Audi Workshop Service and Repair Manuals

Renewing combustion chamber ring seal (teflon ring seal)   Note The combustion chamber ring seal must always be renewed prior to reinstalling the injector. –  Carefully remove old teflon ring 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 teflon ring is fitted, any combustion residue must be removed from ring groove and injector stem using a clean cloth.   Note The illustration shows an injector with „offset connector“. This can be ignored since it is not relevant when replacing the combustion chamber ring seal.

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

–  Use assembly sleeve -T10133/6- to press teflon ring further onto assembly cone -T10133/5- until it seats in groove. Do not use any lubricants during this procedure.   Note The teflon ring is widened as it is pushed onto the injector. The teflon ring must therefore be compressed again after it has been fitted. This is done in two steps. The procedure is described below. Step 1 of teflon ring seal calibration (adaption) is done with calibration sleeve -T10133/7-.

–  Slide calibration sleeve -T10133/7- onto injector as far as the stop by pressing lightly and turning approx. 180°. Pull calibration sleeve -T10133/7- off again by turning it in the opposite direction. Step 2 of teflon ring seal calibration (adaption) is done with calibration sleeve -T10133/8-.

–  Slide calibration sleeve -T10133/8- onto injector as far as the stop by pressing lightly and turning approx. 180°. Pull calibration sleeve -T10133/8- off again by turning it in the opposite direction. –  Fit new O-ring on injector. Lubricate O-ring lightly with clean engine oil before installing. –  The teflon ring must not be lubricated.

–  Before installing injectors, thoroughly clean apertures for injectors in cylinder head using supplied nylon brush -T10133/4-.   Note t  The teflon seal on the injector must not be oiled or greased.

t  Make sure there is no cleaning fluid or oil in the cylinder head bores when installing the injectors. –  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  It should be possible to insert the injector easily. If necessary, wait until the seal has contracted sufficiently. t  Note correct installation position and ensure that injectors are properly seated in cylinder head.

t  If the injector cannot be pushed in by hand, use puller -T10133/2A--2- with striker -T10133/3- to insert the injector. –  The remaining installation steps are carried out in the reverse sequence. Important: the following points must always be observed: l  The teflon seal on the injector must not be oiled or greased. l  Make sure there is no cleaning fluid or oil in the cylinder head bores when installing the injectors. l  Coat O-rings of high-pressure injectors with clean engine oil to facilitate insertion into fuel rail. l  Renew all seals. l  Fuel rail must be positioned on injectors and pressed in evenly. l  Install intake manifold with fuel rail → Chapter.