Audi Workshop Service and Repair Manuals

Removing and installing injectors Removing Remove intake manifold and fuel rail → Chapter. Removing injectors (from fuel rail) Carefully pull injectors out of fuel rail. Removing injectors (from cylinder head) Special tools and workshop equipment required

t  Tool kit with puller -T10133-   Note Special tool T10133/2 (puller) has been modified and now has the designation puller T10133/2 A. If you have not yet received the new tool you can make the modification yourself. Modifying special tool T10133/2 (puller) to make it equivalent to puller T10133/2 A Special tools and workshop equipment required t  Round file, approx. 6 mm –  File out a semi-circular recess as shown in the illustration. The recess allows the tool to be pushed further onto the injector so the contact surface is increased.

–  For identification purposes, mark the modified tool with the letter “A” after the tool number.

Illustration shows injector assembly: 1 -  Radial compensation element, renew if damaged 2 -  Combustion chamber ring seal (teflon ring seal) - renew; when fitting, do not grease ring or use any other lubricant 3 -  Groove on injector 4 -  Spacer ring (renew if damaged) 5 -  O-ring (renew; apply thin coating of clean engine oil prior to installation) 6 -  Support ring (via this support ring, fuel rail exerts force which secures injector in cylinder head)   Note

The radial compensation element -1- is clipped into the support ring -6- with the injector fitted. To remove the injector, the support ring must be removed from the injector so that the puller -T10133/2- can be inserted into the groove on the injector -3-. –  Cover open inlet ports with a clean cloth. –  Unplug electrical connector at injector that is to be removed.

–  Use a screwdriver to bend retainer tabs of radial compensation element to side, and pull support ring off injector.

–  Apply puller -T10133/2A- to groove on injector. –  Then attach removal tool -T10133/16- and pull out injector by turning bolt -1-.   Note The combustion chamber ring seal must always be renewed prior to reinstalling the high-pressure injector → Chapter.