Injector popping out

[Trev1976]

Has anyone had there injectors pop out on a 2.0tdi?
I had it happen last wk,ve fitted new seals washers,bolts & clamp brackets & after 20miles the same 2 injectors have popped again,I’ve used genuine parts & used the correct torque settings which I got from a local engineer who has been building engines all his life. 
I’m hoping it’s happen to someone twice & that they found the solution ,both times the bolt sheared.
Just done a scan & got these codes,don’t know if they are relevant to the issue.

p0135

P1440

P0405

p2454

TIA

[Trev1976]

Has anyone had there injectors pop out on a 2.0tdi?
I had it happen last wk,ve fitted new seals washers,bolts & clamp brackets & after 20miles the same 2 injectors have popped again,I’ve used genuine parts & used the correct torque settings which I got from a local engineer who has been building engines all his life. 
I’m hoping it’s happen to someone twice & that they found the solution ,both times the bolt sheared.
Just done a scan & got these codes,don’t know if they are relevant to the issue.

P0135

p1440

p0405

p2454

TIA

[cliffcoggin]

Trevor.

I have merged your duplicate topics into one. Please don't create duplicates, it will not gain you any more attention.

[spartacus 68]

What’s the history on the engine prior to the injectors blowing? Not sure about codes. ideally you need VCDS to see instance of faults, if historical or as a result of once the injectors blow off. Potentially linked to EGR, etc.

I’ve read one instance, think it was in a VW, where they enlarged M6 to M8 on the clamp bolt, but that’s not the case here, it’s actually shearing off.

Area needs to meticulously clean including injector bores ensuring the old copper seals are removed. Also noticed there’s a ‘o’ ring seal on the injectors. Use new stretch bolt and torque to specification.

Check out Dave Sterl, this is on 2.0TDI CJCA engine. 

 

[Trev1976]

Thanks for the response @spartacus 68

history of the car ,owned for 2 1/2 yrs,fsh 116k on the clock & it’s never missed a beat,other than needing a dpf sensor,since changing that the engine management light came on intermittently,clear code & it would come back after 1 to 2 days.had the sensor programmed in,

I serviced it 2 mths ago so fresh oil filters etc.

Prior to the injector blowing the idle was a little high & I also noticed the fan was staying on when turning the car off.

I changed top seal o ring & copper washers on injectors including new bolts & clamps ,all genuine parts.injector seats I cleaned with a laser injector seat cleaner 

https://amzn.eu/d/f09zaI5

 

I think my next step will be to inspect the injector seats,bores for damage & get the injectors tested

[spartacus 68]

If you had VCDS - that would let you see the high pressure flow rate. I'd also want to check the soot level for the DPF and make sure it's doing a regeneration cycle, plus any other error codes logged. There's an underlying problem here if everything was done to specification regards seating the injectors. Noticed if fuel consumption has dropped like a stone, other than high idle?

Edited 1 hour ago by spartacus 68