I bought this 2008 model back in 2016 as a replacement for my previous B7 2.0TDI Avant. I specifically wanted a 3.0TDI Quattro and the spec and condition on this was great. I bought a set of winter wheels and tyres and put a Tune2Air bluetooth adaptor and it's been a very reliable car.
As it's reached close to 200K miles at the turn of this year I began to get issues due to the inlet manifolds swirl flaps being worn out (the o-rings on the output shaft were blowing). I sourced reconditioned units from AirShox EU in Bulgaria (amazing service and quality) to cure that this time around. The car had received replacements via Audi prior to my purchase at just over 100K so that looks to be the lifespan on them.
At the start of this month the car went into the local Audi dealer to get a new key coded and they did a health check that flagged up a few issues to work through prior to sale including the diesel injector seals. the dealership Master Tech was really good and said he heard it as soon as the car was started up and pointed out you could smell it in the cabin.
Sure enough... Ordered a seal kit and found a really good explanatory video on YouTube.
Mine is a CCWA engine so no stretch bolts and a different way to get the injectors out (slide hammer still needed) - there is a better video for the CCWA job below.
When removing the fuel return lines, the central part of the body comes up about 1/2" and unlocks the clamp. I used a large flat bladed screw driver to get them moving, then you could hold the main part of the body down using the plastic T bars and pull up the rest of the clamp part. Once fully unlocked the return line housing pulled off with very little effort. I didn't take a photo, but it's this bit:
All went really well, with one minor issue, I lost one of the used copper washers when removing the first injector. Whilst it would have saved me hours of work if the myth that these completely vaporise was true, based on the clean condition of the injector where this washer was missing vs the carbon caked state of the one that was leaking, I worked out it must have dropped into the cam cover as I took it out.
So work paused whilst I ordered a new cam cover gasket and then it was inlet plenum off and a bunch of other stuff to get the coolant expansion tank side cam cover off. Not worth the risk of a copper washer being left in the cam gallery. Sure enough, here's the culprit.
This is what they looked like:
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[2] - [5]
[1] - [4]
Just a note on refitting the injectors, to get the curved mounting plate to properly seat and allow the nuts to be put back on the studs a little left-right rotation and downward force allowed them to drop into place the final 1/4".
It was very similar on the fuel return line, applied a little oil to the o-rings and then needed to jiggle them left-right in small arcs with downward pressure until they properly seated, I only noticed one making a 'click' noise as it seated, but you can't fully depress the locking part of the housing unless they are correctly seated. When they are on correctly the locking part sits flush.
Hope this helps some other folks.
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