Rebuild the seat well injector Volkswagen T5 1.9 2.5 TDI Skoda Audi glass replacement 

Rebuild the seat well injector Volkswagen T5 1.9 2.5 TDI Skoda Audi glass replacement.
Correct welding, cylinder head preparation, welding: • Ремонт ГБЦ правильная ...
Correct welding, welding preparation, welding: • Правильная заварка ГБЦ...
When and why crimping is needed: • Ремонт ГБЦ Зачем нужна...
Repair technology playlist: • Технологии ремонта
In this video we will talk about the cylinder head of VW 1.4Tdi 1.9 Tdi 2.5 Tdi engines. These motors use aluminum alloy heads. A feature of the cylinder heads of VW 1.4Tdi 1.9 Tdi 2.5 Tdi engines is the installation location of the pump injectors. As a rule, after long-term operation, approximately after 200-250 thousand raids, the place for the pump injector breaks. The thing is that the injector will be held by one M6 threaded bolt, and during operation the injector experiences quite serious stresses. The unsecured side begins to move in the seat and it breaks. This is fraught with the fact that at one point the fuel will pass into the oil and the engine will come to a kerdyk.
Therefore, in this case, it is necessary to restore the place of the nozzle - to replace the glass.
We carry out the restoration of the seat by screwing it up, installing, as we call it, a metal cup. Many people believe that this cannot be done due to the different expansion of the metal with temperature. But for many years we have been putting metal cups with an interference fit of one dozen and there have never been any complaints. First you need to drill the wells of the nozzles in the head. Jig boring lathe Vitaliy sets the head on the turntable, aligns the head and fixes it with bolts. Then it takes the axial coordinates of the wells.
Places a cutter in the chuck. Exposes the size and starts reaming the footprints. It goes through all the wells in turn in three passes. It grinds roughly at first. The factory dimensions of the nozzle seats are 31 and 32 mm. Vitaly bores a well for a glass with a diameter of 34.5 mm. First, it bores to a diameter of 34 mm. All wells pass by this size. Then he sets the dimension to 0.4 mm. more. All the wells are going through again. And already under the final size he adds another ten and again "goes" through all the wells. Now Vitaly will measure with an internal gauge. Measures dimensions of future bushings. We went to the circular 34.59. Measures the resulting height of the future cup. It was 20.5 millimeters.
On the tightness adds 0.1 ten. The turner grinds out sleeves-glasses according to its dimensions. Now he makes holes in the cups. These holes must be drilled 11 mm. from the edge. Makes drilling. Controls the size. Necessarily removes burrs that remain from drilling. For this he uses a scraper.
In order to press in the finished cups, he heats the head in the oven. For pressing, you need a cup guide. Inserts a guide into the structure.
The glass is lubricated with a sealant. Aligns it with the hole. He takes the mandrel and confidently hammers the glass with a hammer.
Here we see the hole in the head and in the cup coincide. For control, just in case, he sends the head for crimping.
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