Injector copper washer lost!

[The Tangerine Dream]

Good afternoon everyone,

I've changed an injector today and the copper washer was left at bottom, as half expected.

On fishing it out, I lost grip of it and it lodged itself under the seal of rocker cover, then it fell somewhere inside where I can neither see or feel.

Realistically, what are my options?

Thanks all.

TTD

 

[Vinyl1210]

If it was me, I’d buy an ‘endoscope’ (they’re quite reasonable money for a decent resolution) and have a good look for it. You’ll be able to look into the injection port too (sorry not sure from your post if that’s what your saying in that it’s deffo fallen in there) to see if it’s fallen in there. Hopefully you’ll then find it.

 

[PhillH]

You could drain the oil and and remove the sump to see if it has made its way there.

Good luck

 

[manfrotto]

Did it full into the injector hole (so inside the engine), or just somewhere in the engine bay?
I wouldn't think the washer would physically fit through the injector hole?

 

[lateski]

There is a quite big gap between valve cover and camshaft module/head where the washer could have fallen. The oil drain passages in the head are probably smaller than the washer, so the washer might be still in the head. -> This could lead to a catastrophic failure if it gets stuck between valve spring, camshaft or a rocker arm.

Edit: At this point taking the camshaft cover of and buying a new gasket isn't a big job since you already have the injectors out.

 

[The Tangerine Dream]

Thanks for all replies.

The washer sounded like it fell in the gap in the area circled.

Should I see it straight away if I took the cover off?

Thanks

TTD

 

[PhillH]

Thanks for all replies.

The washer sounded like it fell in the gap in the area circled.

Should I see it straight away if I took the cover off?

Thanks

TTD

View attachment 318970

Sorry I thought you already had the rocker cover off. But looking at your photograph it is still on so I would say yes remove it and hope it is there. Unfortunately you will have to remove the other injectors.

 

[The Tangerine Dream]

Update - It's out!

Obviously I had to take the rocker cover off which wasn't too much bother and used a hook to fish the washer out.

Little sod.

I'm going to replace the cover gasket whilst I'm here.

Thanks to you all for the contributions.

~ TTD

 

[The Tangerine Dream]

Chaps, do you have any advice to remove the 4 x Seals on the cover, please?

I've tried to be clever and replace them as the cover is off already and they're not coming out!

I don't have any special tools.

Cheers.

TTD.

 

[PhillH]

Have you got the new seals? I’m sure they just knock out ans the new knock in.

 

[Phil_j89]

Make sure you replace the bolts that hold the injector clamps down, too! These are one time use, and I've seen plenty of these break over the years after being re-used.
Torque figure for the clamp bolts is 8NM + 270degrees.
Ideally, you should be replacing the copper washers on all removed injectors.

With regards to the injector seals on the rocker cover, there was a specific press tool for removing / fitting at VW. They could be a pain at best sometimes, and do take some pressing to get the new ones in nicely.

 

[Dundee_Kev]

The seals should just chap out and back in using a suitabe drift.

I've only ever done them with the cover in situ and used a sliding hammer to get them out, followed by a piece of wood to get them back in. Maybe I've just been lucky on the ones I've done, but they came out quite easily

 

[The Tangerine Dream]

A late reply from me as I've had a busy week in work,

Anyway, the seals came out with the help of this little chap, which is a can opener from a Swiss army knife.

I pried them from the underside of the cover at the 12, 3, 6, and 9 o'clock positions and they came out lovely.

I had new seals to go in and gave them all a little spray of 3-in-One oil and pressed them in from the top with the palm of my hand and a 22mm socket and it worked a treat. The old seals looked OK but as they're 175,000 miles old, I thought it best to change them.

If you want to take them out with the cover in place, follow @Dundee_Kev method above. I only did it my way because the cover was off to retrieve that bloody injector washer.

Onwards and upwards!

-TTD

 

[DXX]

Slide hammer or a drift.