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- Audi A6 C5 How to Replace Fuel Injector<br>Step by step instructions for do-it-yourself repairs.
2.7T fuel injector replacement
07-02-2008, 09:43 PM
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Ok - just got done. I hope this helps... (potential BWW)
Here's what I did. Not sure if there's a difference between APB and BEL engines in this regard, or between tiptronics and 6-speeds (mine's a 6 speed with BEL engine), but anyhow, should be <i>relatively</i> close, I'd guess...
Also, would be a good idea to get a good assortment of oetiker-type clamps and a crimping / removal tool ready. Would not want to be dicking around with screwdrivers trying to pop all these clamps, and wouldn't want to be short when reconnecting things. Just 2 cents.
Anyhow...
First thing you need to do is get access to the fuel rail by removing the y-pipe that's on top of it. Use some big mouth pliers (or if you're popeye, your fingers) and open the clamp holding the accordian hose to the y-pipe (yellow circle), and slide the accordian hose off.
Next, use a 10mm socket and remove the three bolts (green circles) holding the y-pipe in place on the manifold, and set them someplace where you'll forget you put them, just to make things challenging.
Next, use a screwdriver or small socket to losen the clamps holding the upper inlet pipe hoses to the y-pipe (red circles), and pop them off. Might want to stuff them with clean rags to keep anything from falling in them.
<img src="http://audifahrer.com/aw/injector_r&r/002.jpg" border="2">
Use a flathead screwdriver to pop this little guy off (he's circled in blue in the picture above).
<img src="http://audifahrer.com/aw/injector_r&r/003.jpg" border="2">
You can now move the y pipe out of the way and start on the fuel rail.You're going to be undoing a lot of clamps and plugs. The order isn't really important, so long as you get them all.
Here's a rough idea of what you'll be disconnecting (all the little circled bits - problaby missing a few, but the general / obvious idea is anything that is connected to the fuel rail and that will preclude you from removing it neds to be disconnected):
<img src="http://audifahrer.com/aw/injector_r&r/004.jpg" border="2">
First I popped off the N75 mount. There's a rubber band that slips onto a metal flange on the fuel rail. You need to carefully lift it off so the valve is free.
<img src="http://audifahrer.com/aw/injector_r&r/005.jpg" border="2">
Next, I unplugged the harness connecting to the N80 valve. You just depress the metal clip, and it comes right off.
<img src="http://audifahrer.com/aw/injector_r&r/006.jpg" border="2">
After that, I disconnected the harness (same type of clip as above) from the
recirculating valve.
<img src="http://audifahrer.com/aw/injector_r&r/007.jpg" border="2">
Next, I undid these two guys behind the recirc. valve. Be careful, because the plastic can be brittle. I guess you could also disconnect the one hose from the manifold, whatever's easier...
<img src="http://audifahrer.com/aw/injector_r&r/008.jpg" border="2">
This other guy, sorta stuffed behind the fuel pressure regulator, has to go, too:
<img src="http://audifahrer.com/aw/injector_r&r/009.jpg" border="2">
Because I'm a lazy bastard and I hate removing clamps, I also pulled the fuel pressure regulator itself (rather than abusing my fingers any more than necessary). Just slide the retaining clip out of the slots, and pull the regulator outward. There will be some gas - have a rag ready to soak it up.
<img src="http://audifahrer.com/aw/injector_r&r/010.jpg" border="2">
Now it's just a matter of all the little crap. Starting from the right and going clockwise, you'll need to disconnect the 1) suction hose, 2) the lines to your bypass valves, 3) the opposite suction hose, 4) the ventiliation hose, 5) fuel return line, 6) fuel supply line, and 7) hose to evap valve.
<img src="http://audifahrer.com/aw/injector_r&r/011.jpg" border="2">
Suction hose can be disconnected by loosening the clamp with a screwdriver.
<img src="http://audifahrer.com/aw/injector_r&r/012.jpg" border="2">
You can open the clamps connecting the BPV hoses to the fuel rail. My hoses didn't have clamps on the BPV side (they are just super tight), so I just pulled them. My guess is the clamps on the fuel rail side will be more exposed and easier to get to, though...
<img src="http://audifahrer.com/aw/injector_r&r/013.jpg" border="2">
Next comes the passenger side suction hose. In my instance, this was a clamp. Just undo it and remove the hose.
