Hi all, have pulled the injectors from my 2013 3.0 TDI and one injector seat looks a little rough. I've heard 15 x 19mm flat reamer is correct, but on inspection and some other reading it looks like it could be 13.5 x 19mm?
Can anyone confirm as I've looked on quite a few threads on here (and elsewhere online) and haven't been able to determine the exact size.
Thanks for any info you can provide, looking forward to getting back to normal power and no diesel fumes!

Hello and welcome to the forums.
Only mention of flat reamer size I found was for a 7L. See post # 7 of the thread in the link below.

I did find a video showing the injector replacement on a 7P (below) but there's no mention of the reamer size, but it does show the reamer kit used @26:15 of the video. Maybe you could find out based on that.

Link >>>> https://www.clubtouareg.com/threads/repeated-injector-seal-failure.299217/

Video >>>> Injector replacement.

 

Thanks very much for the welcome and very detailed response New2Tregs.....very good of you to find that useful info for me, looks like you did some deep digging there! I'm pretty sure its the 15 x 19mm but I thought the info would be easy to find as it seems to be a pretty common issues with the 3.0 TDI's (injector seals).
I saw the kit used in the video you sent me and actually looked it up online (as the kit only has 4 or so cutters / reams in it and I could see the brand) and that kit doesn't come with a 13.5 x 19mm and does come with a 15 x 19mm so should be the correct one.
Thanks again!!

 

Thanks very much for the welcome and very detailed response New2Tregs.....very good of you to find that useful info for me, looks like you did some deep digging there! I'm pretty sure its the 15 x 19mm but I thought the info would be easy to find as it seems to be a pretty common issues with the 3.0 TDI's (injector seals).
I saw the kit used in the video you sent me and actually looked it up online (as the kit only has 4 or so cutters / reams in it and I could see the brand) and that kit doesn't come with a 13.5 x 19mm and does come with a 15 x 19mm so should be the correct one.
Thanks again!!

Glad I could help as that's what most of us are here for.
Post back with your results as it might help others.
Hopefully you'll get your Treg back to full operational status with no leaks and normal power.

 

Having repaired quite a few seats due to damage after inj washer failure this is what work for me.

• 15 x 19mm flat reamer
• Rocol cutting paste, pull the cutter out after a few turns and clean off the shavings sticking to the paste then repeat till you are happy with the seat.
• Plus, the little aluminum guide that sits at the top of the inj bore i made to hold the whole cutter straight during rotation.

without this guide i believe you could rock the cutter a bit and not achieve a dead flat even seat.

regards
Drag

 

Thanks very much for that Drag, very useful. I actually did the first one tonight and used the technique you described, but without anything like the sleeve / guide you made. I'll try to make up something similar as I think your correct- its hard to get the cutter exactly flat without any rocking.
Have you ever had to use thicker injector seals or 2 seals after cutting the seats? I'd imagine you'd need to cut through quite a lot of material to justify that, but not sure how sensitive the injectors are to being that little bit closer to the action in the engine?
Thanks again

 

Hi Austrag7p,

My personal experience:
The cutter reamer is not very useful, I found is easier to clean and polish the seat with a 3M green fiber for the kitchen, I attached a small piece of fiber with a long screwdriver, and I put enough masking tape to avoid losing the green fiber, then I soak the fiber in gasoline and made the cleaning process moving up/down and turning the screwdriver few times, then use another screwdriver with cotton (used t-shirt) to remove the contaminated gasoline in the seat.

I hope this helps you, regards.

 

Hi Ven3no,
sorry about the late reply but your method was also really useful. I think because I bought a cheap seat cutter seat, it didn't do a great dob so finishing it with the green scotchbrite pad helped clean it up a lot.
All back together now and running a lot better.
Thanks again for the help.

 

Having repaired quite a few seats due to damage after inj washer failure this is what work for me.

• 15 x 19mm flat reamer
• Rocol cutting paste, pull the cutter out after a few turns and clean off the shavings sticking to the paste then repeat till you are happy with the seat.
• Plus, the little aluminum guide that sits at the top of the inj bore i made to hold the whole cutter straight during rotation.

without this guide i believe you could rock the cutter a bit and not achieve a dead flat even seat.

regards
Drag

Having repaired quite a few seats due to damage after inj washer failure this is what work for me.

• 15 x 19mm flat reamer
• Rocol cutting paste, pull the cutter out after a few turns and clean off the shavings sticking to the paste then repeat till you are happy with the seat.
• Plus, the little aluminum guide that sits at the top of the inj bore i made to hold the whole cutter straight during rotation.

without this guide i believe you could rock the cutter a bit and not achieve a dead flat even seat.

regards
Drag

Hi @dragline1570 , any chance you can share the dimensions of the aluminium guide that you machined. I'm looking to do the injectors seals on my 7P soon before or WA travels.
Thanks