Renewing O-rings for unit injectors: Audi 2.0 TDI (AZV, BDJ, BKD, BLB, …)
Step-by-step renewing O-rings for unit injectors for the Audi 2.0 TDI: 14 steps. What to remove, in what order, and what to check after.
Workshop procedure for AUDI — the exact step sequence and torque figures, straight from real workshop data.
🧭 Before you start
Fits: VW Caddy III (2K, 2004–2015)
📐 95 workshop diagrams for AZV
Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.
📋 Procedure
- Lever old O-rings very carefully out of unit injector.
- Pay particular attention to ensure that seat of O-ring is not damaged by burrs. [Note: Always use the assembly sleeves to fit the O-rings. There is a danger of damaging the O-rings if the sleeves are not used.Gradual introduction of O-rings without different coloured markings. Note the correct allocation of O-rings to grooves: the thickness of the rings reduces towards injector nozzle.Avoid any rolling movement when pushing O-rings on. The O-rings must not be twisted in their seats in unit injector.]
- Remove heat shield seal together with circlip.
- Clean seating surfaces for O-rings on unit injector very carefully.
- Slide assembly sleeve T10056/1 onto unit injector as far as stop.
- Push upper, thicker O-ring carefully onto assembly sleeve and into seat on unit injector.
- Remove assembly sleeve.
- Slide assembly sleeve T10056/2 onto unit injector as far as stop.
- Push middle, thinner O-ring carefully onto assembly sleeve and into seat on unit injector.
- Remove assembly sleeve.
- Slide assembly sleeve T10056/3 onto unit injector as far as stop.
- Push lower O-ring carefully onto assembly sleeve and into seat on unit injector.
- Remove assembly sleeve.
- Slide new heat shield seal together with circlip into position.
Ask TorqFix about your Audi AZV — it answers with the exact sequence for that engine and the workshop drawing for each step. First question is free after a 20-second sign-up, no card.
Ask about your Audi AZV — free → or sign up free to see the drawingsOther AUDI procedures
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Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com
The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.