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Go Back   TDIClub Forums > TDI Model Specific Discussions Areas > VW MKIV-A4 TDIs (VE and PD)

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 February 17th, 2004, 05:55   #1
dieseling
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Join Date: Apr 2002
Location: Tx
Fuel Economy: 45 mpg
Default diesel fuel leak

I have a slight leak at #2 injector from either the steel fuel line or possibly the small black hoses.Car has stock injectors never touched.Tried tightening line, very tight.
Is there an o-ring at connection from fuel line to injector?
Hesitant to bring to dealer.
2002 Jetta TDI.
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Old February 17th, 2004, 06:09   #2
weedeater
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Join Date: Mar 2001
Location: Reston, VA
Fuel Economy: 54/43/38
Default diesel fuel leak

How many miles?

There's a washer, I think.

Is the black rubber hose wet? The black hose is the usual source of leaks. The rubber degrades due to heat and vibration. They are simple to replace. The hose clamps are not really required since the line is not pressurized. At least not that much.
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Old February 17th, 2004, 08:02   #3
dieseling
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Join Date: Apr 2002
Location: Tx
Fuel Economy: 45 mpg
Default diesel fuel leak

I have 35000 miles
the fuel line nut is slightly wet the rest of the injectors
just looks dirty. car runs fine.
With all the people changing injectors somebody must know
if its an o-ring or compression seal at the injector fuel line.
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Old February 17th, 2004, 11:27   #4
cattlerepairman
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Location: Ottawa
Fuel Economy: 8.4 l/100 km at 60/40 hwy/city
Default diesel fuel leak

I BELIEVE it is a copper compression washer. I also BELIEVE to have read that by taking the washer, heating it up till it glows and cooling it down in water, it returns to its original shape and seals like new.
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Old February 17th, 2004, 12:11   #5
Kennedy
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Join Date: Jul 2002
Location: Fredericksburg, VA
Default diesel fuel leak

[ QUOTE ]
I BELIEVE it is a copper compression washer. I also BELIEVE to have read that by taking the washer, heating it up till it glows and cooling it down in water, it returns to its original shape and seals like new.

[/ QUOTE ]

NO... The compression washer provides the seal between your head and the injector (during compression). Spray some water on the seam (where the injector and head meet), and look for bubbles. If you see bubbles, you have a small compression leak. Tighten the 14mm bolt 1/4 turn.

If you are leaking diesel fuel tighten the nut where the fuel lines meet the injector. I believe a 17mm crows foot is the easiest to manipulate. There's no O-ring or anything like that.

If your injector return lines are leaking, replace them with some 1/8 internal diameter, 3/8 outer diameter VITON tubing from McMaster.com. 1 foot ($18, not cheap) will do the whole car... It's biodiesel friendly and should last forever.

If you change injectors, I've found you should tighten these at leats twice, as the heat cycling tends to loosen both.
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Old February 17th, 2004, 12:58   #6
mwalters
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Location: SE Michigan - Have VCDS
Default diesel fuel leak

There's no gasket on the fuel line to injector connection. It has a built-in ferrule (sp?) in the steel line. Double-check the little braided cloth lines. They tend to deteriorate rather quickly. They allow excess fuel to flow back to the pump - not high pressure.
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