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2.5tdi oil leak from rocker cover injector grommit

Razor61 May 2, 2019

  1. Razor61

    Razor61 New Member

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    Hi, I'm after some information/advice for the problem below if anyone out there can help please?
    Car is a 2001 A4 B6 2.5tdi quattro sport.
    I recently had an oil leak from the (looking from the front) left hand rocker cover seal/gasket and I had it replaced at the same time as the cambelt/water pump/ thermostat etc was replaced. That has cured the issue but I have now noticed an oil leak from one of the rubber grommets that seals the injector (L/H side at the back). Apparently these grommets are not available from Audi and a new rocker cover is needed, but I've found some replacement grommets on Fleabay from Germany that look decent enough so I'll give them a go. I have no issue doing the job but I'm not sure about reconnecting the injectors and associated pipe work so have a few questions.
    1. will the injectors be pressurized and if so how do I relieve the pressure, is it by simply undoing the fuel line to the injector?
    2. once I've reconnected all the pipework etc, does the fuel system need to bled or will it just work again after a few cranks of the engine.
    3. I've read that the crankcase breather filter can cause leaks from the grommets, if this is the case does anyone have a guide/advice to changing crankcase breather filter on a 2.5tdi AKE engine?

    Thanks in advance
     
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  3. Mike B

    Mike B Well-Known Member

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    It seems that you first need to determine the cause if you feel the crankcase pressure is too high and has resulted in these problems.If the breather is blocked then again whats caused that.I have little expertise but guess there is no pressure unless the engine is running and it is important to keep air out of the fuel lines.I have often had to clean a filter on a petrol engine but no idea if a diesel can bung up in the same way. My 04 has no sign of leaks around these grommets only a slight weep from one of the rocker cover gaskets
     
  4. Razor61

    Razor61 New Member

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    I only mentioned the breather because I’d read in another post about it and figured it probably needs replacing so may do it as well. As it happens I think I’ve solved the issue.
    When I first saw the symptoms of a small amount of oil (it looked like oil) under the front of the car, I wiped the rocker cover clean so I could then check to see if any more oil had leaked as it was all cleaned. I ran the car to work and back for a few days then remembered to check to see if any more oil had leaked. I lifted the bonnet and there was smoke coming from the engine bay, not a massive amount but it didn’t smell like burnt oil. This is the first diesel car I’ve had and I guessed it was diesel and not oil. Earlier in the week I read a post somewhere regarding the injector grommet leak and someone said ‘are you sure it’s oil, it could be diesel from the spill pipes’. So I looked at the spill pipes and one of them was nearly disconnected completely and the others wet with diesel. One pipe was knackered and split at both ends, I think when I cleaned the rocker with a rag I must have caught the pipe and nearly pulled it off because it was so knackered.
    Anyway, off I went to the motor factors and purchased some new spill pipe. Replaced the left hand side spill pipes, 3 of them, and secured with small cable ties. Then went for a 5 min run and checked for leaks etc. To my delight there were no diesel leaks at all now and no smoking.
    I think there is still a small bit of oil weeping from one of the injector grommets and previously it was mixing with the diesel leak from the spill pipe which then looked like it was a larger oil leak. I hope that makes sense!
    I’m still waiting for the new injector grommets to arrive and maybe fit them in the future if needed.
    Just thought I’d document it in case anyone else has a similar issue and it could save them some time and money.
     
  5. Mike B

    Mike B Well-Known Member

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    That makes sense.I have had to replace the spill pipes cos they harden and weep but I wouldn't worry about any minor oil seeping.You were lucky the diesel didn't get too hot.
     
  6. Razor61

    Razor61 New Member

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    Just one other issue that I fixed while doing all this was the glow plugs. From cold the car didn't start straightaway as expected, especially when very cold in winter, and I got into the habit of letting the glow plugs heat up, turn off the ignition and then doing it again. I thought some of the glow plugs were maybe faulty. I didn't do anything about it at the time because I bought the car as a stop gap while my M140i was being repaired ( long story involving house break in and car stolen ) that was 17 months ago, the M140i has now gone and I'm using this car until I decide what to do.
    When I was looking at the oil leak issue I noticed a lot of disintegrated foam from the engine cover laying on the inlet manifolds around the glow plug connectors, I removed all the remaining loose stuff from the engine cover, got the vacuum cleaner and vacuumed up all the bits of foam from the inlet manifolds. While I was doing this one of the glow plug caps came off (and it wasn't me being heavy handed!) so I reconnected properly and then checked the others, from memory I think 3 of them were not connected properly so they were snapped back into place as well.
    Result, car starts much better. I know it's not exactly freezing at the moment but I definitely noticed a big difference and the car starts on the first/second crank. Before it was a few more cranks before it started and wasn't exactly smooth.
    Why they were not connected properly who knows, maybe whoever took them off previously thought they were connected as they take a bit of force to snap in properly. They are definitely connected now though!
     
