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VW MKIV-A4 TDIs (VE and PD) This is a general discussion about A4/MkIV Jetta (99.5-~2005), Golf(99.5-2006), and New Beetle(98-2006). Both VE and PD engines are covered here.

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Old March 8th, 2018, 10:21   #1
Join Date: Feb 2018
Location: Calgary, AB, Canada
Default Broken Injector Fuel Return Nipple

NY cylinder 2 injector decided it didn't want to come out of my old head and caused a bit of grief trying to get it out. Well I got it out but I broke off one of the fuel return nipples. It's on the left side of the injector so I can put it in cylinder 1 but how would I go about blocking that hole off so fuel doesnt go everywhere?

Last edited by Momentslater; March 8th, 2018 at 13:06.
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Old March 8th, 2018, 13:06   #2
Join Date: Feb 2018
Location: Calgary, AB, Canada

I just found a screw that fit the hole and screwed it in. No problems now.
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Old March 8th, 2018, 13:28   #3
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Join Date: May 2004
Location: central Ohio
Fuel Economy: 50/45/35

I'm thinking maybe it needs to drain the injector. Tedious repair no doubt.
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Old March 8th, 2018, 16:22   #4
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Join Date: Oct 2012
Location: Kitchener, ON

You can get replacement nipples. JB Weld will also work to seal it shut and then just use it on the end like you are.
I buy core TDI pumps. PM me for details
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Old March 10th, 2018, 09:43   #5
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Join Date: Sep 2011
Location: Chatsworth, CA
Fuel Economy: 40-ish

When I sent DBW an injector body with a broken nipple he vetoed it.
I found a good used one on ebay for about $50.
2002 Jetta GLS TDI wagon, 2012 Audi A3 TDI S-Line
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