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. Renewing combustion chamber ring seal –  Remove injector → Chapter. –  Carefully remove old combustion chamber ring seal 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 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-.

–  Use assembly sleeve -T10133/6- to press combustion chamber ring seal further onto assembly cone -T10133/5- until it seats in groove. Do not use any lubricants during this procedure.   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. –  Fit new O-ring on injector. Lubricate O-ring lightly with clean engine oil before installing.   Note Make sure there is no cleaning fluid or oil in the cylinder head bores when installing the injectors.

–  Before installing injectors, thoroughly clean apertures for injectors in cylinder head using supplied nylon 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. –  The remaining installation steps are carried out in the reverse sequence. Important: the following points must always be observed. l  Coat O-rings of injector 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.