Audi Workshop Service and Repair Manuals

Renewing combustion chamber ring seal (teflon ring seal)   Note The combustion chamber ring seal must always be renewed before the injector is re-installed.

–  Carefully remove combustion chamber ring seal -3- using suitable tools (e.g. cut open seal using a 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 combustion chamber ring seal is fitted, any combustion residue must be removed from ring groove and injector stem using a clean cloth.

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

–  Using assembly sleeve -T10133/6-, push combustion chamber ring seal onto assembly cone -T10133/5- as far as it will go.

–  Turn assembly sleeve -T10133/6- upside down and push combustion chamber ring seal to end of assembly cone -T10133/5-. –  Remove assembly cone -T10133/5- and push combustion chamber ring seal into sealing ring groove using assembly sleeve -T10133/6-.

–  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. –  Fit new O-ring on injector. Lubricate O-ring lightly with clean engine oil before installing.

–  Before installing injectors, thoroughly clean apertures for injectors in cylinder head using supplied nylon brush -T10133/4-.   Note t  The combustion chamber ring seal on the injector must not be oiled or greased. t  Make sure that there is no cleaning fluid or oil in the holes in the cylinder head 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.

–  Lug -1- and hole -arrow- in cylinder head must face each other.   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. –  Coat O-rings of injectors with clean engine oil to facilitate insertion into fuel rail. –  Install fuel rail → Chapter. –  Install intake manifold → Chapter. –  The remaining installation steps are carried out in the reverse sequence.