2.7 TDI Injector Fuel return L shaped nipple

[smaugc6]

Hi,

I was replacing the injector seals on my 2.7 Tdi A6, however while doing so on two of the injectors I accidently took off the L shaped fuel return nipple. Now I can clip them back on to the injector however when running the engine they leak fuel. Are the injectors ruined now or is there a special way to clip them back on??

[Crasher]

A new O ring should seal it, WHT 007 480 A but £9.50 each..... If the return line is damaged that is only available as a complete assembly 059 130 218 H at £294.23.... plus the O rings.

[smaugc6]

Hi Crasher,

Thanks for the info.

Ive been messing about with it since the post, its definately leaking from the nipple on the injector. I have injectors 059 130 277 S. Seems like the leak is because L shaped fuel return isnt really clicking back onto the injector. Il buy some O rings and give that a try.

[smaugc6]

Okay so time for a follow up, I hope this helps anyone in the future.

I have the earlier injectors so the fuel leak off port is detatchable from the injector head, newer injectors are made from one piece.injector 2.jpg

I had diesel leaking from the leak off port thats part of the injector and the fuel return line.

The fuel return line was a very simple and easy fix, a new O ring as crasher suggested and that stopped the leak from there.

However the fuel was still leaking out from the L shaped leak off port on the injector head, looking closely I noticed although the port clipped on, once the engine was started it would come loose. I guessed the o ring inside this port was pushing against it under pressure and causing it to come off. So I decided to wrap a heat resistant cable tie around it and it stopped the leak.

injector 1.jpg