grateful for the help with this on-going problem. I've owned my 888 (88hp) "special" for over 7 years now and it's always smoked a bit after being left ticking over for a while more when it's cold but the longer you leave it the worse it gets and takes ages to clear once you've started driving. It also smells of neat diesel fumes, very toxic. It doesn't burn oil really and it only has 130K on it even now. I've had the injectors tested and refurbed by a local specialist and they were said to be fine. The timing I'm told is spot on and also had a new injection pump belt and checked again. The mis-fire also is a bit of a mystery too. No loss of power, always pulls fine and good on long runs too but terrible misfire when idling and slightly worse when engine is hot. It's also had a new camshaft and followers to cure tappet noise(turned out to be brake vac pump noise, but you live and learn). I was hoping to persevere with this van as its part of the family but don't want to chuck loads of cash at the engine and get nowhere. My worst fear would be injection pump as it looks expensive particularly if that's not the problem.
If there are any experts out there who can steer me in the right direction or know of any local Tdi experts (Crewe, Cheshire area), I would be very grateful and interested to hear what you know. It's been driving me round the bend for over 3 years now. Cheers.:rolleyes:
 

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Your van is suffering from a very common ailment that exclusively affects the AJT - it's widely known as Stanadyne disease; there is a full & simple cure: change the injectors to PP0.5 (Bosch) from forum member Rake or here: United Diesel Fuel Injection Contact Us. Incidently the 'local specialist' has tucked you up as refurbushment of Stanadyne injectors would mean replacing the nozzles & these are not available.

HH
 

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Discussion Starter #3
Your van is suffering from a very common ailment that exclusively affects the AJT - it's widely known as Stanadyne disease; there is a full & simple cure: change the injectors to PP0.5 (Bosch) from forum member Rake or here: United Diesel Fuel Injection Contact Us. Incidently the 'local specialist' has tucked you up as refurbushment of Stanadyne injectors would mean replacing the nozzles & these are not available.

HH
Thanks for the info HH. I'll certainly look into this. Are you suggesting the injectors would cure excess smoke and mis-fire? That would be the ideal outcome I guess. Does changing the injectors require any other adjustments ie. ECU re-map to suit? Sorry for all the questions but having put up with these problems for so long I'm determined to sort it.

Cheers.
 

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Look for AFN engine injectors, they bolt on and will require no mapping i you want to stay stock...you will need a set + one extra injector to make up a set. One pipe will need careful bending...
 

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If anybody can offer any useful info or similar experiences I'd be very grateful for the help with this on-going problem. I've owned my 888 (88hp) "special" for over 7 years now and it's always smoked a bit after being left ticking over for a while more when it's cold but the longer you leave it the worse it gets and takes ages to clear once you've started driving. It also smells of neat diesel fumes, very toxic. It doesn't burn oil really and it only has 130K on it even now. I've had the injectors tested and refurbed by a local specialist and they were said to be fine. The timing I'm told is spot on and also had a new injection pump belt and checked again. The mis-fire also is a bit of a mystery too. No loss of power, always pulls fine and good on long runs too but terrible misfire when idling and slightly worse when engine is hot. It's also had a new camshaft and followers to cure tappet noise(turned out to be brake vac pump noise, but you live and learn). I was hoping to persevere with this van as its part of the family but don't want to chuck loads of cash at the engine and get nowhere. My worst fear would be injection pump as it looks expensive particularly if that's not the problem.
If there are any experts out there who can steer me in the right direction or know of any local Tdi experts (Crewe, Cheshire area), I would be very grateful and interested to hear what you know. It's been driving me round the bend for over 3 years now. Cheers.:rolleyes:
Same issue here with my AJT ...........switched from supermarket diesel to BP/Shell/Esso diesel still have a little bit of lumpyness and smoke on cold start but once warm now have 100% improvement !! Runs a lot smoother and no smoke on idle.
 

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Same issue here with my AJT ...........switched from supermarket diesel to BP/Shell/Esso diesel still have a little bit of lumpyness and smoke on cold start but once warm now have 100% improvement !! Runs a lot smoother and no smoke on idle.

Thanks for the post. I wonder if anyone has owned an AJT which didn't smoke! I generally use Shell as it's the nearest one to me but still smokes like Puffing Billy in a morning. It's looking like injectors all the way and if that doesn't cure it then it will be a can of fuel and a box of matches. :eek:
Thanks for everyone's input and I'll post some news when I've done something about it..
 

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I do still get blue smoke but mostly in winter though vast improvement using better diesel. Blue smoke is usually a sign of seal damage Im told but Im no mechanic so cant be sure.
Many AJT ACV owners on here have gone down the PP injector /remap route which is around a grand fifteen hundred all in but Im not convinced this is a cure for smokey vans. I know a few T4 2.5 tdi owners round here who all have smokey vans I personally think it is some thing more to do with the timing pump injector timing maybe.

