VW T5 2.5L TDI Injector Leak Repair! | Mendtech EP.05

Volkswagen transporter / caravelle T5 2.5L TDI Injector seal repair.
I know i have been slackin'. I've got a lot of material, it just need to be edited. I will pick it up, I promise!
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[@moretdavid]

Thanks a lot for the tips!

[@xabulidema9454]

If you don'r repair the worn places in the cylinder head (bronze bushes are the usual way), the new gaskets will last in best case ca. 6 month, in worst case 2 weeks. And you can be sure, that after 200.000 km the injectors are worn out of spec, so you have to repair them. The "Bosch Dienst" in Germany does it for 170 Euro/piece. Neglecting this causes later defects on the pistons, and further accelerated wear and tear in the whole engine (camshaft, turbo).

[@TonyMontana-bm3np]

Please let me know how (with what tool and in what order) you clean injctors nests befor instaling back again injectors with new orings. Thank you!

[@MagicVan]

👏

[@bernhardnymo]

Thanks for video. I have same problem. Just hope its not a cracked top. Problem got worse over time. Is it easy to find cracks and where are they usually? Thanks in advance! B!

[@markhodge4804]

Sorry I'm being a bit dull. I need to change the rocker gasket tomorrow. What do I need to remove in order to just loosen the front end and not take the number off completely? I can only find you accessing it in this way which seems a lot easier. Thanks

[@wannabediamondhand6490]

Hi, I'm pretty late for the party but I'm commenting here because I have the same problem with my AXE engine. I didn't see you adjusting the rocker arms at the end before putting the rocker cover back on. Did I miss something? I thought you always has to adjust the rocker arms of each injector and for that you need to crank the engine and need a special tool for that too.

[@Radiomen21]

Hi, nice video and step by step manual for the injectors. Can you tell me the valve clearance for the injectors please? Many thanks :-)

[@christiaanstals5840]

Hi There, can you please help with the torq settings? we have removed the injectors and fitted the new o0ring kit. Can you perhaps help with the Totq settings, please?

[@MegaSobbie]

Hi I’m in uk having injector problem can you recommend best seals to get please

[@donovanmansfield-xg1je]

Where can I get exchange or after market injectors for the 2.5, 5 cylinder diesel.

[@LAW-fv6ys]

What was the symptoms of leaking injector seals? I have a 1.9tdi bxe which idles fine but if you rev it up sharply it will chug and misfire on cylinder 1 only, the injector deviation goes up to 2.99mg /stroke, but if you let it idle for about 3 seconds it smooths out and idle fine. I have replaced the orings and the injectors on cylinder 1, but no change, also replaced noisy lift pump and fuel filter still the same. Tested tandem pump fuel return flow and get 0.8l/minute which is apparently low should be 1.3l/minute. Tested the tandem pump high pressure fuel delivery and got a bouncing needle which showed 3 bar at idle and 7 to 8 bar when revving. As soon as I revved it hard I saw the fuel pressure drop off as it started to misfire on cylinder 1. So now I don't know, is it the injector leaking past the seals into the return side from the high pressure side, or is this the tandem pump flow too low and cylinder 1 being the last injector it's being starved when high fuel flow is demanded? Any advice is more then welcomed pls.

[@osbathzeteny1164]

Hi i have problem with my t5 transporter 131 hp motorcode: bnz, oil and diesel is mixing oring have been replaced any solution?

[@user-ex1kl4ps8p]

Do you have the right Numbers for all the bults ? Plz

[@torrykorneliussen3099]

How to adjust the spring on each injektor?

[@johnhomles2711]

I personally pref to drop radiator out for better excess to intake manifold/ I also fit the upgraded oring kit / which seal better / I don’t recommend the upgraded injector clamp / One because we have a 11 cracked heads due to how they torque injectors down and 2 I repair the bores via lathe to add brass insurts

[@simonbatten2062]

Can you please tell me more about the upgraded O ring kit? I cannot find anything with a google search. Thanks

[@geofftowill1270]

Could you please send me the torque settings for the injector on my T5 transporter 2.5 L Many thanks

[@civierr2832]

What are the torque specs here?

