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 February 5 by spartacus 68

[Trev1976]

After watching the YouTube video,the only thing I didn’t do was change 2 fuel pipes ,towards the end of tge video where he shows the details on his computer it says “when connecting fuel pipes make sure they are not under tension”

mine on 3 & 4 were bent quite bad & I bent back  best I could,but im sure they were still under tension,1& 2 hadn’t moved so pipes wasn’t bent.

this could explain the bolt shearing down to tension pushing sideways ,or the injector not searing correctly due to the tension.

 

ive not got vcds but have got a icarsoft,ill see if i can get flow rates on that when all my new parts have arrived.

[Trev1976]

After speaking with the wife she has confirmed that the fuel consumption has been higher than normal,

I’ve got everything back together now but I’m still not 100% my problem is resolved,I had tge car idling & removed the oil filler cap,which for saying I had it off 2 days ago was really tight,don’t know whether it was gases or steam that came out,not sure I should have either or if this is normal .

on placing the cap back over the hole it would dance about,is this normal?

The icarsoft scanner I have doesn’t seem to good so I’ve ordered a Launch x431 pro which should be with me Monday .

[Trev1976]

Managed to get soot levels & live data on injectors ,readings on 3&4 are a lot different to 1&2

im guessing soot levels of 5.38 is high aswell

[spartacus 68]

Sounds like EGR valve is stuck in open position. I’d either replace it or clean it.

Does your system diagnostic allow you to do a forced regeneration? I would do that afterwards so you’re starting from scratch.

I’m not familiar with this OBD reader. If it were me, then I’d get a can of Forte diesel conditioner and drop it in the tank once you’re down to around 75 miles range and drive it hard. I also assume this is a Euro 5 diesel, so no AdBlue, etc.

Now obviously you’ve just changed the injectors, so can understand your hesitancy. Used to run an old 2.5TDI V6 and swore by that to get it through MOT, etc. In those days the filter was in the engine bay. Now it’s under driver’s side.

The car will smoke a little, but that will clear. Renew the fuel filter and while your at it, the air filter too.

Not sure how long you leave between oil changes, but 10k miles maximum. Use Castrol 5W30 Edge LL and renew the oil filter.

[Trev1976]

@spartacus 68

Will strip the egr off & check that,I also think maybe injector 3 is not in good shape,think I’m going to just get all 4 injectors tested & replaced if need be,my obd  can do a forced regen,I just want to make sure I’ve got to the route cause before doing a regen as don’t want to cause anymore damage,

i normally change the oil every 5-10k,the car had only covered 2k before this issue & I’ve also done an oil change after the 1st repair ,I plan to do another when the problems are sorted,I think then the next step will be bye bye dpf,adblue & egr 

[spartacus 68]

Not advocating DPF, Ad Blue and EGR delete. All are MOT fails.

There's probably lots of life left in this old Q5 yet.

Edited February 10 by spartacus 68

[Trev1976]

So I carried out a compression test today & here are the results ,when removing the compression adapter from c3 it was covered I a gooey residue,the others were dry

[spartacus 68]

I don't know what the compression is meant to be on your engine? You will probably get the full specification details on erWin, but you will need to pay for access. My understanding is diesel compression is high, around 350psi and cylinders should stay within variance of 10% of each other.

I wouldnt refit the same glow plugs. If they break you're in a world of pain. On the stuck one, spray PlusGas on it and let it soak in. I would refit the injectors and run it to get to temperature, then try and remove it.

You probably need more information than your current diagnostics can give you. Think about VCDS. Honestly it pays for itself on this car and future cars. Is EGR blocked, is DPF blocked?