Audi Workshop Service and Repair Manuals

Removing and installing injectors Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Ratchet -V.A.G 1331/1-

t  Open end spanner insert, AF 17 -V.A.G 1331/6-

t  Tool insert, AF 19 -V.A.G 1331/5- (engine code CAPA only)

t  Socket -T40055- Removing   WARNING t  Always read rules for cleanliness and instructions for working on fuel system → Chapter. t  Follow these instructions and rules for cleanliness before starting work and while working on the fuel system.   Note t  The following description shows the removal and installation of the injectors on cylinder bank 2 (left-side). t  Step required only for cylinder bank 1: Remove top section of air cleaner with air mass meter → Chapter. t  On cylinder bank 2 the coolant expansion tank must be detached; coolant hoses remain connected. –  Remove engine cover panel → Chapter.   Caution t  Mark cylinder numbers on injector units. They must always be re-installed on the same cylinders. t  Observe rules for cleanliness when working on the injection system. t  Plug open connections with suitable sealing caps immediately.

–  Pull return line connections off injectors; to do so, press both tabs down and at the same time pull centre piece up to release connection -arrow-.   Note No dirt must be allowed to get into the disconnected return lines or the open connections on the injectors. –  Detach electrical connectors at injectors which are to be removed.

–  Loosen union nuts for high-pressure pipes -1- at injectors using socket -T40055-. –  Loosen union nuts for high-pressure pipes at fuel rail using appropriate socket. –  Remove union nuts, carefully take out high-pressure pipes and put them down on a clean cloth.

–  Unbolt covers for injectors -arrows-. –  Pull covers upwards and turn them 1/4 turn (90°).

–  Unbolt clamping pieces for injectors -arrows-.

–  Pull out injectors using puller -T10055- with adapter -T10055/1-. –  After removal, lay injectors on a clean cloth. Installing new injectors When installing new injectors, the following components must be renewed: t  Clamping piece t  Copper seal t  Renew O-ring for injector bore. t  O-ring for fuel return line connection   Note t  Note identification marks for cylinder allocation when re-installing high-pressure pipes. t  The high-pressure pipes can be re-used after performing the following checks: t  Check taper seats of high-pressure pipes for deformation and cracks. t  The bore of the pipe must not be distorted, restricted or otherwise damaged. t  Corroded pipes must not be used again. Installing used injectors When re-installing used injectors, the following components must be renewed: t  Clamping piece t  Copper seal t  Renew O-ring for injector bore. t  O-ring for fuel return line connection –  Spray tip of injector nozzle with rust-releasing spray. Wait approx. 5 minutes and wipe off soot particles and oil with a cloth. –  If an injector is very dirty, the tip of the nozzle should also be cleaned with a soft brass wire brush to make it easier to remove the copper seal. Do not apply the wire brush to the bores in the nozzle. –  To remove the old copper seal from the injector, clamp the seal carefully in a vice so that it is just held between the jaws without turning. Then carefully pull and twist the injector out of the copper seal by hand. –  Clean off deposits under the copper seal using a suitable scraper. –  Use a plastic bush to fit the new copper seal.   Note Lubricate all O-rings with engine oil or assembly oil before installing.   Caution Risk of damage to injector sealing surface. To remove carbon deposits from the injector sealing surface, clean the injector bore in the cylinder head with a cloth soaked in engine oil or rust solvent. –  Install injectors. –  Hand-tighten union nuts on high-pressure pipes. Make sure that connections are not under tension. –  Tighten high-pressure pipes → Chapter. –  Press return line connections carefully over seals and onto injectors (check seal for damage before connecting return line). The catch should engage audibly. Then press release pin down carefully. After renewing one or more injectors, the „injector delivery calibration values“ and „injector voltage calibration values“ for the new injectors must be written into the engine control unit → Chapter. Additionally, check that the „injector delivery calibration values“ and „injector voltage calibration values“ are correctly entered for all the other injectors. Do NOT attempt to re-enter these calibration values if the correct values are already stored in the engine control unit. Bleeding fuel system and checking for leaks   Note The fuel system is self-bleeding; do not open the high-pressure connections. –  Run engine at idling speed for several minutes and then switch off. –  Switch off ignition. –  Check the complete fuel system including all 6 return line connections for leaks. Renew affected component if leakage still occurs after tightening to correct torque.   Note The return lines can only be renewed together with the pressure retention valve as one unit. –  After completing the repair, road-test the vehicle. Accelerate with full throttle at least once. Then inspect high-pressure section of fuel system again for leaks.   Note If there is any air left in the fuel system, the engine may switch to the backup mode ('emergency running' mode) during the road test. Switch off the engine and erase the event memory. Then continue the road test. l  Tightening torques: refer to exploded view of fuel system → Chapter.