[@barbrapapa28]

Great vid,this is exactly what mine has been doing cost me 2k so far at local garage he carn't fix it....(new cam reconditioned head) any idea why my fuel line form fuel pump bust and cost me a full tank?

[@Mendtech]

that sounds really wierd, I've never heard that happen(??)

[@barbrapapa28]

Yep its got me ive 110k miles in it and two hrs steady driveing on the motorway and pop goes the hose....??

[@JohnThorpIreland]

I have long turnover on cold start, (2006 2.5 tdi T5) smoky exhaust and the tank gets vacuumed, If I open the diesel cap after 100km's its sucks in air and spits diesel out, Ive replaced the fuel lines, the fuel pump. the fuel level gauge and finally the actual fuel tank and 5 or 6 fuel caps. not gone near any injectors yet. @@Mendtech @barbrappa28

[@TheStoney1]

@@JohnThorpIreland Hi John, did you ever solve this?

[@JohnThorpIreland]

@@TheStoney1 Hi Stoney, Not yet, I found an injection place to rpeplace the seals and test my injectors. But I have to get them out myself, I have started loosening the front of the van, when I can between showers and working. I will let you know when I have it done,

[@GaryTaylorvw]

Hi, I’m getting p0305 error, engine runs spot on on tickover, will run all day, but once driving for 10 minutes it cuts out, loss of power and dies, and showing p0305 Got me baffled, don’t know what to check

[@kennethrollo7891]

Hi, ive a t5 2.5 130, 2007, smelly white smoke when hot, but engine running perfect no problem starting, no loss of power, no loss of water, no oil usage, new air filter, new deisel filter, just this smoke, could it be injectors worn, ive replaced one which was playing up about 7000 miles ago van has done 148000, any thoughts.

[@josephcullen2512]

White smoke can be water... These engines can have an issue with the seals in the water pump failing and allowing some water into places not designed for water

[@MrMiszczu1992]

Hi, what is the torque to tighten the bolts from the camshaft and unit injectors?

[@Mendtech]

hi! for the fastening of the camshaft (which i didnt remove. its 8nm + 90degrees. the injector fastenings is 12nm + 270 degrees. this is on my engine AXD

[@franklinfourie5835]

Good day. Does this seal kit improve the injectors diesel delivery as well? I had my injectors tested recently and the results came back stating the the injectors are out of spec. They want to charge me a stupid amount to re calibrate the injectors. So i'm thinking of doing it myself. Any advise.

[@Mendtech]

hi! it does not improve the injectors directly, it can increase the fuel flow though (if your old seals are worn-down) but if you have faults within your injectors, that will stay the same.

[@DuckDuck419]

Hi Mendtech My T5 2.5 tdi adx have same symptoms. But I notice if i hard start it when its cold and then turn engine off before it heat up, there is no air leak and I can start it cold with no problem, even after couple days. Was your van the same?Seals was changed but no difference. 2/5 injectors replaced and now oil level increase approximately by 2.5mm per 100km. Before that diesel filled up the sump to max in 60km. My mechanic want to change other 3 injectors, tappets and camshaft.

[@Mendtech]

Hi, that is the precise problem that I had. Unfortunately, I dont think changing any more injectors will help because chances are high that you have a crack in your cylinder head :/

[@DuckDuck419]

@@Mendtech Thank you for your response. I will consider change head instead. Today I notice that there is steam coming from oil. I tough it is condensation so took my van for long trip. Checked it again at home and there was steam for 1 min and then it suddenly disappear. When I rev steam appear again for approximately 1 min. Is that normal? Maybe oil contaminated with water not diesels. Could steam be created when diesel mix with hot oil? Coolant level is normal and there is no smoke from exhaust.

