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Good job lebowski!


In terms of gaskets, just replace the ones you have come across so far. You'll probably have to search through the online parts catalogue like this one to find the part numbers for each gasket (which should be cheap items from TPS):


http://www.oemepc.com/vw/main_group/markt/RDW/modell/TR/year/1998/hauptgruppen/1234567890/drive_standart/220/lang/e


Also, whilst you have the space, I'd suggest having a look at the plastic intake pipe into the intake side of the turbo. It's a known weak point where the plastic pipe expands over time and causes air leak. Easy hack shown on here:


2.5TDi Plastic Turbo Inlet Pipe Fix How-To (MAF to Turbo)



Carry on with the injector replacement (I've never touched those as I'm not confident on anything down there on the engine).



Good luck and keep us posted!
 

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Discussion Starter #24
Good job lebowski!


In terms of gaskets, just replace the ones you have come across so far. You'll probably have to search through the online parts catalogue like this one to find the part numbers for each gasket (which should be cheap items from TPS):


http://www.oemepc.com/vw/main_group/markt/RDW/modell/TR/year/1998/hauptgruppen/1234567890/drive_standart/220/lang/e


Also, whilst you have the space, I'd suggest having a look at the plastic intake pipe into the intake side of the turbo. It's a known weak point where the plastic pipe expands over time and causes air leak. Easy hack shown on here:


2.5TDi Plastic Turbo Inlet Pipe Fix How-To (MAF to Turbo)

Will do dude, ps i've no confidence either, just an ill advised compulsion! I:



Carry on with the injector replacement (I've never touched those as I'm not confident on anything down there on the engine).



Good luck and keep us posted!
Will do dude, ps i've no confidence either, just an ill advised compulsion! I:
 

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WTF? Are you serious :D

If you are, I'll get onto Barry ASAP

Yep...TOTALLY serious.
Ron (Rake) advised me to use it......injectors came out just using a spanner.T:
Since then, used it for many jobs where steel and alloy come into contact!
Just don't leave it on too long.
 

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So the PP 1 injectors have arrived (thanks Rake)
PP1 rather than PP0.5 ? not sure the pros and cons but would be interested to hear the logic/ reasoning. IIRC PP1 better for power but needs remap, PP0.5 good all round replacement, and doesnt need remapping immediately ? I'm more interested in torque than power, 300 Nm (AXG spec) would be great and a big upgrade from standard ACV / 250 Nm, this should be achievable with stock I/C and turbo ? and PP0.5 or PP1, that is the question ? !
top tip from Gaz/ Rake re the Cillit Bang, i'll try and remember that.
 

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Discussion Starter #28
PP1 rather than PP0.5 ? not sure the pros and cons but would be interested to hear the logic/ reasoning. IIRC PP1 better for power but needs remap, PP0.5 good all round replacement, and doesnt need remapping immediately ? I'm more interested in torque than power, 300 Nm (AXG spec) would be great and a big upgrade from standard ACV / 250 Nm, this should be achievable with stock I/C and turbo ? and PP0.5 or PP1, that is the question ? !
top tip from Gaz/ Rake re the Cillit Bang, i'll try and remember that.
I thought about the 0.5 but after chatting with Rake, the 1 seemed a better option. My van is already quite torqued up and in fact I had to mellow a previous remap as the extra torque was shredding clutches (even with Sache upgraded clutch!) :eek:
 

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Torque is my main issue...as I have an auto-box, and it's already 10% over-run (from the factory specs...which were again 20% MORE than the box could handle I think!!!)

Rake is very helpful T:
 

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Discussion Starter #30
Any ideas how to get these ers out!!!





Am starting to lose confidence, think I've bitten off more than I can choose, getting that 'oh no, will I remember where all the bits go' feeling :eek:
 

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i'm sure the experts on here will advise best way, but heat I guess is only way, after you've 'exhausted' (sorry, but it looks like EGR pipe :D) all the usual options, i.e. penetrating fluid etc etc.
thanks for the info btw.
 

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Discussion Starter #34
After yesterdays foray into hostile terriority the spoils and casualties are as follows:

Spoils::)
4 Injectors
EGR Pipe and nuts removed T:


Casualties :(
-15mm Spanner
-Size 5 Extra long Allen Key
-Large Molegrips
-2 Knuckles and 1 little pinky
-1 EGR pipe mounting bolt (slight evidence of coking up in the exhaust I:)


-1/4 of an injector



Thanks for all the help so far, just gotta get the snapped bolt out and the last bit of the injector, anybody got any ideas? See this thread for all the gruesome details :eek:

https://www.vwt4forum.co.uk/showthread.php?p=6496959#post6496959

Cheers folks
 

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Discussion Starter #35
Does anybody know if it's possible to work on the engine block with the engine still in? I think I'm going to have to get the last injector from the inside out! Thought it might be worth replacing the head gasket whilst i'm this far in now as well! Can this all be done still in the bay and is it tricky/requiring specialist tools?

Thanks dudes.
 

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Did you clean the cack out of the intake manifold or just fitted the delete pipe?

Photos please - need to sort mine out.
 

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Usual way is to just wipe as much out of the manifold as possible (wipe OUT...not inwards..LOL).
Cleaning the actual the old EGR pipe and fitting blanking washers avoids the need to buy a new pipe...just a couple of S/S blanking gaskets.
 

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Discussion Starter #39
I had a mechanic mate who had a groovy bit of kit, so he cleared out most of the shite using that, no photos I’m afraid, but it came out pretty clean and after the remap I’ve got zero smoke at any speed/revs and running better than it ever has before!
 
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