PD injector install

[jnecr]

I was bored.. so I figured I'd this up in case anybody was curious or if anybody ever gets a PD TDI and wants to upgrade their injectors... :)


So.. pic 1:
Valve cover has been taken off, you can see the injectors (the things with the large springs), injectors rockers, and just barely the cam shaft (shiny part behind the injectors, you can see the exhaust and intake lobes).
http://www.ncdubs.com/photopost/data/503/install4.jpg

Upper view of previous, you can see that there are two rocker banks:
http://www.ncdubs.com/photopost/data/503/install5.jpg

Rocker released!
You can plainly see the cam shaft now with the much larger lobes for the injectors than the valves, showing just how hard it is to compress the fuel to 29,000psi.
http://www.ncdubs.com/photopost/data/503/install7.jpg

Removing the injector:
Pry up with one and turn the injector in place with the other...
http://www.ncdubs.com/photopost/data/503/install3.jpg


Here you can see the injector itself and the wedge that keep it in place:
http://www.ncdubs.com/photopost/data/503/wedge.jpg

And here is the injector itself:
http://www.ncdubs.com/photopost/data/503/PD150injector.jpg

[gerich]

What all performance gains will you see from the pd150 injectors? Are there any other pd150 parts that are an "upgrade" for the pd100?

[jnecr]

Basically what I've found is that by themselves PD150 injectors won't give you any more power. But what they let you do is increase boost with a different program. The PD100 injectors were at their limit with the boost I was running (18psi I think is what RC2 gives you). So I'm sure these injectors will take me well into the mid 20s for boost, I just have to get the program to do it now.. :)

As for other PD150 parts. PD150s also have a bigger turbo than the PD100s, but being the way that VW is the PD150 turbo (VNT17) is not a direct bolt on to North American PD100s. Although, I believe it is a direct bolt-on for Euro PD100s... crazy bastids. PD150s, I think, have a bigger IC, but I may be wrong.

Nobody really ever upgrades to PD150 stuff because it's too hard to find because they were kinda limited in Europe, so finding stuff and then shipping it across the pond gets expensive.

Most performance parts can be found at www.kermatdi.com Charlie is a great guy and knows his stuff. He has all kinds of upgrades for the older ALH engines, but only a few for PDs. He does have the best injector upgrades around (even European customers order from him). He also has a Eurojet FMIC that I'm eyeing.. :)

[Shiftlink]

That's very interesting. So you have to take the fuel pressure out of the head before you pull the injectors? Or do you just change the oil when your done?

[jnecr]

Thought I would add to this thread... I know it's very old, but it's better than starting a new one on the same topic.

First, to answer Shiftlink's post that I never saw:
The fuel will fall into the cylinder, after replacing the injectors themselves you remove the glow plugs (all 4) and then turn the engine over a few times, this will spit the fuel all over the damn place but will keep you from hydrolocking and it won't go into the crankcase either.

Second, I was finally going to get around to balancing the injectors Saturday morning, but I didn't know how to turn the crank?? Can anybody help me out with that? Do I have to do it from underneath the car (I couldn't even reach my hand down to the crank)?

[kcfoxie]

Yes, below the car. Remove the passenger side wheel to make more room. I'd do this on a lift or at the very least, jack stands on concrete. You don't want the car to move while hand turning the crank.