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  1. #1
    Established Member Two Rings
    Join Date
    May 21 2014
    AZ Member #
    233777
    My Garage
    2004 Jetta TDI, 1998 Beetle TDI, 1995 Dodge 1500 SWB, 2003 Audi A4 1.8TQA
    Location
    Bend, Oregon

    Problem pulling injectors

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    2002 S6 4.2 140,000 miles

    I was pulling the intake and when I went to pull the injector manifold off, some of the Orings stayed in the head, pulling the plastic piece off the end of the injector and breaking four of the plastic pieces. Audi doesn't offer the plastic piece, just the rubber seals.

    Am I SOL here and need injectors? Are the plastic pieces available someplace that I haven't found yet? It seems that this piece is needed to keep the fuel off of the Oring, so I'm kinda stuck on this.

    Any help appreciated.

  2. #2
    Established Member Two Rings allroadmark's Avatar
    Join Date
    Apr 30 2014
    AZ Member #
    202869
    Location
    Earth

    I think jhm carries pintle caps for injectors.

  3. #3
    Established Member Two Rings
    Join Date
    May 21 2014
    AZ Member #
    233777
    My Garage
    2004 Jetta TDI, 1998 Beetle TDI, 1995 Dodge 1500 SWB, 2003 Audi A4 1.8TQA
    Location
    Bend, Oregon

    Thanks. I just looked on their site and the only pintle cap I found was for a chain 4.2 so I'll give them a call today.

  4. #4
    Veteran Member Three Rings
    Join Date
    Jun 10 2013
    AZ Member #
    116885
    Location
    United States

    You could try Whitchhunter performance. They are a professional injector cleaning service.

  5. #5
    Active Member One Ring S/RConcepts's Avatar
    Join Date
    Jan 10 2018
    AZ Member #
    412301
    Location
    Illinois

    I recently rebuilt the injectors on my 4.2, OEM is Bosch Type 3. Check out this rebuild kit, I used it for mine, only $13 on EBay: https://rover.ebay.com/rover/0/0/0?m...2F263433619646

    Sent from my SAMSUNG-SM-G920A using Tapatalk

  6. #6
    Established Member Two Rings
    Join Date
    May 21 2014
    AZ Member #
    233777
    My Garage
    2004 Jetta TDI, 1998 Beetle TDI, 1995 Dodge 1500 SWB, 2003 Audi A4 1.8TQA
    Location
    Bend, Oregon

    Quote Originally Posted by S/RConcepts View Post
    I recently rebuilt the injectors on my 4.2, OEM is Bosch Type 3. Check out this rebuild kit, I used it for mine, only $13 on EBay: https://rover.ebay.com/rover/0/0/0?m...2F263433619646

    Sent from my SAMSUNG-SM-G920A using Tapatalk
    Awesomeness! I'll get that kit coming! I'll drink a beer in your honor!

  7. #7
    Established Member Two Rings
    Join Date
    Jul 27 2011
    AZ Member #
    78852
    Location
    Collegeville, PA

    Did you retrieve all of the plastic retainer rings? If you're unlucky (like me) they can drop into the cylinder if that intake valve is open.

    If you're lucky, it will sit on the closed intake valve.

  8. #8
    Established Member Two Rings
    Join Date
    May 21 2014
    AZ Member #
    233777
    My Garage
    2004 Jetta TDI, 1998 Beetle TDI, 1995 Dodge 1500 SWB, 2003 Audi A4 1.8TQA
    Location
    Bend, Oregon

    Quote Originally Posted by CJKaz View Post
    Did you retrieve all of the plastic retainer rings? If you're unlucky (like me) they can drop into the cylinder if that intake valve is open.

    If you're lucky, it will sit on the closed intake valve.
    I was lucky. I got a vacuum in there and got everything cleaned out.

    So, now that I have the parts coming, I have to ask, did I do anything wrong? Is there something I could have done to get the orings to break loose without breaking the shields?

  9. #9
    Active Member One Ring S/RConcepts's Avatar
    Join Date
    Jan 10 2018
    AZ Member #
    412301
    Location
    Illinois

    Nothing you did wrong... the o-rings are over 16 years old at this point, they get really seized on there. I presoaked mine with PB Blaster about a day ahead of time, same thing happened to me.

    Sent from my SAMSUNG-SM-G920A using Tapatalk

  10. #10
    Established Member Two Rings
    Join Date
    May 21 2014
    AZ Member #
    233777
    My Garage
    2004 Jetta TDI, 1998 Beetle TDI, 1995 Dodge 1500 SWB, 2003 Audi A4 1.8TQA
    Location
    Bend, Oregon

    Ok. I also have read to spray soapy water on them. I guess it's worth a shot if I have to do this again. I don't feel so bad now. Thanks.

  11. #11
    Established Member Two Rings
    Join Date
    May 21 2014
    AZ Member #
    233777
    My Garage
    2004 Jetta TDI, 1998 Beetle TDI, 1995 Dodge 1500 SWB, 2003 Audi A4 1.8TQA
    Location
    Bend, Oregon

    That wasn't too bad once I found the proper screw. But who hasn't said that before?

    I was struggling to get the filters out of the injectors, but I found a large sheet metal screw that worked a treat. I think it was used to hold down a piece of plastic on an Audi and it had a 1/4 inch lead in before the threads started. This allowed me to get it pushed in straight before the threads started. I put the screw head in a vice and screwed the injector filter onto the screw. Once I got it in there far enough, I was able to pull and wiggle and pop out the filter. I then put the new filter in and used my water pump pliers to squeeze the new filter in. O-rings went on, then the plastic shield was laid on the table and I just popped the tip of the injector over it.

    Easy-peasy.

    Thanks for the link. Good price and considering the conditions of the fters, they were worth changing. They were very brown and brittle. He might notice an improvement.

  12. #12
    Active Member One Ring S/RConcepts's Avatar
    Join Date
    Jan 10 2018
    AZ Member #
    412301
    Location
    Illinois

    Glad to hear it worked out for you!

    My filter baskets were pretty bad as well, I'm glad I went ahead and got the kit myself. It also beats sending them in for essentially the same thing @ $20/each injector. I did flow some cleaner through mine as well to check the spray pattern, each one was perfect.



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