Installing Used Fuel Injectors

WARNING: This page is about a different car, the 2015 Audi A7 Quattro and 2014 Audi A7 Quattro. However, it is still accessible from the selected car via links, so may be relevant.

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.

Continuation for Used and New Fuel Injectors

CAUTION:

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

To remove the rust particles on the fuel injector sealing surface, clean the fuel injector shaft in the cylinder head using the Cleaning Set VAS 6811.

-- 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 O-Ring Assembly Sleeve T10377.

Fig 1: Guide Sleeve T10377 To Replace Fuel Injector Shaft Seal

Courtesy of AUDI OF AMERICA, LLC

-- Install the fuel injectors.

Install in reverse order of removal. Note the following:

-- 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.

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.

Tightening Specifications

Refer to OVERVIEW - FUEL INJECTORS