Fuel Rail, Removing And Installing

Special tools and workshop equipment required 

• Pry Lever - Remove Outside Mirror 80 - 200
  Fig 1: 80-200 Pry Lever

  Courtesy of AUDI OF AMERICA, LLC
• Torque Wrench 5-50 Nm VAG 1331
  Fig 2: Ident ifying Torque Wrench (5 To 50 Nm) VAG 1331

  Courtesy of AUDI OF AMERICA, LLC
• Ratchet, Reversible VAG 1331/1
  Fig 3: Identifying Ratchet, Reversible VAG 1331/1

  Courtesy of AUDI OF AMERICA, LLC
• Socket T40055
  Fig 4: Identifying Socket T40055

  Courtesy of AUDI OF AMERICA, LLC
• Tool Insert, AF 17 VAG 1331/6
  Fig 5: Assembly Tool SW 17 VAG 1331/6

  Courtesy of AUDI OF AMERICA, LLC

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

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

Fig 6: Bolts -2 And 3- And Remove The Wiring Guide -1-

Courtesy of AUDI OF AMERICA, LLC

-- Pull coolant hose back -arrow-.

-- Remove the bolts -2 and 3- and move the wiring guide to the rear.

-- Open the union nuts from the respective fuel rail that must be removed.

Fig 7: Clamp And Bolts

Courtesy of AUDI OF AMERICA, LLC

Cylinder Bank 1 Fuel Rail

-- Remove the connectors -1 and 2- and the check valve -3- from the bracket.

Fig 8: Connectors And Check Valve

Courtesy of AUDI OF AMERICA, LLC

-- Open the clamps -arrows- and remove the air guide pipe -1-.

Fig 9: Air Guide Pipe & Clamps

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connector -arrow- from the Fuel Pressure Regulator Valve -N276-.

Fig 10: Fuel Pressure Regulator Valve -N276-

Courtesy of AUDI OF AMERICA, LLC

-- Remove the union nut -1- on the fuel rail.

Fig 11: Bolt -1- On The Right Intake Manifold Bracket

Courtesy of AUDI OF AMERICA, LLC

-- Remove the banjo bolt, refer to -item  14-, for the fuel return lines from the fuel rail (See Figure).

-- Open the high pressure line union nuts -2, 3 and 4-.

Fig 12: High Pressure Line Union Nuts & Open Lines And Connections

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -arrows- from the fuel rail and carefully place on a clean surface.

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

Cylinder Bank 2 Fuel Rail

-- Remove the coolant reservoir and move it to the side.

Fig 13: Identifying Coolant Reservoir Marking

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connector from the Fuel Pressure Sensor -G247- -arrow-.

Fig 14: Fuel Pressure Sensor -G247- - Tightening Specification

Courtesy of AUDI OF AMERICA, LLC

-- Unclip the bracket for the connectors -6 and 7-.

Fig 15: Component Locations for the Exhaust Gas Temperature Sensors

Courtesy of AUDI OF AMERICA, LLC

-- Free up the wiring harness.

-- Remove the rear fuel supply line union nut on the fuel rail.

-- Open the union nuts for the high pressure lines between the fuel injectors and the fuel rail.

-- Remove the bolts from the fuel rail and carefully place on a clean surface.

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

Installing

Install in reverse order of removal. Note the following:

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

Tightening Specifications

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