Removing and installing injectors - plastic intake manifold (gradual introduction in model year 2009) — AUDI

🧭 Before you start

Fits: Audi A5 (8T, 2007–2016)

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

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• When inserting the puller, there is a risk of destroying the radial compensation element due to the retainer tabs breaking.
• Renew combustion chamber ring seal and O-ring.Renew spacer ring if damaged.Lightly lubricate O-rings for injectors with clean engine oil.The injectors must be re-installed on the same cylinders.
• The combustion chamber ring seal is widened when it is pushed onto the injector. After pushing it on, it therefore has to be compressed again. This is done in two stages, as described below.
• The combustion chamber ring seal must not be lubricated.
• Do not install mounting brackets until high-pressure pipes have been finally secured.

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ 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 .
2. Remove intake manifold (bottom section) on relevant side .
3. Guide puller T10133/2A into groove on injector.
4. 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.]
5. Carefully remove old combustion chamber ring seal (arrow). To do so, cut open ring using knife or prise open ring with small screwdriver and then pull off forwards.

6. Take care not to damage groove on injector. The injector must be renewed if the groove is damaged. [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 injectors must be re-installed on the same cylinders.]
7. Clean bore in cylinder head with nylon cylinder brush T10133/4.
8. Clip radial compensation element (1) into support ring (2).
9. When re-installing an injector, clean any combustion residue off groove for combustion chamber ring seal and injector stem with a clean cloth.
10. Fit assembly cone T10133/5 with new combustion chamber ring seal (1) onto injector (2).
11. Push combustion chamber ring seal onto assembly cone T10133/6 as far as it will go using assembly sleeve T10133/5.
12. 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 it on, it therefore has to be compressed again. This is done in two stages, as described below.]
13. Push calibration sleeve T10133/7 onto injector as far as it will go and simultaneously turn it slightly (approx. 180°).
14. Pull calibration sleeve T10133/7 off again by turning it in the opposite direction.
15. Push calibration sleeve T10133/8 onto injector as far as it will go and simultaneously turn it slightly (approx. 180°).
16. Pull calibration sleeve T10133/8 off again by turning it in the opposite direction. [Note: The combustion chamber ring seal must not be lubricated.]
17. 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.] [Note: The connections of the high-pressure pipes must not be damaged.Do not attempt to bend high-pressure pipes to a different shape.]
18. Do not install mounting brackets until high-pressure pipes have been finally secured.
19. Install relevant bottom section of intake manifold .
20. Install intake manifold .

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