Spill Pipe come off

[dean warren]

So my 2012 3.0 BiTDi died tonight on the m40, started to stutter glowplug light then engine check light, then engine seemed to turn off, pulled onto the hard shoulder and tried to restart, nothing so i got out popped the bonnet to be greeted by diesel smell so had a look around and noticed diesel spill pipe had come off, the pipe had pushed off the t piece, i pushed it back on, car restarted but sounds like an injector seal or manifold gasket has gone now as have a tic tic noise, got about 10 miles and pipe came off again, are there supposed to be clips holding the pipe to the plastic? Is this a common issue as a few other joins look to be wet on the spill pipe too


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[Crasher]

After the check valve into the banjo fitting there should be an "ear crimp clamp" N 102 313 01 which is £1.21 and on the return line side a reusable spring band clamp 4B0 422 379 which is £1.13.

[dean warren]

This is driver side front injector, as the spill pipe comes to the 1st injector it keeps popping off the T peace on top of the injector, but it is weeping on several other joints too.


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[philipharmes]

It sounds like there is excessive pressure building up in the spill pipes causing them to weep, & eventually blowing off the weakest one.

I think they go through a non-return valve & back to the fuel return pipe.

Check for a blockage or perhaps a faulty non return valve.

[Crasher]

That’s what I was thinking

[dean warren]

I have ordered a new spill pipe it comes as both sides and goes to a return valve then into a single pipe. Also going to change the injection seals and the bolts that hold the injectors in.


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[philipharmes]

If you're removing the injectors, perhaps worth getting them tested.

One or more might be leaking excessive fuel back to the return pipes exacerbating the situation.

[dean warren]

This car [emoji594] is a money pit lol [emoji23]. Can the rebuild these injectors? Or are they piezo like the C6 where rebuilds were not advised?


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[Crasher]

Assuming it is a CGQB engine, they have been revised and VAG don't do an exchange which probably means it isn't economical, the new part number is 059 130 277 EL and £660.31 each retail inc VAT. Bosch offer them new under their part number 0 445 117 028. A common failure is the compression blowing by and even disintegration of the fire ring, this is often shown by this

https://live.staticflickr.com/4869/44783048580_5115996b61_o.jpg (https://flic.kr/p/2bejQ8f)

If the injector bodies are covered in carbon when they come out, the fire rings need to be checked to make sure they are intact (or you have to find the bits) and the bores must be immaculately cleaned using solvent, compressed air and VAG cleaning kit VAS6811, I quote "Ensure cleanliness, as even minute dirt or soot particles in the copper seal area can cause another leak"

[dean warren]

Yeah it is blowing by the injector, started if from cold with the bonnet up and got a blueish haze round the front injector drivers side.


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[Crasher]

stop using it, it may not yet have broken the fire seal.

[dean warren]

stop using it, it may not yet have broken the fire seal.

Not used it since last week, whats the fire ring? Im hoping to look it over Sunday need to do a leak off test


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[Crasher]

The fire ring is between the injector and head, if it disintegrates the bits fall into the cylinder as you exact the injector and as they are non magnetic are a pain to get back out, the manual states you MUST account for all the pieces.

[dean warren]

Thats the copper ring? I noticedthe once vw sent are very beefy compared to normal cars few mm thick and domed


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[dean warren]

https://uploads.tapatalk-cdn.com/20210313/7a51dbe16d3c8e9c2abce5bc0cc586e6.jpg


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[dean warren]

Well i have done a leak off test on the driver side bank of 3, there is hardly an difference in the volume, so i don’t think it’s excessive leak off from the injectors.
Im not sure how the cylinders are numbered but drivers side front injector was loose, i have removed it and the port is a state! Oil seal is damaged, but the copper fire ring is virtually burned away, https://uploads.tapatalk-cdn.com/20210316/ccae27c75fae679ae618381d913655af.jpg
The next cylinder back has no oil ring at all, but little crap inside or on the injector and number 3 closest the drivers side has all the sludge on the exhaust manifold as your previous picture Crasher so clean up duty’s next.


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[Crasher]

I hope it all cleans up well.

[dean warren]

Yeah I brought the laser cleaning kit as could not justify the vag tool @ £900. Wasn’t bad to be honest, all ports clean on the one bank all new copper genuine seals, turns out one injector isn’t genuine so i need to check that was coded in properly, but none of the injectors had the o ring on them, not sure if they had disintegrated or I suspect some one has been in here b4 and left them off. Need to do passenger side bank next. Still unsure why the spill pipe was coming apart on the joints but will swap that too.


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[Crasher]

I imagine the spill pipe was coming off due to excessive return pressure. When you have done all six it should run a lot better.

[dean warren]

So it appears only 2 of the injectors are the original as only 2 matched the ones coded, i have now correct coded them all, i still need to pull injectors 2 4 and 6 as its clear someone has been here before and bodged everything, cylinder 5 had a flat copper washer not the proper domed version https://uploads.tapatalk-cdn.com/20210319/63265f240d4f951020e51a56a42e9be8.jpg


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[dean warren]

https://uploads.tapatalk-cdn.com/20210319/32de3a34a9ac5486e66d6381cde3a923.jpg
And thats worn, it sounds a lot better now though.


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[dean warren]

All done both sides now cleaned and new seals and o rings sounds a lot better was same as the other side one copper fire ring burnt out and incorrect fire ring fitted and no oil o rings


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[dean warren]

And new spill pipe fitted to be safe. Thanks for the help Crasher


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[Crasher]

I struggle to see how the last person in there brain was working, how do you intentionally reassemble something in that manner?

[dean warren]

It makes you wonder, I could possibly get it on a old low value car, but on a BiTDi they clearly didn’t care just wanted to get it in n out the door.


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[Crasher]

For me not even an old shed, do it right do it once.

[LordAudiQ7]

Hi, We need help please 🙏

It's an emergency. I have the exact same problem. Spill pipe line came off 2 times one week ago. I'm on a trip in Italy. Now stuck in florence. Driving on the aoutostrada like 120kmh putting pressure i think. Suddenly the car spitts out big smoke clouds in the exhausts then died. The service where they left the car after towing. They want $6000+ to fix the car. I think that fire copper ring broke and took in oil or water and caused the smoke. Code says something like to high pressure according to the Italian service center.
I work on cars a little bit. Fix brakes built an exhaust for my Bentley, change oil and filters, change sparkplugs, change tyres by hand etc. But I'm not a pro.

Can i fix this my self with parts and tools on site? Do i have to change the injector that broke? How do i code the injectors?

First i go home leave the family then come back to fix the car.

Regards
Mr Bentley

[dean warren]

You will get a code for fuel pressure as a pipe came off, not sure what caused the smoke thought, best change the spill pipe n go from there.


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[LordAudiQ7]

Hi thanks for answering.

Ok, I got flasshing glowplug lamp at the same time as smokecloud and start and stop failure warning. The tow guy and me started the car with start gas. First knocking sound then I could rev it between 2000,-3000rpm but BiG smoke cloude fromexhaust white cloud. No idel. After that we sa diesel dripping from the exhaust. Mechanic said it could be a injector staying open from dirt. But then it woldnt be high pressure in leak line? If the valve was broken then rhe would be a code for that?

Regards