Removing and installing injector with needle lift sender G80 — AUDI

🧭 Before you start

Fits: Audi A4 B5 (8D)

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• Before operating the starter, make sure that all the injectors are secured with their retainers and that the injection pump connector is detached. — Operate the starter briefly.
• The copper seal must always be renewed.
• When installing injector, make sure that locating pin (3) fits into groove in cylinder head.
• Do not slide the semi-circular rubber seal along the wire (the seal is bonded to the wire to ensure proper sealing).

🔧 Engine codes this applies to

📋 Procedure

1. Remove cylinder head cover (right-side) 15.
2. Unplug connector for needle lift sender G80 (brown connector on bulkhead).
3. Slacken the two nuts on retainer for injector in No. 3 cylinder.
4. Pull out injector together with needle lift sender G80.
5. Engage 4th gear and push the vehicle forwards slightly.

6. Screw retainer back onto injector again.
7. Unplug connector from injection pump.
8. ⚠ Before operating the starter, make sure that all the injectors are secured with their retainers and that the injection pump connector is detached. — Operate the starter briefly.
9. Remove copper seal (between injector and cylinder head) from cylinder head. [Note: The copper seal must always be renewed.]
10. Install new injector with collar (2) and new copper seal (1).
11. When installing injector, make sure that locating pin (3) fits into groove in cylinder head.
12. Guide injector wire through retainer.
13. Secure retainer.
14. Run electrical wire along metal channel in camshaft bearing (arrow).
15. Fit semi-circular rubber seal on wire into cut-out provided in top of cylinder head. [Note: Do not slide the semi-circular rubber seal along the wire (the seal is bonded to the wire to ensure proper sealing).]
16. Re-install cylinder head cover (right-side) .

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