Audi Workshop Service and Repair Manuals

Removing and installing injectors Special tools and workshop equipment required

t  Tool set for FSI engines -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.

High-pressure injector - exploded view 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 The fuel system operates at extremely high pressure. This can cause injury. t  The fuel pressure in the high-pressure section of the injection system must be reduced to a residual pressure prior to opening the system → Chapter. t  Wrap a clean cloth around the connection and carefully loosen the connection to allow the residual pressure to dissipate. –  Remove intake manifold (top section) → Chapter. –  Remove intake manifold (bottom section) on relevant side → 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.

–  Guide puller -T10133/2A- into groove on injector. –  Then attach removal tool -T10133/16- and pull out injector by turning bolt -1-.   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 groove on injector. The injector must be renewed if the groove is damaged. Installing   Note t  Renew combustion chamber ring seals and O-rings. t  Renew spacer ring and radial compensation element 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.

–  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 -T10133/6- as far as it will go using assembly sleeve -T10133/5-. –  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. Installing injectors

–  Clean bore in cylinder head with nylon cylinder brush -T10133/4-. –  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 injector easily. If necessary wait until the combustion chamber ring 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. l  Electrical connector of injector must engage in recess in cylinder head. Remaining installation steps are carried out in reverse sequence; note the following: –  Install intake manifold (bottom section) → Chapter. –  Install intake manifold (top section) → Chapter.