RS3 Direct injection leaking from outside the block

[Max2015]

Hi, have anyone face direct injection of cylinder leaking outside the block?

[dhearns]

Yeah. A few of us talked about it here: https://www.audizine.com/forum/showthread.php?t=977587

Do you have specific questions? Maybe some info there can help you?

[Max2015]

Yeah. A few of us talked about it here: https://www.audizine.com/forum/showthread.php?t=977587

Do you have specific questions? Maybe some info there can help you?

I replaced the seals before 2 month, because they were burnt and tiking noise can be heard from far away .

But, now fuel leak from the injector or from the seal. But the leak is from outside and can be seen dripping.

What could it be the cause ? Is it the pressure or evap ?

[Alex D]

Best to just replace all of the direct injectors with the last revision if they are leaking or failed.

[Woobachuckie]

For the "top" injectors(above the intake manifold), make sure the O-rings were properly seated if you replaced those. For the "bottom" injectors(below the intake manifold) make sure the O-rings were seated AND the teflon retainers weren't damaged. I'd recommend replacing those with all 5 "bottom" injectors. Once one fails, the rest will go. I just had mine replaced a few weeks ago and I somehow melted off the retainer for cylinder 4 causing 70% loss of fuel from that injector. I also had 10% loss on cylinder 2. Had all 5 replaced and now runs like it did 58k miles ago(car has 87k as of this morning).

[dhearns]

Yeah, similar to what woobachuckie said. If you didn't replace the orings (where fuel rail and di injectors mate) on the first go, I'd check them first, then go from there.

If you did, maybe there's a chance they could've been damaged, or the line from the hpfp not fully tightened during reassembly??

[StreetLethal]

Not to hijack this thread, but what is everyone replacing these with? OEM DI and MPI from FCP Euro? Or something like Injector Dynamics?

[Woobachuckie]

Not to hijack this thread, but what is everyone replacing these with? OEM DI and MPI from FCP Euro? Or something like Injector Dynamics?

"Bottom" injectors should be upgraded to the new revision N from Audi. Part number: 07K906036N

"Top" injectors are dependent on what your build is. I went with the recommended 980cc injectors from Unitronic since I'm running their Stage 2 e85 file. You shouldn't have to upgrade the top ones unless you're going with a certain build.

[leon7891]

"Bottom" injectors should be upgraded to the new revision N from Audi

do you know why/how the N revision is better ? did you have any additionnal information ?
I'm about to change my 5x 07K906036G, one plastic retainer was melt and the compression gasket was disappeared (probably melt). The green oring was little bit hurt as well.
But only on the cylinder 1. Everything is in perfect condition for the 4 other cylinders (oring, compression gasket and plastic retainer), which is very weird.

Thank you

[DrMerl]

do you know why/how the N revision is better ? did you have any additionnal information ?
I'm about to change my 5x 07K906036G, one plastic retainer was melt and the compression gasket was disappeared (probably melt). The green oring was little bit hurt as well.
But only on the cylinder 1. Everything is in perfect condition for the 4 other cylinders (oring, compression gasket and plastic retainer), which is very weird.

Thank you

Yes go to 07K906036N, they have better material. Might be a degrading problem, seems E85 doesn't help. I'll be replacing mine soon.
https://www.europeanoempartsdirect.c...ctor-7k906036n

[airjordan117]

"Bottom" injectors should be upgraded to the new revision N from Audi. Part number: 07K906036N

"Top" injectors are dependent on what your build is. I went with the recommended 980cc injectors from Unitronic since I'm running their Stage 2 e85 file. You shouldn't have to upgrade the top ones unless you're going with a certain build.

Makes me wonder if stage 1 users should worry as much.

I know for sure stage 2 pushes both direct and MPI injectors much harder, but in my case I’m on 034 stage 1 e85 which has a lot less torque than some of the other tuners.

[leon7891]

what does have a better material ? the injector internals ? any of the gaskets (since you can buy them alone) ?

