Fuel Injectors, Removing And Installing

WARNING: This page is about a different car, the 2016 Audi Q5, 2015 Audi Q5, and 2014 Audi Q5. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Cleaning Set VAS6811
Pry Lever - Remove Outside Mirror 80 - 200

Fig 1: 80-200 Pry Lever
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Puller T10055 with Adapter T10055/1 and Adapter T10055/3

Fig 2: Identifying Puller T10055
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Socket T40055

Fig 3: Identifying Socket T40055
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Guide Sleeve T10377

Fig 4: Guide Sleeve T10377
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Removing

NOTE:

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

-- Remove the engine cover.

Cylinder Bank 1 (right)

-- Remove the air filter housing and air guide hose. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

Cylinder Bank 2 (left)

-- Loosen the clamp -3- and remove the air duct tube.

Fig 5: Connector At The Throttle Valve Control Module, Screw Clamp & Air Guide Hose

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NOTE:

Ignore items -1 and 2-.

-- Remove the coolant expansion tank.

Fig 6: Identifying Coolant Reservoir Marking

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-- Free up the coolant line on the longitudinal member.

Continued for Both Sides

-- Remove the union nut -1- and the bolt -2-.

Fig 7: Bolt -1- On The Right Intake Manifold Bracket

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CAUTION:

Danger of malfunction caused by dirt.

Refer to FUEL SUPPLY SYSTEM SAFETY PRECAUTIONS

-- Free up the wiring harness and hoses on the wiring guide -1- using the Pry Lever - Remove Outside Mirror 80 - 200.

Fig 8: Bolts -2 And 3- And Remove The Wiring Guide -1-

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-- Pull coolant hose back -arrow-.

-- Remove the bolts -2 and 3- and remove the wiring guide.

-- Disconnect the connectors from the fuel injectors -arrows- and from the Fuel Pressure Regulator Valve -N276- -1-.

Fig 9: Fuel Injector Connectors

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-- 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 10: Center Piece On Retaining Strap

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CAUTION:

Used injectors may only be installed on the same cylinder.

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

-- Remove the high pressure line union nuts -2, 3 and 4- using the Socket T40055.

Fig 11: High Pressure Line Union Nuts & Open Lines And Connections

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

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

Fig 12: Identifying Tension Bracket And Bolt

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-- Remove bolt -2- and tension bracket.

-- Repeat procedure on remaining fuel injectors.

-- Position the Puller T10055 with Adapter T10055/1 on the fuel injector as illustrated. Remove fuel injector using knocking motions.

Fig 13: Identifying T10055 And T10055/1

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-- Place removed fuel injectors on a clean cloth.

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

When installing a new fuel injector, the following components must be replaced:

Tensioning Claw
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 Sleeve T10377.

Fig 14: Guide Sleeve T10377 To Replace Fuel Injector Shaft Seal

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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 shaft in the cylinder head using the Cleaning Set VAS6811.

-- Install the fuel injectors.

Install in reverse order of removal. Note the following:

Tightening Specifications

Fuel injectors assembly overview: (refer to FUEL INJECTORS OVERVIEW )

-- Install the high pressure lines. Refer to HIGH PRESSURE LINES, REMOVING AND 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 fuel injectors must be programmed into the Engine Control Module (ECM) after replacing one or more fuel 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.

-- Switch off 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.

-- Check the DTC memory after the road test.