[@madjidben8240]

If the oil smells like diesel, it's because the tandem pump has failed, check that out because it might cause serious damage

[@srutenbarg2529]

Hello, How were your injector borings? Did you see any symptoms of wear when you pulled them out? I got mine out, but I can see they have some wear on all of them. Not too bad but.. Do you think it will last long until the new o-rings will let fuel pass trough again?

[@Mendtech]

Hi! Yea there were some wear in the holes where the injectors rubbed against the wall of the cylinder head. I smothed them down with fine sand paper (plug the bottom of the hole first and make sure to get the debris of aluminum out of there) and then I wraped the fittings for the o-rings on the injectors with 2 laps of ptfe-tape so the total diameter of the o-ring increased slightly. I was lucky in this case but there have been some problems on OTHER van's that the wear in the cylinder head has been big and it cracked the head.

[@srutenbarg2529]

@@Mendtech Thank you for your answer! I have exactly the same so I will try your method. Because otherwise there need to be placed in new injector seats or the complete cylinder head must be replaced.

[@BERRYcompany]

What are the clear signs of worn injector gaskets? I have 2007 t5 BPC 2.5 5cly

[@Mendtech]

The signs of worn injector gaskets on mine was that the van was hard to start after it's been sitting for a while after being driven warm. Then it took about 30sec before it started. When it was warm, it was all fine. Another sign can also be a increase of oil (actual diesel) in the engine.

[@BERRYcompany]

@@Mendtech Thank you for your swift response! Indeed, thats is what I have! :) This far I have changed all of the fuel lines and added nrv, in tank pump and tandem pump with no improvement. Tried to go for quick fix ended up it seems expensive way. 😪 But now I know I should do injectors, thank you very much!

[@Mendtech]

@@BERRYcompany no problem at all, I wish you the best of luck! I have some great ideas for the channel coming up soon. Remember to subscribe!

[@VilleKarjalainen93]

Does IT have much white smoke on start. I have and 1 cyl -1.98 mg/STR 2 cyl -3.01 mg/STR 3 cyl 2.59 mg/STR 4 cyl 1.22 mg/STR 5 cyl 2.99mg/STR Code was p0305

[@VilleKarjalainen93]

So alla injectors Are broken? Seals notnhelp?

[@JonssonGustav]

where did you find torque specs?

[@Mendtech]

I use a software called Autodata. Injector fastening 12nm + 270 degrees, the axle that pushes the injectors: 20nm + 90 degrees. Always use new bolts.

[@amlucky1975]

hi i need some help ! i have white and blue smoke while engine hot ! can any one tell me if injectors or turbo failure! and also when hot not easy to start up ! thanks

[@Mendtech]

I would say it could be a crack in the cylinder head where the injector sits. is it a early 2.5 tdi 5cyl?

[@amlucky1975]

Mendtech hi my transporter 2007 t5 2.5 tdi 130phb

[@amlucky1975]

yes when it’s hot worm up start miss fire as well ?!?!?

[@MelodicSounds101]

Did you sort it in the end? If so what was the issue?

[@amlucky1975]

No sold as a spear

[@johnhomles2711]

Why remove

[@Deontjie]

Is it common rail or not?

[@Mendtech]

not really no, the injectors are connected to the fuel through the same line as in a common rail system, but i wouldnt call this a common rail system. the fuel runs from the cam-activated pump through the cylinder head and then in to the injectors through ports in the tube for the injectors.

[@willybaldsirhenry]

It is called Pumpe Düse TDI

[@eshameshamudheen6715]

Pd injector coding need yes or no

[@Mendtech]

No, you're good as long as you put them back in the same order.

[@j.w.5060]

Schlepphebeleinstellen wohl vergessen?!

[@michalmatlak1726]

you forgot adjustment injectors ...

[@philippecanivet2809]

Vw t5 2.5 tdi est LA plus Grosse merde qui a sur le marche