[dillybacon]

this just happened to me recently. 19 ttrs tte700 15k miles. car has never run e85, i don't even drive it hard. came home late one night in pretty cold temps...maybe 20F, parked car in my driveway, everything seemed fine. next morning i was repositioning cars in the driveway, only had it running for maybe 1 full minute, never got above 2500rpm, smelled fuel. popped hood and saw it dripping from the front of the engine but couldn't see the exact spot, immediately shut car off and it stopped. was busy so it sat for a couple days...i have since driven 5 times, short trips around the neighborhood and no leaks. was hoping i could get it to leak again without pushing the engine to high rpm and get a scope in there to find the exact spot before i start taking everything apart. obviously just replacing the full di set with the N revision is best, but is it the seals that fail on the earlier gen di or are those injectors mechanically bad as well?

[Crowlski]

this just happened to me recently. 19 ttrs tte700 15k miles. car has never run e85, i don't even drive it hard. came home late one night in pretty cold temps...maybe 20F, parked car in my driveway, everything seemed fine. next morning i was repositioning cars in the driveway, only had it running for maybe 1 full minute, never got above 2500rpm, smelled fuel. popped hood and saw it dripping from the front of the engine but couldn't see the exact spot, immediately shut car off and it stopped. was busy so it sat for a couple days...i have since driven 5 times, short trips around the neighborhood and no leaks. was hoping i could get it to leak again without pushing the engine to high rpm and get a scope in there to find the exact spot before i start taking everything apart. obviously just replacing the full di set with the N revision is best, but is it the seals that fail on the earlier gen di or are those injectors mechanically bad as well?

Did you identify the location where it's leaking? A fitting? Cracked hose?

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[dillybacon]

Did you identify the location where it's leaking? A fitting? Cracked hose?

Sent from my SM-N981U using Audizine Forum mobile app

No, I can't get it to leak again. After about 10 low rpm short drives I finally took it out for a few longer typical drives and drove it hard, no leaks. In the next week or so I will pull the DI rail and take a look at the injectors. I have a full set of replacement seals but I will probably just replace them all with the N revision injectors, not really excited about that considering the car only has 15k miles but worth it for peace of mind. If I pull them and notice something obvious like a damaged or missing oring, I'll be tempted to just replace the seals/orings and stick with these injectors. I am not sure yet which version injectors I have, but the car being a 19 I would imagine they are not N. I just want to know what the root cause of the di failures in these cars is - are the N injectors mechanically better or is it just the seals that were updated?

[Crowlski]

No, I can't get it to leak again. After about 10 low rpm short drives I finally took it out for a few longer typical drives and drove it hard, no leaks. In the next week or so I will pull the DI rail and take a look at the injectors. I have a full set of replacement seals but I will probably just replace them all with the N revision injectors, not really excited about that considering the car only has 15k miles but worth it for peace of mind. If I pull them and notice something obvious like a damaged or missing oring, I'll be tempted to just replace the seals/orings and stick with these injectors. I am not sure yet which version injectors I have, but the car being a 19 I would imagine they are not N. I just want to know what the root cause of the di failures in these cars is - are the N injectors mechanically better or is it just the seals that were updated?

Good luck man. I'd hate to hear that you had a real issue with leaking fuel. Maybe take it to a shop?? Just not want you to screw around and wait until something bad happens

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[Skunkwerx]

At 40k (on 2018 MY), I had a similar issue with the smell of gas while driving; immediately stopped driving, and had a mechanic inspect the direct injectors. I was told #4 & #5 had leaking fuel and had burned connectors due
to some of the combustion leaking past the injector seals. So, in my case, seals most likely appeared to be the cause. I replaced all five injectors, gaskets etc and there have been no issues since. As recommended above... I'd have it fully inspected and don't drive at all if smelling gas.

[leon7891]

yeah, all of this is just a simple problem.

The chamber seal gasket that starts to break... then hot combustion pass through and get to top of Direct injectors, and burn the plastic gap parts, and hurt the injector oring to rail. Then leak of gas starts.

I never understood why it happened (to me too), but since replaced, it's perfectly OK.

Until it starts again...