<img src="http://audifahrer.com/aw/injector_r&r/014.jpg" border="2">
Next pull the ventilation hose - another clamp. Your fingers should be hurting pretty good by now.
<img src="http://audifahrer.com/aw/injector_r&r/015.jpg" border="2">
Now's the time you get to sterilize some of the cuts you've accumulated, a baptism by fuel!
Use some pliers or olympian fingers to loosen the clamp on the fuel return line (circled in green), and remove the hose. There will be fuel in here, so have some rags ready for it.
Next, use a few wrenches to unscrew the supply line at the connector. You can see the fuel supply line peeking out from behind the line to the evap valve, circled in yellow. Again, there's going to be some gas here, so have some rags ready for it.
<img src="http://audifahrer.com/aw/injector_r&r/016.jpg" border="2">
Lastly, unclamp the line to the evap valve.
<img src="http://audifahrer.com/aw/injector_r&r/017.jpg" border="2">
At this point, everything should be more or less disconnected. Go back and check to see if there are any additional hoses / lines still connecting the fuel rail to the rest of the engine, and remove them.
At this point you can also disconnect the fuel injector harnesses from the fuel injectors themselves. Space is a little tight, but the same types of connectors the connect the harness to the evap valve above are used here - that is, they are easy to disconnect. Just depress the metal clip, and pull.
Obviously, there's three on the right side, three on the left. On the passenger side, the plugs on the injectors face rearward, on the driver's side, forward.
<img src="http://audifahrer.com/aw/injector_r&r/018.jpg" border="2">
<img src="http://audifahrer.com/aw/injector_r&r/019.jpg" border="2">
You've now got everything disconnected and are ready to pull the fuel rail. First you have to unbolt it from the manifold. There are 4 allen bolts that hold it down. I forget the size of the key to use. Regardless, remove the bolts and set aside.
<img src="http://audifahrer.com/aw/injector_r&r/020.jpg" border="2">
At this point, you can remove the fuel rail by lifting up. It might be on there tight! Quit being a sissy and it will come out. Don't drop any o-rings into the injector ports - might want to cover them with something clean.
You'll have your fuel rail in hand in no time.
<img src="http://audifahrer.com/aw/injector_r&r/021.jpg" border="2">
The last thing will be to remove your injectors from the rail. Each injector is secured in place by a clip that slides into grooves in the injector, and around the port lip on the rail. Just pop the clips off and pull the injectors from the rail. They might be in there tight. Again, just pull and you'll get it.
<img src="http://audifahrer.com/aw/injector_r&r/022.jpg" border="2">
<img src="http://audifahrer.com/aw/injector_r&r/023.jpg" border="2">
Installation of new injectors is the opposite or removal. Note that thenew o-rings mightbe a little "stiff," and it might be helpful to lube them up a little to get everything to slide in the way it should.
If you're adding stage III fueling, enjoy the new power, and hit yourself in the head for ever going stage "three minus" like a jerkoff. What were you thinking!!
Also, would be a good idea to get a good assortment of oetiker-type clamps and a crimping / removal tool ready. Would not want to be dicking around with screwdrivers trying to pop all these clamps, and wouldn't want to be short when reconnecting things. Just 2 cents.
Anyhow...
First thing you need to do is get access to the fuel rail by removing the y-pipe that's on top of it. Use some big mouth pliers (or if you're popeye, your fingers) and open the clamp holding the accordian hose to the y-pipe (yellow circle), and slide the accordian hose off.
Next, use a 10mm socket and remove the three bolts (green circles) holding the y-pipe in place on the manifold, and set them someplace where you'll forget you put them, just to make things challenging.
Next, use a screwdriver or small socket to losen the clamps holding the upper inlet pipe hoses to the y-pipe (red circles), and pop them off. Might want to stuff them with clean rags to keep anything from falling in them.
<img src="http://audifahrer.com/aw/injector_r&r/002.jpg" border="2">
Use a flathead screwdriver to pop this little guy off (he's circled in blue in the picture above).
<img src="http://audifahrer.com/aw/injector_r&r/003.jpg" border="2">
You can now move the y pipe out of the way and start on the fuel rail.You're going to be undoing a lot of clamps and plugs. The order isn't really important, so long as you get them all.
