MK2 8v DigiII is/was leaking at the injectors. I pulled the rail and the injectors. Definitely needs new seals, however I am a bit dumbfounded by the plastic spacers that sandwich the seal.

All of my spacers are cracked and/or missing a nice chunk. There is no way I could remove the spacers or the seals without destroying what is left of this brittle plastic (one already exploded in my hands). Any ideas for replacement spacers? I can't seem to find anything.

Red is the seal. Yellow are the spacers (notice the bottom most one with the chunk missing):


Cracked:

 

Checked ETKA

These are the only #'s listed in the diagram
037906031P Entire Injector
035906149A O-ring
037133047 Spring Clamp
037133555A Injector end
037906149 Some unknown injector Support washer

It doesn't even look like seal kits come with any
Parts4vws.com and Parts4Audis.com - Injector Seal Kit Digifant

I remember when I did my injector seals for CIS-e I ran into a similar problem with no one knowing about the E-clips that held the o-ring in place. I was told not to worry about it as it is more of a vacuum system than a pressure system, so the o-ring would still seal. It could be different for Digi. If worse comes to worse I'd imagine getting some generic E or C-clips should do the trick.

 

That grey spacer in the seal kit is what a German Auto Parts sales rep told me could work. Guess I could spend a little extra and order them since I need the seals anyways. If that wider grey spacer is the same width as my two smaller spacers combined it could work but I'd need to figure out whether or not to put it above or below the seal.

 

Quick update. Posted something on Bently's forums. One person on there had a replacement set of injectors for his Digi2 that had the seals without the plastic spacers. So it seems they aren't necessary. Reckon I'll get new seals, swap them out, and give it a go.

Fuel leak is probably from a bad top seal, but since they are out and those bottom seals look pretty flat/old I'll do them all at the same time. Hoping the injector itself isn't leaking (i.e. cracked). They all pass the visual inspection.

 

i had to do the same to a friends 8v a few years ago and we were able to get the injector seals and spacers from advanced auto...

if i remember they were like 3 bucks per injector.

 

As stupid as this sounds I never thought to check with Advanced or NAPA (assumed they wouldn't have anything for the car). I'll swing by there.

Took a closer look at the injectors and a couple have some rust at the seam where the plastic top part meets the metal bottom portion. Apparently these injectors hardly fail, but when they do it is at that seam. Thinking this rust could be evidence of a slow leak. Since my ECU is toast I know I can get it to fire the injectors for me. Going to test them out by spraying them into a bottle to determine if I have leaky injector(s).

 

lol.... sometimes the most difficult problems have the simplest solutions.

 

NAPA has them.

Interesting thing about NAPA is they are stocking a ton of Boge, Bosch, etc parts for European imports. Glad to have a local retailer of quality replacement parts.

 

Do you have a part # for them?

 

Didn't write it down. The seal set is listed on their website though.

I went ahead and ordered new injectors from GAP. $36 per injector for new VW/Audi parts. Beats the $137 for rebuilt Bosch injectors at Napa.