Overview - Fuel Injectors

Fig 1: Exploded View Of Fuel Injectors

Courtesy of AUDI OF AMERICA, LLC

1. Bracket
   • Various Tightening specifications
     • 2.5 Nm on camshaft bearing
     • 9 Nm on cylinder head
     • For the tension clamp
2. Tension Clamp
   • Mark fuel injector and tension bracket with paint to each other and to the cylinder for reinstallation, when installing pay attention to the markings.
   • When exchanging (as a test), the tension clamp moves with the fuel injector
   • After troubleshooting, the tension clamp and the fuel injector are reinstalled on the original cylinder
   • The tensioning claws can be reused, when new fuel injectors are installed.
3. Bolt
   • First tightening 6 Nm
   • Second tightening 90 degrees
   • Replace
4. High Pressure Line
   • 25 Nm
   • Coat the thread on the union nut with clean engine oil.
   • From high pressure pump to fuel rail
   • Do not change the shape of the line
   • Check for damage before installing
   • Installing, refer to HIGH PRESSURE LINES, REMOVING AND INSTALLING .
5. Clamp
   • For the high pressure line
6. Bolt
   • 9 Nm
7. Clamp
   • For the high pressure line
8. Bolt
   • 9 Nm
9. High Pressure Line
   • 25 Nm
   • Coat the thread on the union nut with clean engine oil.
   • From the opposite fuel rail
   • Do not change the shape of the line
   • Check for damage before installing
   • Installing, refer to HIGH PRESSURE LINES, REMOVING AND INSTALLING .
10. Fuel rail
    • Removing and installing, refer to HIGH PRESSURE RESERVOIR (RAIL), REMOVING AND INSTALLING .
11. Fuel Return Hose
    • To the fuel tank
12. Fuel Return Hose
    • From the fuel injectors
    • Do not disassemble
    • Replace completely along with the restrictor
    • After replacing the engine, allow engine to idle for 2 minutes to bleed the fuel system.
    • Check the fuel return hoses for leaks.
13. Hose Connection Ring
14. Banjo Bolt
    • 25 Nm
15. Seals
    • Replace
16. Fuel Pressure Regulator Valve -N276-
    • With biting edge for sealing
    • Cannot be used again
    • Perform an adaptation after replacing the high pressure pump and / or the Fuel Pressure Regulator Valve -N276-. Use a Vehicle Diagnostic Tester
    • Removing and installing, refer to FUEL PRESSURE REGULATOR VALVE -N276-, REMOVING AND INSTALLING .
    • Tightening specification, refer to Fig 2.
17. Bolt
    • 22 Nm
18. High Pressure Line
    • 25 Nm
    • Coat the thread on the union nut with clean engine oil.
    • From fuel rail to fuel injector
    • Do not change the shape of the line
    • Mark the part allocations for reinstallation and follow them when installing
    • Check for damage before installing
    • Installing, refer to HIGH PRESSURE LINES, REMOVING AND INSTALLING .
19. Fuel Return Hose
    • From the fuel injectors
    • Do not disassemble
    • Replace completely along with the restrictor
    • After replacing the engine, allow engine to idle for 2 minutes to bleed the fuel system.
    • Check the fuel return hoses for leaks.
20. O-Ring
    • Replace
21. Injector
    • Mark fuel injector and tension bracket and high pressure lines with paint to each other and to the cylinder for reinstallation, when installing pay attention to the markings.
    • When exchanging (as a test), the tension clamp moves with the fuel injector
    • Replace the copper ring seal during every assembly/disassembly procedure.
    • After troubleshooting (exchange), the fuel injector and tension clamp are reinstalled on the original cylinder.
    • 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 in the event of leaks).
    • Removing and installing, refer to FUEL INJECTORS, REMOVING AND INSTALLING .
22. O-Ring
    • Replace
23. Copper Ring
    • Replace the copper ring seal during every assembly/disassembly procedure.

Fig 2: Fuel Pressure Regulator Valve -N276-

Courtesy of AUDI OF AMERICA, LLC

-- Align the Fuel Pressure Regulator Valve -N276- so that connecting the connector -arrow- does not cause the electrical wiring to be placed under tension.

-- Counterhold the housing hex bolt to tighten union nut on regulator valve in four stages as follows:

Fig 3: Fuel Pressure Sensor -G247- -arrow-

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the Fuel Pressure Sensor -G247- in four steps as follows:

Special Tools And Workshop Equipment Required 

• Socket - 27 mm T40218
• Torque Wrench