Audi Workshop Service and Repair Manuals

Renewing combustion chamber ring seal (teflon ring seal)   Note The combustion chamber ring seal must always be renewed before the injector is re-installed. Renewing combustion chamber ring seal –  Remove injector → Chapter. –  Carefully remove old combustion chamber ring seal using suitable tools (e.g. cut open ring using razor blade, or prise open ring with small screwdriver and then pull off forwards). It is important to ensure that the groove and the continuous ridge in the bottom of the groove are not damaged.   Note The injector must be renewed if the groove is damaged. –  Before new combustion chamber ring seal is fitted, any combustion residue must be removed from ring groove and injector stem using a clean cloth.

–  Fit assembly cone -T10133/5- with new teflon ring -1- onto injector -2-.

–  Use assembly sleeve -T10133/6- to press combustion chamber ring seal further onto assembly cone -T10133/5- until it seats in groove. Do not use any lubricants during this procedure.   Note The combustion chamber ring seal is widened when it is pushed onto the injector. After pushing it on, it therefore has to be compressed again. This is done in two stages, as described below.

–  Push calibration sleeve -T10133/7- onto injector as far as it will go and simultaneously turn it slightly (approx. 180°). –  Pull calibration sleeve -T10133/7- off again by turning it in the opposite direction.

–  Push calibration sleeve -T10133/8- onto injector as far as it will go and simultaneously turn it slightly (approx. 180°). –  Pull calibration sleeve -T10133/8- off again by turning it in the opposite direction. Renewing support ring and O-ring –  Remove O-ring -3-. –  Cut open support ring -2- with small side-cutting pliers and remove support ring.

–  Detach spring element -1- from injector and fit locking plate -T10133/12- in place of spring element. –  Fit a new support ring -1- onto assembly cone -T10133/13- and fit onto injector (as illustrated).

–  Using calibration sleeve -T10133/17- (knurled side faces towards injector), push support ring -1- into first groove -arrow- on injector. –  Then turn round calibration sleeve -T10133/17- (knurled side now faces away from injector). Push calibration sleeve over support ring -1- in direction of -arrow- until it makes contact with locking plate -T10133/12-.

–  Pull calibration sleeve -T10133/17- off again. Support ring now has its correct installation depth. –  Now install a new spring element -1- in place of locking plate -T10133/12-.

–  Renew O-ring -3-.   Note Lubricate O-ring lightly with assembly oil or engine oil before installing. Installing

–  Before installing injectors, thoroughly clean apertures for injectors in cylinder head using supplied nylon brush -T10133/4-.

–  Always renew spring element -arrow- if injectors have been removed.

–  Fit a new O-ring on each injector. Lubricate O-ring -3- lightly with clean engine oil before installing. –  Push injector by hand as far as it will go into aperture in cylinder head (do not use oil or grease). Ensure that the injector is properly seated in the cylinder head.   Note

t  The teflon seal -arrow- must not be lubricated when fitting the injector. t  Make sure there is no cleaning fluid or oil in the cylinder head bores when installing the injectors. t  It should be possible to insert the injector easily. If necessary, wait until the teflon seal has contracted sufficiently. t  Note correct installation position and ensure that injectors are properly seated in cylinder head. The remaining installation steps are carried out in the reverse sequence. –  Install bottom section of intake manifold → Chapter. –  Install intake manifold → Chapter.