Correct way of re-installing injectors after oil separator replacement

[Mike Literous]

Hey chaps
Greetings from down under.

Just having a few issues with re-installation of my injectors as now twice the car has run nice but a bad fuel smell has been found that upon re-installation I'm rupturing the top O ring. I smear it with some engine oil to help it feed in, but on both occasions I've inserted the injectors in the head first then guided the manifold on them. Should I consider inserting them in the manifold first then walking them down with slow cross tightening of the bolts. Also im considering replacing all the O rings on each injector. Car has done 100000km (approx 60000miles).

Something else I thought of is perhaps torquing them down to a lower setting then letting it sit overnight, then retorquing back to spec? What do you chaps think?

One good thing is I fixed the coolant leak, it pressure tested great holding 15psi nicely, which is great, and I have the forum to thank for all the help. Probaby a 4k + job to do here in a workshop, and even worse with original head gasget diagnosis.

Sorry for the extra questions, but as there is a little bit of green paste in the oil, my plan is to once commissioned back to life, is to run the car to warm then change the oil, then run for another 500km and change the oil and filter again.

[Mike Literous]

hehe answerin my own question here. No way they can be inserted first in the manifold, they have to be inserted in the head first. One tip I got off my mechanic is spray with carb cleaner which works nice as a lubricant. After replacing all the O-rings, they were tight getting into the head, but slipped on reasonably easily into the housings on the intake/fuel manifold. I torqued them down 3x tonight, first at 5Nm, secondly at 7.5Nm, then finally to the said 10Nm. I re-installed the fuel pump fuse and primed them opening the LHS front door. Ill re-torque them in the morning just to be sure everything is good, then hopefully, I can re-install the supercharger and start using the car again.

[sivletho]

I have to replace my pcv valve tomorrow I have Coolant in oil hopefully it’s the pcv and not a head gasket.
You had to pull the injectors out of the block?
I thought if you take the manifold out they would stay in the block
from my understanding I would only need to replace the top oring from the injector

I’m planing on only removing the left side manifold to replace the pcv I saw videos doing it that way.

Hopefully I don’t have any gas leaks like you do


2011 Audi A6 c6.5 3.0t S Line package
Phantom black pearl effect

[Mike Literous]

Yes you could probably leave the Left side manifold in tact. I just got a new set of O-rings for all injectors, and use some carby cleaner to lubricate them as they went back in. Some of my injectors were in place and some came out when removing the manifold. It may be tricky to remove the PCV seperator with only one of the manifolds. You will most likely need to replace the hard coolant line as removing this you tend to break it and the O ring is in bad shape when its removed. You have to watch the brittle air line as it is easy to split. I resealed mine with some High Temp self fusing silicone tape and a 5/8" brass coupling which I had to get compressed down slightly (by the hydraulics shop that I bought the fitting off).


Happy to say it is all back together, coolant circuits pressure tested great, and with the carbon cleaned from the intake ports (wasnt too bad, but good time to clean them) the car runs strongly.

[MATT0404]

I have to replace my pcv valve tomorrow I have Coolant in oil hopefully it’s the pcv and not a head gasket.
You had to pull the injectors out of the block?
I thought if you take the manifold out they would stay in the block
from my understanding I would only need to replace the top oring from the injector

I’m planing on only removing the left side manifold to replace the pcv I saw videos doing it that way.

Hopefully I don’t have any gas leaks like you do


2011 Audi A6 c6.5 3.0t S Line package
Phantom black pearl effect

When I pulled my intake manifolds, all of the injectors stayed firmly in the block. I ordered the injector repair kits and put new o-rings on top of the injectors (lubed with oil) and slid the intake manifolds back down over top. You have to tug on the intake manifolds pretty hard to get them to lift up. Just pull from one side and then the other. Kinda like rocking it back and forth.

My coolant crossover pipe came out intact, but I had a replacement on-hand and re-installed the new one. That torx bolt on the back, aka the devil bolt, is a major PITA. Even worse than getting it out is getting it back in. I realized during my 45 minute ordeal trying to reinstall the bolt that the electrical connections on the bracket that attaches in the same location can be pushed out of the bracket to give you more room to work. That was my saving grace.

[Mike Literous]

When I pulled my intake manifolds, all of the injectors stayed firmly in the block. I ordered the injector repair kits and put new o-rings on top of the injectors (lubed with oil) and slid the intake manifolds back down over top. You have to tug on the intake manifolds pretty hard to get them to lift up. Just pull from one side and then the other. Kinda like rocking it back and forth.

My coolant crossover pipe came out intact, but I had a replacement on-hand and re-installed the new one. That torx bolt on the back, aka the devil bolt, is a major PITA. Even worse than getting it out is getting it back in. I realized during my 45 minute ordeal trying to reinstall the bolt that the electrical connections on the bracket that attaches in the same location can be pushed out of the bracket to give you more room to work. That was my saving grace.

Yes without sliding those connectors out its almost impossible to re-install the "devil" bolt. I used a small cable tie so my mrs could hold it while I lined it all up and got it started, just so I didnt drop anything down. With hindsight probably should have removed the lower cover under the car beforehand to eliminate the risk, as you have to do it anyway to drop the oil.