VIDEO PART 1 - Injectors and Glow Plugs test and nozzle replace on VW T4 ACV 2.5TDI 75KW

Injectors

• 4x injector 074130201C (BOSCH 2FH KBEL 58 P 119 with nozzles DSLA150P442)
• 1x injector 074130202A (BOSCH 2FH KBEL 58 P 107 with nozzle DSLA150P442)

Tightening torques

• Injection pipes = 25 Nm
• Retainer nut = 20 Nm
• Injector upper + lower part = 60 Nm

Replacement parts

• 5x DSLA150P442 buy from Aliexpress $4.5/piece + shipping (5 pieces needed)
• 5x Heat shield seal - Copper Nozzle ring BOSCH F 00V C17 505 (046 130 219 A, 057 130 219 A) - inner Diameter ~7,1-7,7mm, Thickness 2,5mm!!, Diameter 13mm buy from Aliexpress

Injector test

• Injector test unit V.A.G 1322 with pressure pipe V.A.G 1322/2 (GEKO G02658, Mar-Pol M57686, Matabro MB-INJ02)
• Engine code ACV - Transporter 1991 ➤
  New injectors: 190 ... 200 bar (Wear limit: 170 bar)
• Engine codes AHY, ACV with automatic gearbox:
  New injectors: 220 ... 230 bar (Wear limit: 200 bar)
• Engine code AJT
  New injectors: 220 ... 230 bar (Wear limit: 200 bar)

My injectors test + disassembly/reassembly + nozzle replacement video + shims and other inside parts measurements

Injector pressure adjust

When servicing used injectors adjust breaking pressures to specifications for new injectors.

• Thicker shims increase breaking pressure
• Thinner shims decrease breaking pressure.
• Increasing spring compression by 0.5 mm increases breaking pressure by 5.0 bar

Adjustment shims are available from 1.00...1.95 mm thick and increase by 0.5 mm. Use box 3065 to store shims.

Injector parts - first picture in gallery bellow

• Fig. A: Injector with needle lift sender -G80-
• Fig. B: Injector without needle lift sender
• 1 - Injector lower part
• 2 - Nozzle body
• 3 - Nozzle valve (needle)
• 4 - Intermediate disc
• 5 - Pressure pin
• 6 - Pressure pin
• 7 - Nozzle valve spring
• 8 - Shim
• 9 - Injector upper part

Glow plugs

• 5x M10x1, length 92mm, pin 4mm, Voltage 11V MEYLE 100 020 2022 or N 101 401 05

Test prerequisites

• Battery voltage at least 11.5 V
• Ignition switched off
• Diesel direct injection system control unit (J248) OK
• Glow plug strip fuse (S39) OK.

Test cable fault

• Pull connector off coolant temperature sender - Pulling the connector off sender, simulates engine condition "cold" and when switching the ignition on the relevant glow period is carried out.
• Pull glow plug connector off glow plug.
• Connect multimeter to measure voltage between a glow plug connector and vehicle earth.
• Switch on ignition for approx. 20 seconds and approx. battery voltage must be displayed

Remove and install new glow plugs with tightening torque: 15 Nm

Oldschool test

Connect special cable to battery+ and check pin by pin over the 5 pin connector which is located on the bottom side of the engine

Injector pump Specifications:

• Model Type: VP37
• Connector: 7 pin+3 pin
• Bosch part number: 0 460 415 996
• Audi / VW Part-Nr: 074130107N
• Engine codes: ACV // AHD // ON // AXL // AYC
• Displacement: 2461cc, Cylinders: 5, Power: 75kW - 102hp
• Part Numbers: 0 433 302 501, 0 433 303 651, 0 460 415 996, 0 986 440 565, 0 986 440 656