Removing and installing injectors - magnesium intake manifold — AUDI

🧭 Before you start

Fits: Audi A5 (8T, 2007–2016)

• Special tools named: T10133/2A, T10133/16, T10133/5, T10133/6, T10133/7, T10133/8, T10133/4, puller
• Renewed: combustion chamber ring seal, spacer ring

Don't miss

• For identification purposes, mark the modified tool with the letter "“A”" after the tool number.
• Seal off the injector openings in the cylinder heads with clean cloths.
• Unscrew high-pressure pipe (7) at connection on fuel rail. To do so, counterhold at hexagon flats with an open-end spanner and slacken union nut.
• Do not attempt to bend high-pressure pipes to a different shape.
• When inserting the puller, there is a risk of destroying the radial compensation element due to the retainer tabs breaking.

🔧 Engine codes this applies to

📋 Procedure

1. File out a semi-circular recess as shown in the illustration. The recess allows the tool to be pushed further onto the injector so the contact surface is increased.
2. For identification purposes, mark the modified tool with the letter "“A”" after the tool number.
3. ⚠ The fuel system operates under high pressure. The pressure in the high-pressure part of the injection system must be reduced to a residual pressure prior to opening the system .A clean cloth must then be wrapped around the connection and the residual pressure dissipated by carefully loosening the connection. — Remove intake manifold . [Note: Seal off the injector openings in the cylinder heads with clean cloths.]
4. Unplug electrical connectors at injectors.
5. Unscrew high-pressure pipe (5) at connection on fuel rail.

6. Unscrew high-pressure pipe (7) at connection on fuel rail. To do so, counterhold at hexagon flats with an open-end spanner and slacken union nut.
7. Remove bolts (1, 2, 3, 4, 6 and 8). [Note: Do not attempt to bend high-pressure pipes to a different shape.]
8. Pull off fuel rail together with injectors.
9. Use a screwdriver to bend retainer tabs (1) of radial compensation element to side (arrow) and pull support ring (2) off injector.
10. Remove O-ring from injector.
11. Guide puller T10133/2A into groove on injector.
12. Then attach removal tool T10133/16 and pull out injector by turning bolt (1). [Note: When inserting the puller, there is a risk of destroying the radial compensation element due to the retainer tabs breaking.]
13. Carefully remove old teflon ring (arrow) using suitable tools (e.g. cut open ring using razor blade, or prise open ring with small screwdriver and then pull off forwards). It is important to ensure that the groove and the continuous ridge in the bottom of the groove are not damaged. [Note: The injector must be renewed if the groove is damaged.]
14. Before new teflon ring is fitted, any combustion residue must be removed from ring groove and injector stem using a clean cloth. [Note: Renew combustion chamber ring seal and O-ring.Renew spacer ring if damaged.Lightly lubricate O-rings for injectors with clean engine oil.The injector pipes must be re-installed on the same cylinders.]
15. Clip radial compensation element (1) into support ring (2).
16. When re-installing an injector, clean any combustion residue off groove for combustion chamber ring seal and injector stem with a clean cloth.
17. Fit assembly cone T10133/5 with new combustion chamber ring seal (1) onto injector (2).
18. Push combustion chamber ring seal onto assembly cone T10133/6 as far as it will go using assembly sleeve T10133/5.
19. Turn assembly sleeve T10133/6 upside down and push combustion chamber ring seal into sealing ring groove. [Note: The combustion chamber ring seal is widened when it is pushed onto the injector. After pushing on the combustion chamber ring seal, it therefore has to be compressed again. This is done in two stages, as described below.]
20. Push calibration sleeve T10133/7 onto injector as far as it will go and simultaneously turn it slightly (approx. 180°).
21. Pull calibration sleeve T10133/7 off again by turning it in the opposite direction.
22. Push calibration sleeve T10133/8 onto injector as far as it will go and simultaneously turn it slightly (approx. 180°).
23. Pull calibration sleeve T10133/8 off again by turning it in the opposite direction.
24. Lubricate new O-ring lightly with clean engine oil before installing. [Note: The combustion chamber ring seal must not be lubricated.Do not apply grease, oil or any other lubricant to combustion-chamber ring seal.]
25. Clean bore in cylinder head with nylon cylinder brush T10133/4.
26. Push injector by hand as far as it will go into aperture in cylinder head (do not use oil or grease). Ensure that the injector is properly seated in the cylinder head. [Note: It should be possible to insert injector easily. If necessary wait until the combustion chamber ring seal has contracted sufficiently.Note correct installation position and ensure that injectors are properly seated in cylinder head.If the injector cannot be pushed in by hand, use puller T10133/2A(2) with striker T10133/3 to insert the injector.]
27. Press fuel rail evenly onto injectors.
28. Tighten bolts (1, 2, 3, 4, 6 and 8) in diagonal sequence and in stages. [Note: The connections of the high-pressure pipes must not be damaged.Do not attempt to bend high-pressure pipes to a different shape.]
29. Install intake manifold .
30. Install high-pressure pipes .

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