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- 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 → Chapter. –  Take noise insulation off cylinder head cover.

–  Unscrew union nuts at high-pressure pump -6- and fuel rail -1- and remove high-pressure fuel pipe. –  Remove bolts -arrows- for high-pressure fuel pipe. –  Detach fuel return hose -3-.

–  Release retaining clips -arrows- and move wiring harness clear.

–  To do so, unplug the following electrical connectors: 1 -  Fuel pressure sender -G247- 2 -  Fuel pressure regulating valve -N276-  -  Injectors  -  Glow plugs   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. –  Loosen union nuts for high-pressure pipes at injectors using socket -T40055-, 17 mm. –  Loosen union nuts for high-pressure pipes at fuel rail using open end spanner insert, AF 17 -V.A.G 1331/6-. –  After removal, lay high-pressure pipes on a clean cloth. –  Unscrew both bolts and remove fuel rail. Installing Installation is carried out in the reverse order; note the following: –  Install high-pressure pipes so they are free of tension.   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. l  Tightening torques: refer to exploded view of fuel system → Chapter