Fuel Injectors: Removing

WARNING:

There is a risk of injury because the fuel is under very high pressure.

The fuel pressure must be reduced to residual pressure before opening the high pressure area of the fuel injection system. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .
To reduce remaining residual pressure, lay a clean cloth around the connector and carefully loosen connector.

-- Remove upper section of the intake manifold. Refer to UPPER INTAKE MANIFOLD .

-- Remove affected intake manifold lower section. Refer to LOWER INTAKE MANIFOLD WITH FUEL RAIL .

If the fuel injectors cannot be pulled out of the cylinder head by hand, proceed as follows:

-- Using a screwdriver, bend the retaining tabs -1- of the radial adjustment aside -arrow- and pull the support ring -2- from the fuel injector.

Fig 1: Identifying Screwdriver, Retaining Tabs Of Radial Adjustment And Support Ring From Fuel Injector

Courtesy of AUDI OF AMERICA, LLC

-- Guide puller T10133/2A in the groove on the fuel injector.

Fig 2: Identifying Position Of Puller T10133/2A

Courtesy of AUDI OF AMERICA, LLC

-- Then position the trim removal wedge T10133/16 and remove the fuel injector by loosening bolt -1-.

NOTE:

When setting the puller in place, the radial adjustment can be destroyed, because the retaining tabs break.

-- Carefully remove the old combustion chamber seal -arrow-, thereby cutting seal open with a knife or spreading seal open with a small screwdriver and pulling it forward and off.

Fig 3: Cleaning Fuel Injector In Area Of Sealing Ring

Courtesy of AUDI OF AMERICA, LLC

-- Make sure that the groove of the fuel injector does not become damaged. If the groove is damage, the fuel injector must be replaced.