Thats the one plus side of 1 time use bolts on VW, lots of free spare hardware for projects like this

Thanks, hoping to get some good content on some power adders and swaps next.

I though it was a cool video to see what’s inside. I’ve got a future project that will need larger nozzles so I’m hoping to do some videos on pressure and flow testing these on a budget.

Off the top of my head I believe max boost was around 2600mBar, minus atmospheric should put it around 21-22 psi. I’d have to look in my service manual but I remember from my 4 cyl. it was around 450 psi and no greater then 10-15% difference, I can’t imagine the v10 being to far out from that. Sucks about the manifold, I had seen a lot about the manifold and the flex joint between the manifold and turbo leaking. The cats/dpfs/egrs are all up in my attic for the time being on my “off-road” Touareg. Should definitely help prolong the manifolds and turbos.

No everything came apart good, I’ve had one apart 6-7 times and sheared the pin once from me being rammy. They need to be held together quite tight, between the friction and carbon holding the nozzle to the nut when you go to loosen the nut the nozzle and the stack want to turn which shears the pins.

This was more of a "does this work" video vs an actual repair. They're quite tight for a wrench alone, I was doing this by feel alone. I'm hoping to do an actual "DIY repair" sometime in the near future.

I haven’t had time to set a flow bench up so I haven’t really played around with that. We’re they all out of the same engine? I’d be curious what the pop pressures are set at as well.

It’s not very often they’re repaired from what I’ve seen just replaced. I’d google authorized Bosch dealers nearby and see if they can get the parts

I don’t think the pressure is needed during reassembly, I only broke one set of pins and that was from me being lazy and not tensioning it down enough when removing. Yeah that could work but you need to make sure everything is held tight, it doesn’t take much to shear the pins. I’m hoping to get back into playing with these again so I’ll check torque during disassembly.

The top of the stack have some pitting from the pressure, i think it can be cleaned up though

Yes need to keep pressure on the nozzle to prevent spinning, without applying pressure the nozzle will spin with the nut and shear the locating pins off making the entire assembly scrap.

Any codes? Did you replace the rear main? As the crank sensor reads off that.

@@JoshsJettas not any serious codes. Yes I did replace. I’m also getting an rpm reading off it also.

I was just using wrenches in this video so i don't have a precise torque sorry.

Sorry no I don't, we never got the AGR engine here in north america

find some elsawin, and look for your wiring diagram there.. actually fixed a sensor problem this way on my 1.9 asz

Hey sorry for the late response, was on vacation for a few weeks. I’ve got a very rough bench test unit made with a pop tester and a modified body from the video. I need to refine it yet but will be posting the video once I’ve got it 100%. Issue with the pop tester alone is it’s just checking pressure whereas a Cambox will check BIP and injection quantity between all 4 as well. Got some ideas in the back of my head for a diy flow tester just need some time to get back at this project.

Probably will work but won’t be 100%. Idealling the intermediate discs should be cleaned up/lapped, nozzles should be pop tested and entire set flowed

I just used scraps of whatever i had around. You need a way to clamp the injector still then something to apply the force to hold the tip. Without something pushing inwards the injector stack will shear the dowels

Hey, no that was a BRM injector as they're the smallest/least desirable. I'll take a look and see what the codes are

I had made this one, i think the oem tools are pricey

Yup, keeping these projects on a budget. I’ve got a little container of all the nice size used tty bolts for projects like this.

Are you sure it’s the injector solenoid and not the injector harness inside the head? The harness is known to have poor crimps and which cause issues

@@JoshsJettas no it's just the plug's broken but I don't know the torque to assembled it back

@@lilsimgold4037 I don’t have any torque specs, I usually will just run the torque wrench in reverse and see how much torque is required to loosen then make a decision from there on re-assembly

Hey are you looking for slight larger or oem size? I had planned on ordering my oversized nozzles from powertdi.pl, they sell both wzm and firad.

@@JoshsJettas I am looking for normal size nozzle tip for 1.6 TDI Engine for 03L130277B injector.

We never got 1.6 TDI’s here, darkside developments in the uk might be your best bet. I know they ship all over

No, todavía no, espero hacer un video sobre ensamblaje/prueba aquí en el futuro

Hé désolé, la traduction m'a échoué ici, demandez-vous où j'ai obtenu l'outil de maintien ? Si oui celui-ci était fait maison

@@JoshsJettas oui c’est bien cela . D’accord avais vous deux trois astuces pour le fabriquer ? Ou pour faire sens ? Merci

La principale chose à faire est de s'assurer que vous pouvez mettre suffisamment de charge contre la pointe pour qu'elle ne tourne pas et ne cisaille pas les broches. Je renforcerais la pièce contre la pointe si je recommence, je recommanderais également d'utiliser un jeu d'injecteurs de rechange

je suis en train de fabriquer un avec un étaut

Elles doivent être davantage tendues dans l’outil de contre-prise pour éviter de cisailler les goupilles

Bonjour à tue fb ?

I wouldn’t tear one down this far for re-assembly, I’m hoping to use this body for a pop testing fixture. But my plan is to check before and after tearing a set down and then nozzle swap afterwards and see what deviation looks like after as well.

@@JoshsJettas exactly my thought

My only running PD engines at the moment is my wife's car as well as my V10's and i dont want to experiment on those. Ive got a mk2 golf I'm planning on PD swapping and that'll be my test dummy once i get some other projects tidied up.

@@JoshsJettas wife's car experiments goes wrong 😉☠