  7. Mike B

    Mike B Well-Known Member

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    That's a bonus.They are usually good starters if timed right.Mine hardly needs any help now.The foam lining is best replaced with the adhesive panels you can buy for insulation
     
  8. Razor61

    Razor61 New Member

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    Mike B, yep definite bonus and thanks for the advice. I've had petrol BMW's for a long time, 2002Tii, E36 M3, E46 M3, M140i to mention a few but this 2.5 Tdi Quattro Sport has grown on me. The Mrs has been using it for the last 12 months and she loves it, now she's using a Dacia Sandero and isn't happy!!!
    I bought it for £1700 17 months ago and replaced the discs, callipers and pads as rears were shocking and the fronts weren't much better, as said before it was just a stop gap but it's done us well to be honest and has done 112,000 miles. Recently had timing belt and other stuff done @ £1100, suspension needs attention if I'm going to keep it for a while. I don't think it's worth a lot so I need to decide to keep or sell. Head says keep and run to get moneys worth, heart says look for a S5 or E92 M3...…..we'll see how it goes:sm4:
     
  9. Mike B

    Mike B Well-Known Member

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    You are very welcome just comments really as I am past doing much.My first one was a manual Avant and now have an auto with some nice extras.I have been delaying the cambelt job cos the cost is hard to justify but it seems they may be holding value a bit better now so who knows.I once had an Accord that did 132k before the belt snapped but I knew it was safe and the Honda workshop manual said nothing about changing it!!.Also you need to find someone who knows how to the job well.Never had a BMW being a Quattro fan since my son started on Subarus and I inherited from him.He now has an S5 V6 which I enjoyed helping him source but have never driven; its probably worth about 10 times the A4.However we do share aTT roadster which I can just about manage.Have you cleared the grommets under the battery?
     
  10. Mike B

    Mike B Well-Known Member

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    Correction... I have had a BMW a 60s Isetta bubble car before I had a car licence.Fun but the transmission kept failing probably cos we kept having another passenger and overloading it.So I passed my test and gave it to the lad next door to keep in his front garden as his Batmobile.Wouldnt do that now
     
  11. Razor61

    Razor61 New Member

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    Just an update on a leak on 'the rubber grommets that seals the injector ' (don't know what else to call them)
    Yesterday I got round to replacing these rubber grommets and it took a few hours. Longer than expected but I did take my time.
    Removed the air filter box completely with the MAF assy attached - removed the air intake pipe work to the turbo - removed the spill pipes and couplings from the injectors - set aside the couplings along with the copper washers etc - disconnected the injectors - placed a length of wood over the engine rocker cover area and used cable ties on the injector pipes/vacuum pipes/wiring attached to the wood to lift them out of the way a few inches. I did this to create some room to remove the rocker cover without fighting with pipes and wires. I also removed the oil dipstick as it was in the way as well. Removed the rocker cover and rocker gasket. Cleaned the gasket and rocker cover. Removed the old grommets and removed the remains of the original glue and rubber, cleaned up with emery cloth and brake cleaner. Applied some gasket sealant in the groove round the outside, I did this because the fit onto rocker cover wasn't tight and the originals are glued in. Cleaned up the head, applied a thin layer of gasket sealant to the bottom side of the rocker gasket and placed onto the head. Applied a thin coat of gasket sealant to the sealing surfaces on the rocker cover and re fitted the rocker cover. Re installed the turbo air intake pipework to the turbo and bolted down the rocker cover. Cleaned up the spill pipe connection faces on the injectors and the faces for the injector pipe connections, remove the cable ties holding the injector pipes etc out of the way, refitted the injectors, refitted the spill pipe connections using new copper washers and tightened. Refitted the rest of the air intake and anything else that was removed (including the oil dipstick).
    Fired up the car and it ran very lumpy for a while due the injectors being removed and checked for oil around the rocker cover and diesel round the grommets and spill pipes, all seemed ok so I gave myself a pat on the back:)

    I had just finished when the Mrs wanted to know if the car was ready to use, I wanted to leave it overnight to let the sealant all set etc, but I said yes it is and it will give all the work a good test doing a 20 mile journey. So when the car came back a few hours later I checked for any signs of diesel leaks on the injectors and spill pipes and oil leaking from the rocker cover. I couldn't see or feel anything so it looks ok.
    I had to take more stuff off the car than expected and if I had to do it again it would take a couple of hours (if that) rather than 4 hours but (depending on the price of a new rocker cover from Audi) I would just put a new rocker cover on with all the grommets in place next time I think. The replacement grommets were around £30 for six but they are available as a set along with the rocker gaskets as well for around £60.
     

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