Fuel Injectors

WARNING: This page is about a different car, the 2015 Audi Q7, 2014 Audi Q7, and 2013 Audi Q7. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Removing and installing for cylinder bank 2 (left) is described.

Special tools and workshop equipment required

Cleaning SetVAS 6811
Pry Lever - Rmv Outside Mirror80-200
PullerT10055 with AdapterT10055/1 and AdapterT10055/3
SocketT40055
Guide SleeveT10377

Removing

NOTE:

All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

-- Remove the engine cover. Refer to ENGINE COVER .

-- Remove the upper air filter housing.

CAUTION:

Danger of malfunction caused by dirt.

Note, refer to FUEL SYSTEM SAFETY PRECAUTIONS

-- Disconnect electrical connectors at fuel injectors -arrows- and at Fuel Pressure Regulator Valve -N276- -1-.

Fig 1: Fuel Injector Connectors

Courtesy of AUDI OF AMERICA, LLC

-- Free up electrical wiring harness on the cylinder head cover and fuel rail.

-- Remove the fuel supply hoses from the fuel injectors by pressing both retaining straps down while pulling up on the center piece to release -arrow-.

Fig 2: Center Piece On Retaining Strap

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Used injectors may only be installed on the same cylinder.

Note the sequence of each fuel injector to the cylinder when reinstalling.

-- Loosen the tightening union nuts -2, 3 and 4- with the SocketT40055 to disconnect the high pressure lines.

Fig 3: High Pressure Line Union Nuts & Open Lines And Connections

Courtesy of AUDI OF AMERICA, LLC

-- Seal off all open lines and connections with clean plugs.

-- Mark fuel injector and tension bracket -1- with paint for reinstallation.

Fig 4: Identifying Tension Bracket And Bolt

Courtesy of AUDI OF AMERICA, LLC

-- Remove bolt -2- and tension bracket.

-- Repeat procedure on remaining fuel injectors.

-- Mount the SocketT40055 on the fuel injector using the T10055/1 as illustrated. Remove fuel injector using knocking motions.

Fig 5: Identifying T10055 And T10055/1

Courtesy of AUDI OF AMERICA, LLC

-- Place removed fuel injectors on a clean rag.

Installing Used Fuel Injectors

When installing a used fuel injector in the same cylinder, the following components must be replaced:

Screw for tensioning bracket
Copper ring
O-ring for the fuel injector shaft
O-ring for the fuel return line connection

-- Spray the tip of the fuel injector with a rust removing spray. Remove the rust or oil particles with a cloth after approximately 5 minutes.

-- To remove the used copper sealing ring from the fuel injector, clamp the sealing ring carefully in a vise until the clamping jaws on the vise prevent the ring from turning. Pull the fuel injector out of the copper sealing ring by hand with slight twisting and pulling motions.

-- Use a scraper to remove any deposits under the copper sealing ring.

Installing New Fuel Injectors

The following must be replaced when installing a new fuel injection:

Tension bracket
Screw for tensioning bracket
Copper ring
O-ring for the fuel injector shaft
O-ring for the fuel return line connection

Continuation for Used and New Fuel Injectors

-- Install the new copper ring seal.

-- Lubricate all of the O-rings with assembly oil or engine oil before installing.

-- Replace the fuel injector shaft O-ring using the Guide SleeveT10377.

Fig 6: Guide Sleeve T10377 To Replace Fuel Injector Shaft Seal

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Danger of causing damage to the sealing surface on the fuel injector.

To remove rust particles on the fuel injector sealing surface, clean the fuel injector duct inside the cylinder head with Cleaning SetVAS 6811 or with a cloth dampened with engine oil.

-- Install the fuel injectors.

Install in reverse order of removal. Note the following:

Tightening Specifications

Fuel injectors overview, refer to FUEL INJECTORS OVERVIEW

-- Install the high pressure lines. Refer to HIGH PRESSURE LINES, INSTALLING .

NOTE:

Lubricate all of the O-rings with assembly oil or engine oil before installing.

-- Carefully press the return line connections over the new sealing ring and onto the injector. The connection must engage audibly. Then press the release pin down carefully.

The "injector quantity calibration" and the "injection pressure calibration" for the new injectors must be must be programmed into the Engine Control Module (ECM) after replacing one or more injectors. Refer to FUEL INJECTORS, ADAPTING CORRECTION VALUES .

Check all the other injectors as well regarding their "injector quantity calibration" and "injection pressure calibration" to make sure all comparison values have been entered correctly. If the correct comparison value have been stored in the ECM, then these comparison value must never be re-entered.

Fuel System, Bleeding and Performing a Leak Test

-- Let the engine run a few minutes at idle without pressing the accelerator pedal and then stop the engine.

NOTE:

The high pressure connections must not be opened; the fuel system bleeds itself.

-- Turn off the ignition.

-- Carefully check the entire fuel system and the six return line connections for leaks.

If there are leaks even though the correct tightening specification was used, replace the affected component.

-- Perform a road test where the accelerator pedal is pressed all the way down at least one time. Then check the high pressure area again for leaks.

NOTE:

If there is still air in the fuel system, the engine may switch to emergency mode during the road test. Turn off the engine and erase the Diagnostic Trouble Code (DTC) memory. Then continue the road test.

-- After the road test, check the DTC memory again.