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1996 Passat TDI Engine Knocking- Valve Adjustment

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2.8K views 5 replies 2 participants last post by  chittychittybangbang  
#1 ·
Hello, just recently bought a 1996 Passat TDI and thus decided to join this forum for help restoring it since it was somewhat neglected.

The engine is making a knocking sound that increases along with the rpm. I think it might be one of two things/ or both. The injectors are worn and need to replace injector nozzles, or/and its needs to have valve adjustment done. I was searching around and couldn't find a DIY/ Thread for instructions for valve adjustment and if its manageable for a DIY like myself. I have previously done a valve adjustment on an 1983 MB 300SD with step by step instuctions from DIEASELGIANT.COM http://www.dieselgiant.com

Any suggestions??
 
#3 ·
I saw that when i pulled the valve cover off. Im thinking its most likely something to do with the fuel delivery, IP going out, bad/worn injectors/nozzles, been trying to pull out my injectors for the past week, just cant get them out of there. I just got one out the the others wont budge. I've been using PB Blaster, a homemade slide hammer, and still no results, today i will try getting a heavier weight onto the slide hammer, from 2lb to 5lb or so, hopefully it helps. Any suggestions perhaps?
 
#5 ·
Went to a body shop that had a 15lb slide hammer for pulling out huge dents on cars, borrowed that for my injectors, they came off within 10 minutes. When it comes to a slide hammer and injectors, you can never go too big/heavy with the weight on the slide hammer. Now I need to take them apart to replace the nozzles, anything i should watch out for or be cautious about? Also was trying to remove my intake manifold and seems like the 6mm allen bolt heads are stripped, how can i get them out to remove it?