2009 B8 2.0 TDI CAGA Injector Torque Spec?

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jackouk1337

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Hi all,

Cannot find this either on the internet or using the forum search function. Does anyone know the torque needed for the 2x nuts that clamp the injectors down? They are only 10mm nuts which is strange considering they need to hold the entire force of combustion! I've gone to 18nm but don't want to push them further.

Thanks!
 
I take it you mean Item 18 on the diagram below? They are M6 nuts which I would hazard a guess at needing a 10mm socket to remove & fit them.

Torque spec for Item 18 shown below is 10nm, so you have over-tightened them!

10nm does not sound like a lot and they may seem small, but remember the clamping force will be hundreds if not thousands of lb's, you would be surprised how much clamping load those little fastners can actually put down, even if the torque spec seems "low".

a4-6453.png


Online service manual can be found here, but it is terrible to navigate, so I use ElsaWin which I have installed on my own laptop. At work just now though, so I had to use this online manual to get the info for you. The info in the online manual is identical to ElsaWin, just a nightmare to navigate as the website isn't that good.

http://workshop-manuals.com/audi/a4...m_diesel_injection/fuel_system_exploded_view/
 
Last edited:
Thats exactly what I needed, thanks! It may have been 16 or 18, I'll go back and do them again. At least my common sense took over and I figured that these surely can't be meant to be so tight.

Those nuts might be single use as well so I'll check that out before starting the car back up and replace if needed.

Cheers for the link as well, will check it out when I'm not at work as well!
 
jackouk1337 said:
Those nuts might be single use as well so I'll check that out before starting the car back up and replace if needed.
Click to expand...

The nuts are not single use, if it was it would say "Renew" under the torque spec in the link above. Doesn't say that, so you can re-use them, but if you have over-torqued them then replacing may not be a bad idea, they will probably be pretty cheap.

However it does say the following about each clamp (Item 17)....

  • If they are to be re-installed, the injectors and clamping pieces must always be re-fitted on the same cylinder.
  • When an injector is renewed, the corresponding clamping piece must be renewed at the same time

And there is this caution at the top of the page.....

Caution
To prevent the high-pressure fuel pump from running while it is empty and to ensure that the engine starts quickly after parts have been renewed, it is important to observe the following:
  • If components of the fuel system between the fuel tank and the high-pressure fuel pump are removed or renewed, the first fuel filling must be performed.
  • If a fuel pump, fuel line (between fuel tank and high-pressure fuel pump) or fuel filter is removed or renewed, the fuel system must be bled before the engine is started for the first time.
  • If the high-pressure fuel pump is removed or renewed, the fuel system must be bled before the engine is started for the first time.
  • Procedure for first fuel filling → Chapter
 
Thanks again, I did also spot the replacement of the clamps/re-use on the same cylinder. I also spotted a few more things that I'll re-do (nothing major to be honest, everything I need to address doesn't require the removal of the bumper again).



Side note:

And yep about the caution, I've done that before. You could wonder if that caused my HPFP failure but I replaced the filter/primed the system over 20,000 miles ago, and whilst it hasn't escaped me that I could have damaged the HPFP and its slowly worn over the 20,000 miles I think its a little unlikely. I've tore down the fuel system (inc HPFP) and gone over with a magnet. LOADS of swarf inside the HPFP. None in the fuel filter. None in the fuel rail. None visible in the injectors (but it could be further down where I can't see). None in the fuel supply line. A handful in the return line and a handful in the tank. So to me doesn't look like it was slowly dying.

What I do think killed it was my new 70 mile commute over the back roads (right foot happy and big hills) on an engine that's already done 130,000 miles.
 
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