A4 b6 1.9 tdi injector loom replacement

[brucielee]

Ok so the question is, has anyone replaced the injector loom/harness on this engine awx code, given that the engine runs front to rear and the loom/harness has to be taken out going towards the bulkhead of which there is no chance of it coming out, does the engine need to be unbolted and lifted up above the bulkhead in order to do this, bit of a nightmare if it does for such a simple enough replacement, which seems to be a common fault in the 19tdi throughtout all audi/vw vehicles
If someone could shed some light it would be greatfully appreciated

[zollaf]

it will bend enough to get it out, better so if its warm. the new one will also bend better if warm. love the way you say its a common fault. the awx went out of production in what, 2004, so it must be at least 13 years old.. ???

[brucielee]

Cheers zollaf,I know its an old engine lol, When I said common, I meant common as in it is a part on these engines that needs replacing as there quite a few related problems to the injector loom failing, ill try it over the weekend and see
Thanks

[zollaf]

a kettle is your friend, or pan of hot water to make it bendy enough.

[zollaf]

a kettle is your friend, or pan of hot water to make it bendy enough.

[arman123]

awkward but can be done hot air gun would be best to bend harness

Removing and installing electrical [COLOR=#1B8EDE !important]wiring harness[/COLOR] for unit injectors Special [COLOR=#1B8EDE !important]tools[/COLOR] and workshop equipment required

t Hot air blower -V.A.G 1416-

Removing – [COLOR=#1B8EDE !important]Remove[/COLOR] [COLOR=#1B8EDE !important]cylinder head[/COLOR] cover → Rep. gr.15. – Unplug electrical connector -1-. – Move aside fuel hoses at air pipe. – Remove [COLOR=#1B8EDE !important]bolt[/COLOR] -2-. – Remove air pipe -arrows-.

– To unplug electrical multi-pin connector for unit injectors and glow plugs, pull release pin -arrow 1- and slacken knurled nut -arrow 2-.

– Pry off connector from the unit injector using a screwdriver -arrow-. Press gently against the other side of connector with finger to prevent it from tilting.

– Unbolt multi-pin connector from cylinder head and press it out of hole on cylinder head. – Push the wiring harness out of the guides -arrow- and remove the retaining clips. Note Take care that the wiring harness does not break when pulling it out. Make sure that no parts break off the wiring harness and get into the engine.

Installing – Pull retaining clips -2- off new wiring harness. – Insert connectors -1- into [COLOR=#1B8EDE !important]assembly[/COLOR] guides to facilitate [COLOR=#1B8EDE !important]installation[/COLOR] of wiring harness.

– Heat wiring harness -1- using hot air blower -V.A.G 1416- only until you can bend the wiring harness to install it without breaking.

– Working from the bottom right side, slide wiring harness -2- into hole on cylinder head -arrow-. l [COLOR=#1B8EDE !important]Guide[/COLOR] wiring harness so that electrical connectors -1- for unit injectors come to rest in the position shown in the [COLOR=#1B8EDE !important]illustration[/COLOR]. – Attach retaining clips and move wiring harness into installation position. – Tighten bolts on multi-pin connector. – Attach electrical connectors for unit injectors. Remaining installation steps are carried out in reverse sequence; note the following: – Remove cylinder head cover → Rep. gr.15. Tightening torque

Component	Nm
Connector for wiring harness to cylinder head	10

[brucielee]

Thanks for that arman123, much appreciated, thankfully I didnt need to go to the hassle of removing the loom, when I got the cover off and started to take connectors off the injectors I noticed that the one closest to the timing belt was far too easily removed, the other three were harder, when I had it connected to vcds it was telling me there was an electrical fault on injector 1, assuming the one closest to the tb is number 1 and it was easy to remove I got a thin screwdriver and put a small bend in the connectors contacts, put it back in and two days later still running without a problem, it was strange as the problem only occured when the engine was cold first thing, assuming the metal of the injectors expands slightly when heated up this made the contact between injector and loom close tighter, so it would make sense that it never happened again until the next morning, that seems to be that problem solved for the time being anyway, thanks for all comments and help and I would suggest anyone with this problem check the contacts between loom and injector first to make sure there is good tight contact before going to the expense of buying a loom, I know there not pricy and it wont always be as easy as that but worth a try
Thanks again