injector O-ring replacement - estimated cost?

[kismetcapitan]

I want to get my leaky injector O-rings done this month, but the wife wants a cost estimate, and she didn't think it was funny when I said the rubber rings would cost about $10.

I'm estimating what it'll take to do the job...feel free to add your expertise over my guesswork:
- remove airbox
- unbolt fuel rail
- pull rail, replace O-rings
- reassemble

That's what, an hour or two of shop labor?

Potential problems/delays:
- poor O-ring fitment: can't recall which site, but I came across a thread discussing A4s(?) with the same problem and that the VAG part was a touch too small, which compounded the problem
- getting injectors serviced: I know someone mentioned this, but who's good at servicing injectors? Pulling the injectors and sending them out overnight back and forth isn't a problem. I'd love to put in my favorite injectors (RC Racing), but even if I matched the flow rate, the lag times are completely different as RC uses a different mechanism (a rotating disc instead of a piston I think) that has them injecting faster. Without compensating for that in the ECU, it'll throw everything off. So stock it is.

btw, what's the commonly accepted longevity for fuel pumps? Is the stock main pump a Bosch 044? If not, is anyone using one? and then there's the lifter pump in the tank. I have reason to be paranoid about fuel pumps; if you're unlucky and a pump fails while you're at maximum boost, you can fry all your pistons. This happened to me with my old Skyline, and that damned $200 part ended up costing me $15,000 in an engine rebuild. Doesn't happen that often when a pump fails, but it can be catastrophic.

And I guess I'll have my Phaeton ducts installed as well at this point.

And THEN, my car will be at 100%!! (the fuel leak lasts only until the car is warm; at that point, whatever is loose has expanded and seals it off. This only happens when the temps drop below 50 degrees and the car is outside and completely cools down...which is why I was baffled as to why it wouldn't do it when starting cold from home, since my garage is warm).

[4everRS]

If you don't have a problem taking off the airbox, you can DIY the injectors. You'll need to remove a few vacuum lines. Mark them so you know which is which upon reassembly. Take your time removing the injectors, with rail attached. They can be stubborn to get out.

Then, send them to Mr. Injector. They will rebuild them for you, do flow and spray pattern tests, as well as replacing more than just O-rings.

[Brav]

I did the o-rings when I pulled my manifold. Wasn't too hard. Having a pick really helps. Razorblade to cut old ones off. Pick to get them back on and stretch them over the top. 2 hours is probably what you would get charged for.



pull airbox, disconnect all of the injector/coil/sensor connectors, etc. You will have to cut a few zip ties.


With harness out of way, should look like this. there are some hex bolts and studs you will have to pull to unbolt the whole rail. You will have to pull and jiggle to get it out.


14mm and 17mm wrenches for pressure lines


These little plastic pintles (sp?) may crack or fall off. I am told they aren't necessary..


Rail pulls out with injectors attached.

[JRS-RS6]

I did these with V8Weights help two years ago this month:
The part number for the 16 injector O-rings is: 16 035 906 149 A -- Total was $ 37.44 through genuine

Two hours sounds about right.

[ben916]

I did these with V8Weights help two years ago this month:
The part number for the 16 injector O-rings is: 16 035 906 149 A -- Total was $ 37.44 through genuine

Two hours sounds about right.

So did the plastic piece get replaced or tossed?
The rubber O-ring obviously is replaced and tossed...

Also, did you disconnect the battery or pull a fuse for the fuel pump? Or did you live recklessly like Fire Marshall Bill?

[Brav]

I didn't replace any plastic pieces.. just used the pick to stretch over without breaking them. pretty sure they are impossible to replace

[V8weight]

Replacement pintle's are available through JHMotorsport http://jhmotorsports.com/shop/catalo...h=21_56_61_240, although I have no personal experience with them. Having broken one of my own, I did a lot of research and concluded that they really don's serve much of a purpose. They are technically a diffuser. Despite that, I couldn't live with the fact that i was missing one, and ultimately bought a new injector.

[kismetcapitan]

great detail Brav, thanks!