Audi Workshop Service and Repair Manuals

Removing and installing fuel rail 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  Socket -T40055-

t  Pliers -3314- 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. –  Remove engine cover panel. –  Unscrew bolt -3- from bracket for high-pressure fuel pipe.

–  Unscrew union nuts at high-pressure pump -4- and fuel rail -1- and remove high-pressure fuel pipe -2-.   Note

To remove union nut at high-pressure pump, it must be possible to move bracket (for engine lifting eye); for this, loosen bolts -4-.

–  Open catches -arrows- on cable duct to move clear wiring harness.

–  Apply groove -arrow A- of pliers -3314- to collar of support sleeve -arrow B-.

–  Carefully unplug connectors from glow plugs in direction of -arrow-.

–  Unplug electrical connectors -1 and 4-. –  Detach fuel return line -2-.   Note Disregard -item 3-.

–  Unplug electrical connectors -1, 6 and 7-.   Caution t  Mark cylinder numbers on high-pressure pipes. 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. –  Remove high-pressure pipes between injectors and fuel rail.   Note

t  Counterhold connection -A- to loosen union nuts at injectors. t  Disregard -arrow-. –  After removal, lay high-pressure pipes on a clean cloth.

–  Unscrew both bolts -arrows- and remove fuel rail. Installing Installation is carried out in the reverse order; note the following: l  Tightening torques → Chapter „Fuel rail and injectors - exploded view“ –  Install high-pressure pipes → Chapter.   Note t  Retaining clips must be renewed. 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. –  Install engine lifting eye → Rep. gr.15.