I don`t know any one who`s had the PP injector do da upgrade so dont know for sure if this is the answer.
 

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Hi Adam,

You seem quite knowledgeable. I am intrigued by your suggestion of AFN injectors for AJT engines. We are normally advised to change to ACV 102 Bosch injectors in every post I have read on this forum so far. As far as I can see AFN injectors cost a lot less than the ACV ones therefore I wondered why this has not been suggested before by anybody.
Cheers
 

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Because most folk working on t4's don't also work on other diesels... I have audi a6 c4 2.5 tdi injectors in my van, basically a 2.5 tdi engine is a 1.9 tdi with an extra piston grafted on...the slogan for the 2.5 tdi back in the day was "powerful like a 6 cylinder engine and frugal like a 4 piston engine !''...
 

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Thanks Adam, makes sense. You are essentially suggesting getting 5 AFN injectors? Excuse my ignorance but I thought one of the injectors in 2.5 TDI was somehow a little different the others,?pilot injector or something. Is that something easily overcome?
 

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AFN injector set also have a needle lift sensor (the injector with the cable), you will need an extra injector as the afn is only a 4 pot engine...
 

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I suggested going from stanadyne injectors to bosch by using AFN inejctors as they are a cheap alternative to ACV injectors and miles better than stana's. Bosch injectors are 2 stages so quieter and more economical at the same time. I personally go with larger injectors as they can be turned down in the map...have extra scope for tuning later down the road if more supporting mods are added into the mix !
 

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We have been supporting the T4 community with replacement injectors for these for over 14 years.
As others have said the cause of the issue is the crappy stanadynes fitted to the 88.

What we offer is a complete set of Bosch injectors that have been professionally reconditioned and fitted with our PP0.5 nozzles.
This not only gives you the benefit of fully reconditioned units that wont let you down as buying second had ones will, they also give about 120 bhp on installation with no need to remap. We developed these injectors to be a direct replacement of the stanadynes to a much more reliable Bosch set.

I would not recommend buying used injectors - false economy.

Please feel free to contact me directly via pm or phone and Ill be more than happy to advise.

Regards

Ron
 

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Alternately buy a set of 0.216 bosch nozzles like these on ebay or any decent members

://www.ebay.co.uk/itm/Set-of-FIVE-VW-2-5-TDI-BOSCH-injector-nozzles-DSLA150P764-AHY-AXG-0-433-175-176/222751513790?hash=item33dd065cbe:g:TyUAAOSwqbxaLohl

get a set of used AFN/ALH/AHU/AHH Injectors + an extra one to make a set then take them both (nozzles and injectors) to your local diesel specialist and ask them to fit and pop test the new nozzles to 180 Bar.

Step 3 fit them to your car and enjoy clutch slip after previously you've done the hammer mod !

Another option is sourcing full set of AXG 150 Bhp injector off german ebay/breakers or even buy full set of injectors like these on ebay... there's a 200 euro core charge to pay but i'm sure you can send a set of injectors from breakers as core units...

 

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Much appreciated Adam, you are a star.
Not quite sure what you mean by clutch slip though, ?too much power for the clutch to cope with.
And I don't know what the hammer mod is, I am not a mechanic but I'll tackle things if I am given guidance.
Thanks again.
 

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Clutch will slip if worn and hammer mod is a procedure by which you bring down the injected quantities on idle so the engine will not gallop after large nozzles are fitted. I had that issue after fitting large injectors and hybrid turbo on my old t4 van...was a builder van with almost 300k on odometer.

Google hammer mod for exact procedure and values to achieve although some tuners will reduce injected quantities on idle in the map...ask your tuner what he fancies !
 

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Clutch will slip if worn and hammer mod is a procedure by which you bring down the injected quantities on idle so the engine will not gallop after large nozzles are fitted. I had that issue after fitting large injectors and hybrid turbo on my old t4 van...was a builder van with almost 300k on odometer.

Google hammer mod for exact procedure and values to achieve although some tuners will reduce injected quantities on idle in the map...ask your tuner what he fancies !
You can also adjust injection quantity in VagCom but it's a bit trial and error until you get it right. A little at a time is the way.
 

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I hope i am not pushing my luck but would like to ask something not quite related to this thread.
I read in one of the 'engine&gearbox' threads a few days ago someone mentioning a 'wobbling crankshaft throwing timing out'. I have not been able to relocate it hence the reason for bringing it up here. I wondered what the symptoms of a wobbling crankshaft would be apart from timing. Are there any physical manifestations at all such as noise, vibration etc? I have an issue with my 03 AJT Multivan that so far about 5 different garages failed to identify or cure!
I'd be grateful again for your advice.
 
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