2010 Jetta Fuel Leak

2010 VW JettaMy daily driver, and currently my only driver, is a 2010 Volkswagen Jetta.  It is the Wolfburg edition for 2010 and has the 2.0T TSI engine.  I put a lot of miles on the car and it has a fairly comfortable ride.  When I was looking for a new car it was between the Jetta and the Mazdaspeed 3.  I made the “responsible” choice by getting the Jetta which had more rear seat leg room and a more comfortable ride.  Even though the Mazda was faster, and more fun, most of the driving that I do is with the cruise control on just cruising down the highway.  That being said, the choice was made to purchase the more comfortable car.  Of course, it does have a Turbo motor which pushes 200HP so it is no slouch and can be quite fun in its own right.

2010 VW Jetta Engine Bay

On to the issue at hand, I got into my car the other day and smelled fuel.  At first I thought that it might just be the crankcase ventilation so I ignored it and continued on with my day.  As I continued driving the smell did not really dissipate, so I began to wonder where it was coming from.  When I arrived at my destination (maybe I should not have kept going, hindsight is 20/20!) I popped the hood and began to investigate.  I could smell the fuel but could not locate the source of the leak.  Thinking of all the possible things that could be causing this, It occurred to me that I had to replace the intake manifold about a year ago and started to think that the screws were loose.  I pushed down on the manifold hoping to seal the injectors into the motor until I could tighten the screws.  This was a valiant attempt but did not resolve the issue.  I continued to drive the car for the rest of the day and when I pulled into my driveway at the end of the day, the smell of fuel was very strong!  This needed to be resolved!

Damaged VW Jetta Injector O ringsSo the following weekend I set out to find the source of the leak.  I pretty much knew that I would have to remove the intake manifold but I started the car and looked for the leak anyway, hoping to find an easier fix.  I could smell the fuel but could not see the source, most likely under the intake manifold.  I removed the intake manifold to get to the injectors using this DIY thread to help but since I did this about a year ago(also following that thread) it went pretty quickly without too much referencing.  I discovered that 3 out of the 4 blue o rings were showing signs of damage and that one was completely missing.  I did find the missing O ring under the oil cooler but since it was that loose and just came off I am assuming that it was the culprit.  Later on the day I purchased a fuel injector installation kit and a fuel injector puller/installer tool from ECS Tuning.  I figured I would rather have the tool and make my life easy than to not have it and need it!

Waiting For installation…….

Special Delivery!

Fast forward two weeks , not that the shipments were late or anything, because of the rain!  I finally got back to work on the car.  I started my day by pulling out the flat, air buffers (I don’t know what they are called, but they are in the picture) and cleaning them with the Sea Foam Engine Cleaning Product.  I show a before and after picture so you can see how well it worked.  I then decided to spray the product on the intake valves to let it soak while I pull out the injectors.

Air Baffles


It really paid off to have the fuel injector removal tool handy to pull the injectors out and to put the combustion chamber seal on.  I don’t know how I would’ve done it without that tool, it was a good investment.  It allowed me to get the injectors out very easily and replace all the seals.  It made the job very easy.  Just goes to show you, use the right tool for the job!  So, I pull out all the injectors and replace all the seals.  I then proceeded to attempt to scrape off the carbon that was built up on the intake valves.  I did the best I could with what I had but I would have liked to have cleaned them a little better.  I was able to see the tops of the valves again so I was satisfied with the results.  I just wish I would’ve had a smaller wire brush; it might have made the cleaning process a little easier.  I pretty much used the pipe cleaner that came with the fuel injector puller kit to clean off the valves.

I put the intake manifold back on in the reverse order from the instructions in the above link, get it all together, and start it up.  Oh no!  I got a check engine light and the car is running really rough!  I’m starting to think that the sea foam cleaned off the valves and now the carbon is stuck in the cylinders causing a misfire.  So I rev the engine a little bit to see if it will blow out but it just keeps running terrible.  I shut it off and start going over my work.  Luckily, I found the problem,  I forgot to plug in the Air Idle Control Valve!  Plug in the valve, start it up, and she purrs like a kitten!  Unfortunately, that stupid check engine light is still on!  I take it around the block to see if it will go off but it doesn’t.  The car is now running great, but the check engine light is on.  Now I plug in my code reader, and it doesn’t work!  Great!  I went out and purchased a new one which works on my car, I got the Actron PocketScan Plus which gives you the code and a brief description of the issue.  I plug the reader in to see what the code is and it’s for the Air Idle Control Valve, and numerous misfires in all cylinders.  I kind of figured that is what the issue was but I wanted to be sure before I started driving this car all over the place again. I cleared all the codes, took the car for a short ride, and all was well!  No more check engine light, no more fuel leak!  I can finally drive my car again!

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