Audi Workshop Service and Repair Manuals

Removing and installing injectors Special tools and workshop equipment required

t  Tool set for FSI engines -T10133-

High-pressure injector - exploded view of components 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 the support ring the fuel rail exerts force which secures injector in cylinder head) Removing   WARNING t  The fuel system operates under high pressure. The pressure in the high-pressure part of the injection system must be reduced to a residual pressure prior to opening the system → Chapter. t  A clean cloth must then be wrapped around the connection and the residual pressure dissipated by carefully loosening the connection. –  Remove intake manifold (top section) → Chapter. –  Remove corresponding bottom section of intake manifold → Chapter.

If injectors cannot be pulled out of cylinder head by hand, proceed as follows: –  Use a screwdriver to bend retainer tabs -1- of radial compensation element to side -arrow- and pull support ring -2- off injector.

–  Screw striker -T10133/3- onto puller -T10133/2-. –  Insert puller -T10133/2- into groove on injector and carefully knock out injector.   Note When inserting the puller, there is a risk of destroying the radial compensation element due to the retainer tabs breaking.

–  Carefully remove old combustion-chamber ring seal -arrow-. To do so, cut open ring using knife or prise open ring with small screwdriver and then pull off forwards. –  Take care not to damage injector groove. The injector must be renewed if the groove is damaged. Installing   Note t  Renew combustion-chamber ring seal and O-ring. t  Renew spacer ring if damaged. t  Lightly lubricate O-rings for injectors with clean engine oil. t  The injector pipes must be re-installed on the same cylinders.

–  Clean bore in cylinder head with nylon cylinder brush -T10133/4-.

–  Clip radial compensation element -1- into support ring -2-. –  When re-installing an injector clean any combustion residue off groove for combustion-chamber ring seal and injector stem with a clean cloth.

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

–  Push combustion chamber ring seal onto assembly cone -T10133/5- as far as it will go using assembly sleeve -T10133/6-. –  Turn assembly sleeve -T10133/6- upside down and push combustion chamber ring seal into sealing ring groove.   Note

The combustion-chamber ring seal is widened when it is pushed onto the injector. After pushing it on, it therefore has to be compressed again. This is done in two stages, as described below. –  Push calibration sleeve -T10133/7- onto injector as far as it will go and simultaneously turn it slightly (approx. 180°). –  Pull calibration sleeve -T10133/7- off again by turning it in the opposite direction.

–  Push calibration sleeve -T10133/8- onto injector as far as it will go and simultaneously turn it slightly (approx. 180°). –  Pull calibration sleeve -T10133/8- off again by turning it in the opposite direction. –  Lubricate new O-ring lightly with clean engine oil before installing.   Note The combustion-chamber ring seal must not be lubricated.

–  Use assembly tool -T10133/9- to push injector as far as it will go into hole in cylinder head.   Note It should be possible to insert injector easily. If necessary wait until the combustion-chamber ring seal has contracted sufficiently. –  Make sure injector is in correct installation position in cylinder head: l  Electrical connector of injector must engage in recess in cylinder head. Perform further installation in reverse order, paying attention to the following: –  Install bottom section of intake manifold → Chapter. –  Install intake manifold (top section) → Chapter.