Fuel Injectors, Removing And Installing: Notes

Special tools and workshop equipment required

Injector/Combustion Chamber Seal Tool Set: T10133C

Fig 1: Identifying Injector/Combustion Chamber Seal Tool Set
Courtesy of AUDI OF AMERICA, LLC
Fuel Injector Removal Tool: T40433 , not illustrated

Removing

Only remove the fuel injectors when the engine is cold.
Follow the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

-- Before removing the fuel injectors, clean their surroundings thoroughly and, if necessary, blow out using compressed air; wear protective eyewear while doing so.

-- Remove the fuel rail. Refer to FUEL RAIL, REMOVING AND INSTALLING .

-- Remove the fuel injectors from the cylinder head.

Remove jammed fuel injectors as follows:

-- Cylinder 1: remove the Piston Cooling Nozzle Control Valve -N522-. Refer to Piston Cooling Nozzle Control Valve -N522-, REMOVING AND INSTALLING .

-- Cover the open intake channels with a clean cloth.

-- Remove the support ring -5- from the fuel injector -2-.

Fig 2: Exploded View Of Fuel Injector

Courtesy of AUDI OF AMERICA, LLC

Use a torque wrench to remove the fuel injector.
Adjust to 5 Nm on the torque wrench
The fuel injectors may be damaged if the tightening specifications are not observed.

-- Fuel injector, Bosch: slide in the Fuel Injector Removal Tool - Puller: T40433/1 -2- into the fuel injector groove.

Courtesy of AUDI OF AMERICA, LLC

-- Fuel injector, Continental: slide in the Fuel Injector Removal Tool - Puller: T40433/2 -2- into the fuel injector groove.

-- Position the Injector/Combustion Chamber Seal Tool Set - 16A: T10133/16A .

-- Remove the fuel injector by using the torque wrench to turn the bolt -1-.

-- If the tightening specification limit of >>5 Nm<< is achieved without the fuel injector loosening, remove the puller and loosen the fuel injector with the sleeve.

-- Repeat this on each fuel injector.

Disassembling the Fuel Injector

Fig 3: Exploded View Of Fuel Injector

Courtesy of AUDI OF AMERICA, LLC

-- Remove the O-ring -4- and spacer ring -3- from the fuel injector -2-.

-- Carefully remove the old combustion chamber seal -1- by cutting the combustion chamber seal with a knife or widen it with a small screwdriver and remove it forward.

5 -

Support Ring

-- Clean the seal groove in the area of the seal -arrow-. Remove any deposits (coking) with a brass wire brush.

Courtesy of AUDI OF AMERICA, LLC

Make sure that the groove of the fuel injector does not become damaged. If the groove is damaged, the fuel injector must be replaced.