#6295542 - 04/22/12 09:28 PM
So you wanna upgrade the injectors in your '04-06 PD VW...
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LNXGUY
Tougher than Logan Roy
Post Master Supreme
Registered: 08/06/00
Posts: 107955
Loc: Barrie, Ont,
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Sure! You just need to take the valve cover off and do all kinds of other crazy shit to do it 
Although to be honest, the job itself is really easy. There are a few things you just need to pay very close attention to however or else you can fuck your shit up with the quickness. Setting up the lash incorrectly on the injector could lead to the plunger inside the injector bottoming out, then you're out $800 for.a.single.injector. So take your time, have a good reference manual (Bentley in this case) and have everything you need on hand.
The way the PD fuel system work is nothing short of amazing.. Passage through the head leads to each individual fuel injector, fed by a tandem pump which runs off the end of the cam.. Fuel flows into the injector, extra lobe on the cam pushes the plunger within the injector down and sprays fuel into the top of the piston.. So fucking cool and very intimidating to work on.. Detroit Diesel still utilizes unit injection in their motors...
Here's the unit injector you'll be pulling out of and installing into the head.
There are 3 o-rings on the injector. One to keep the oil out of the fuel, one to seal the fuel from the injector hole and one to keep the combustion and the rest of the shit (along with a copper sealing washer) from coming back up into the head.
Pic of the injectors before removal still inside the head. The other great thing about this is that you need a injector install kit from VW at the price of $50 PER INJECTOR. Fuck me... Luckily I got 4 kits and 4 stretch bolts for the retainers with my injectors.. I just needed to buy the 8 stretch bolts from VW at a price of $9.80 a piece 
I didn't get any pics of the injectors out of the head (I should have, stupid me).. But really it's a nice shiney hole, I'm sure you've seen similar before, lol.
After we installed the new o-rings and lubed them up with assembly grease they went back in the head. After they were all installed we need to measure each and every one of them to make sure that the fuel opening in the head lines up with the fuel opening in the injector (or else it won't be fueled properly and will run like shit).. You do this by very carefully measuring the distance from the right side of the head to the far left side of each injector.. So basically you get a long ass ruler, pre-mark the lengths according to the Bentley then line them up... simple stuff.
After the injectors are installed the rocker arms are re-installed you've gotta set the injector lash..
This is what we are doing here..
You want to bottom out the big spring on the injector by rotating the cam manually.. Once you've bottomed it out you undo the nut in the picture and use an allen key to turn down the thread until you've bottomed out the plunger.. You want to do this 3 times to get rid of any fuel in the injector before setting the lash.. Once you do that you'll want to turn it down until snug then back off 225 degrees.. Do that for all 4, put the valve cover back on and you're done!
PD150 injectors will support 200whp with the appropriate turbo (Luckily I've got one of those as well).. Problem with running the PD150 injectors on tuning based off PD100 injectors is that the pulse width of the injectors is half as much.. My fucking car idles like it's got a monster cam it and it's basically got no power, lol. Tuner will be sending me an update for the injectors tonight and I'll re-tune tomorrow.. After that the upgraded SMIC goes in along with custom IC pipes and a 3bar..
_________________________
-Bill The GN would OWN you, your children and your children's children. Left foot, right foot, just keep moving!!! -Jeffrey P. Murphy 
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#6298096 - 04/24/12 06:43 AM
Re: So you wanna upgrade the injectors in your '04-06 PD VW...
[Re: cacasesi]
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LNXGUY
Tougher than Logan Roy
Post Master Supreme
Registered: 08/06/00
Posts: 107955
Loc: Barrie, Ont,
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You pretty much nailed it My tuner is having a fun time dialing these things in... Still idles like I've got a monster cam installed.
_________________________
-Bill The GN would OWN you, your children and your children's children. Left foot, right foot, just keep moving!!! -Jeffrey P. Murphy
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#6298192 - 04/24/12 08:28 AM
Re: So you wanna upgrade the injectors in your '04-06 PD VW...
[Re: kyden]
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LNXGUY
Tougher than Logan Roy
Post Master Supreme
Registered: 08/06/00
Posts: 107955
Loc: Barrie, Ont,
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I really do miss my rotary pump ALH. So simple. But if you want big power, the BEW is the ticket.
_________________________
-Bill The GN would OWN you, your children and your children's children. Left foot, right foot, just keep moving!!! -Jeffrey P. Murphy
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