2009 Q7 TDI fuel injector reset?

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apbreaux

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I recently cleaned the fuel injectors on my 2009 Q7 TDI. I did the passenger bank first, then started the car to see how things went. It ran pretty rough. I, then, did the driver side and tried starting it...it wouldn't start. Would crank, but no ignition. I put the injectors back in their original cylinders, and primed the pump/system via VCDS 3-4 times after each reassembly. Do I need to reset the injectors as you would when installing new ones using VCDS (http://wiki.ross-tech.com/wiki/inde...9_and_Injector_Voltage_Adjustment_.28ISA.29)?

Both the rear and secondary pumps sound like and appear to be functioning normally - there is fuel pressure build-up during the forced priming.
 
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Uwe

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Curious: How exactly did you clean the injectors?

How many miles on the engine?

I wouldn't think it's necessary or appropriate to tell the ECU it has new injectors, and I'm pretty confident doing so won't fix a no-start issue.

-Uwe-
 
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apbreaux

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Uwe said:
Curious: How exactly did you clean the injectors?

How many miles on the engine?

I wouldn't think it's necessary or appropriate to tell the ECU it has new injectors, and I'm pretty confident doing so won't fix a no-start issue.

-Uwe-
Click to expand...

I took out each injector one-by-one and took them apart very carefully. I verified with each injector the proper order and direction of all components. I cleaned the injectors with carb cleaner. I sprayed through the nozzle and ensured all the ports were flowing properly. One thing I should've done the first time was to replace the seals - I used the old copper seat washers/gaskets, as they looked pretty good to me. However, all the injectors are back out waiting on new washers and o-rings for installation.

115,000 miles.
 
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Jack@European_Parts

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This is not the correct way to do this and you didn't reference a pop test of them to check full spray atomization or at different rates of pulse to observe the patterns or for static drip/weep?

You do realize that when breaking the injectors & even new, "apart", the calibration changes each time and even if at the same shim or TQ level compressed in case?

On the cheap........



The right way, volume, psi and atomization.....

 
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apbreaux

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Jack@European_Parts said:
This is not the correct way to do this and you didn't reference a pop test of them to check full spray atomization or at different rates of pulse to observe the patterns or for static drip/weep?

You do realize that when breaking the injectors & even new, "apart", the calibration changes each time and even if at the same shim or TQ level compressed in case?
Click to expand...

I was not aware of these things. Is there any way to now use these injectors?
 
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Jack@European_Parts

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I was not aware of these things. Is there any way to now use these injectors?
Click to expand...


Yeah couldn't you send to a Bosch licensed re-builder and have calibration test done so the new data readings can be installed in the ECU controller & to set the adaption as if a new set?

This way all is happy and provided the rest of the fuel system & ECU + harness are working correctly!
 
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apbreaux

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Jack@European_Parts said:
Yeah couldn't you send to a Bosch licensed re-builder and have calibration test done so the new data readings can be installed in the ECU controller & to set the adaption as if a new set?

This way all is happy and provided the rest of the fuel system & ECU + harness are working correctly!
Click to expand...

Sounds like it might work. Know of any said re-builders?
 
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apbreaux

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Also kinda curious, does the ECU automatically adjust for slight variations in fuel flow and such? Did my "cleaning" process alter these outside the ECU's parameters for adjustment?
 
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Jack@European_Parts

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Sounds like it might work. Know of any said re-builders?
Click to expand...



https://www.boschautoparts.com/en/service-concepts/diesel-center


Also kinda curious, does the ECU automatically adjust for slight variations is fuel flow and such? Did my "cleaning" process alter these outside the ECU's parameters for adjustment?
Click to expand...

RTFB & SSP

http://www.volkspage.net/technik/ssp/ssp/SSP_365.pdf


JPPSG.......

REMOVE FOD!

https://forums.ross-tech.com/showth...essional-Problem-Solver-Guide-quot-JPPSG-quot

eTu9lha.png
 
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apbreaux

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This has been an expensive lesson. As Jack said, I can't just take these things apart. Tolerances are too tight for me to just put them back together by hand. I sent them off to get tested and none of them had flow. As far as getting new ones, it seems only dealers have access to "new" injectors. Distributors have access to "remanufactured". Ordered six remanned which should arrive tomorrow.
 
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Jack@European_Parts

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Did you know a simulator can be created by vehicle itself to experiment with injector spray patterns & by shimming changes to establish a threshold using glass jar and extra line while freewheeling the crank and injectors removed by cranking starter?
 
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apbreaux

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Jack@European_Parts said:
Did you know a simulator can be created by vehicle itself to experiment with injector spray patterns & by shimming changes to establish a threshold using glass jar and extra line while freewheeling the crank and injectors removed by cranking starter?
Click to expand...

I didn't. I can visualize what you're describing, but at this point I just want to start fresh and be done with it. Hopefully these injectors will last the life of the vehicle. Much appreciated, though.
 
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apbreaux

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Got injectors installed and car is running great. When running VCDS to reprogram the injectors, a message popped up saying to enter "0" and then save when installing new injectors. I wasn't able to do this. I just entered the new injector codes and that worked fine.
 
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