Overview - Fuel Injectors

Fig 1: Exploded View Of Fuel Injector

Courtesy of AUDI OF AMERICA, LLC

1. Seal
   • In the cylinder head cover
   • Replace is leaking. Refer to FUEL INJECTOR SEALS, REMOVING AND INSTALLING .
2. Copper Washer
   • Replace the copper gasket during every assembly/disassembly procedure.
3. O-Ring
   • Replace after removing
4. Fuel Injector
   • Fuel injectors and high pressure lines which have been removed and are being re-installed may only be installed back into the same cylinder.
   • Replace the copper gasket during every assembly/disassembly procedure.
   • To remove rust particles on the fuel injector sealing surface, clean the fuel injector shaft in the cylinder head using the Cleaning Set: VAS 6811  (always clean due to leaks).
   • Removing and Installing. Refer to FUEL INJECTORS, REMOVING AND INSTALLING .
5. O-Ring
   • Replace after removing
6. Fuel Return Line
   • To the fuel tank
   • must not be bent, damaged or plugged
   • Do not disassemble
   • Bleeding and filling the fuel system after exchanging. Refer to FUEL SYSTEM, FILLING/BLEEDING .
7. Tensioning Claw
   • Mark fuel injector and tensioning claw with paint to each other and to the cylinder for reinstallation, when installing pay attention to the markings.
   • The tensioning claws can be reused, when new fuel injectors are installed.
   • Installation position. Refer to Fig 2.
8. Bolt
   • Replace
   • Initial torque 2 Nm then install the union nuts for the high pressure lines by hand and align the fuel injectors.
   • 8 Nm + 270° (3 x 90° additional turn)
   • Note the warning messages regarding the tensioning claw -item  : Tensioning Claw
9. High Pressure Line
   • between the high pressure reservoir and the fuel injectors
   • If no component (fuel injector or high pressure reservoir) are replaced, the high pressure lines can be reused when all notes for the installation of the high pressure lines are followed. Refer to HIGH PRESSURE LINES, REMOVING AND INSTALLING .
   • Install without tension
   • Attach the balance weight. Refer to Fig 3.
   • 28 Nm
10. Grommet
    • In the cylinder head cover
    • Replace if damaged

Tensioning Claw Installation Position, Version 1 (2.0L TDI) 

Fig 2: Installed Position Of Tensioning Bracket

Courtesy of AUDI OF AMERICA, LLC

• A tensioning claw touches two fuel injectors.
• The bulge in the tensioning claw -arrow- faces downward.

Tensioning Claw Installation Position, Version 2 (1.6L TDI) 

Courtesy of AUDI OF AMERICA, LLC

• A tensioning claw touches two fuel injectors.
• The bulge in the tension bracket -arrow- faces upward.

Attach the balance weight to the high pressure lines.

Fig 3: Position The Balance Weight

Courtesy of AUDI OF AMERICA, LLC

-- Attach the balance weight -1- to the high pressure lines.