How2: 2.5 TDI Injector replacement.
Good Afternoon Ladies and Gents.
I replaced my injector this morning on the old girl, when I was looking for information on the internet on how to do this. I found very little, sadly.
So I thought I'd make a very brief and basic how2. Some photos are from putting it back together, as my memory to do things is crap!
Firstly, pop the bonnet and remove the Engine cover.
I took off the maf and airbox for room.
You can then see the rocker covers with the 3 pipes going into the injectors.
In this picture you can see I've removed the pipes and the bleed off pipes.
You'll need a 10mm socket to remove the bleed off pipes from the injector heads. These are sealed by copper washers. I thought best to replace the washers when putting back together.
Undo the pipes going into the injector, these require a 17mm spanner to undo, they're a tiny bit tight. But do come undone.
Looking round the rocker cover, you can imediatly see 8 nuts holding it on. There is actually a 9th nut to the rear of the rocker cover. Unod these nuts and the rocker rover will be come slightly loose.
On the lower part of the cover, you can see the nuts also hold the metal pipe for the induction system. You can pull this out of the way quite easily.
You need to unclip all the wiring clamps from the rocker cover, these easily pop off without issue.
I found the when removing the rocker cover, it slightly fouled on the cambelt cover. with abit of wiggling it comes away from the head.
Once the cover is off you can see this.
You can see a clamp that sits over the injector holding it into place. I evenly undid the 2 nuts holding the clamp down. Once the nuts are off, you can feed the wiring through the clamp. You can then gently work out the injector from the head.
Once the injector is away and free from the head. You will see a copper washer on the end of the injector, these needs transfering to the new injector (or preferably a new copper washer, if I'd known it'd have bought one) also there is a shoulder that needs transfering from the old to the new one. It rests on the circlip about a third of the way down.
You can then put the injector carefully into the hole. You'll find there is a recess in the head for the stud sticking out the side of the injector. (I put a tiny bit of fresh oil on the seal to help it slip into place)
Feed the wiring through the clamp as before and gently push down on the injector till the seal 'clicks' into place. Gently and evenly tighten the nuts down till the injector is fully located.
Feed the wiring back the original route to the outside of the head.
Carefully fit the rocker cover back on and the rest is reverse of removal.
Things to note, this is an ideal time to think about replacing the bleed off pipes. I did mine whilst I was there. I also fitted new copper washers to the bleed of bits.
I hope this helps anyone out.
059130201F and E for AKE engine
Originally Posted by Turkster
can you advice me, please?
By reading this tread I understood that injectors E and F difference is in nipples??? I have an allroad AKE with the faulty needle lift sensor (00542 fault code) and also have an A4 B6 with the same AKE engine. I want to swap the injectors. Allroad AKE is fitted with 059130201F and A4 AKE is fitted with 059130201E injector. Will I have the same spec injector after swapping them if I take the returning diesel nipples off?