Here's a rough idea of what you'll be disconnecting (all the little circled bits - problaby missing a few, but the general / obvious idea is anything that is connected to the fuel rail and that will preclude you from removing it neds to be disconnected):
<img src="http://audifahrer.com/aw/injector_r&r/004.jpg" border="2">
First I popped off the N75 mount. There's a rubber band that slips onto a metal flange on the fuel rail. You need to carefully lift it off so the valve is free.
<img src="http://audifahrer.com/aw/injector_r&r/005.jpg" border="2">
Next, I unplugged the harness connecting to the N80 valve. You just depress the metal clip, and it comes right off.
<img src="http://audifahrer.com/aw/injector_r&r/006.jpg" border="2">
After that, I disconnected the harness (same type of clip as above) from the
recirculating valve.
<img src="http://audifahrer.com/aw/injector_r&r/007.jpg" border="2">
Next, I undid these two guys behind the recirc. valve. Be careful, because the plastic can be brittle. I guess you could also disconnect the one hose from the manifold, whatever's easier...
<img src="http://audifahrer.com/aw/injector_r&r/008.jpg" border="2">
This other guy, sorta stuffed behind the fuel pressure regulator, has to go, too:
<img src="http://audifahrer.com/aw/injector_r&r/009.jpg" border="2">
Because I'm a lazy bastard and I hate removing clamps, I also pulled the fuel pressure regulator itself (rather than abusing my fingers any more than necessary). Just slide the retaining clip out of the slots, and pull the regulator outward. There will be some gas - have a rag ready to soak it up.
<img src="http://audifahrer.com/aw/injector_r&r/010.jpg" border="2">
Now it's just a matter of all the little crap. Starting from the right and going clockwise, you'll need to disconnect the 1) suction hose, 2) the lines to your bypass valves, 3) the opposite suction hose, 4) the ventiliation hose, 5) fuel return line, 6) fuel supply line, and 7) hose to evap valve.
<img src="http://audifahrer.com/aw/injector_r&r/011.jpg" border="2">
Suction hose can be disconnected by loosening the clamp with a screwdriver.
<img src="http://audifahrer.com/aw/injector_r&r/012.jpg" border="2">
You can open the clamps connecting the BPV hoses to the fuel rail. My hoses didn't have clamps on the BPV side (they are just super tight), so I just pulled them. My guess is the clamps on the fuel rail side will be more exposed and easier to get to, though...
<img src="http://audifahrer.com/aw/injector_r&r/013.jpg" border="2">
Next comes the passenger side suction hose. In my instance, this was a clamp. Just undo it and remove the hose.
<img src="http://audifahrer.com/aw/injector_r&r/014.jpg" border="2">
Next pull the ventilation hose - another clamp. Your fingers should be hurting pretty good by now.
<img src="http://audifahrer.com/aw/injector_r&r/015.jpg" border="2">
Now's the time you get to sterilize some of the cuts you've accumulated, a baptism by fuel!
Use some pliers or olympian fingers to loosen the clamp on the fuel return line (circled in green), and remove the hose. There will be fuel in here, so have some rags ready for it.
Next, use a few wrenches to unscrew the supply line at the connector. You can see the fuel supply line peeking out from behind the line to the evap valve, circled in yellow. Again, there's going to be some gas here, so have some rags ready for it.
<img src="http://audifahrer.com/aw/injector_r&r/016.jpg" border="2">
Lastly, unclamp the line to the evap valve.
<img src="http://audifahrer.com/aw/injector_r&r/017.jpg" border="2">
At this point, everything should be more or less disconnected. Go back and check to see if there are any additional hoses / lines still connecting the fuel rail to the rest of the engine, and remove them.
At this point you can also disconnect the fuel injector harnesses from the fuel injectors themselves. Space is a little tight, but the same types of connectors the connect the harness to the evap valve above are used here - that is, they are easy to disconnect. Just depress the metal clip, and pull.
Obviously, there's three on the right side, three on the left. On the passenger side, the plugs on the injectors face rearward, on the driver's side, forward.
<img src="http://audifahrer.com/aw/injector_r&r/018.jpg" border="2">
<img src="http://audifahrer.com/aw/injector_r&r/019.jpg" border="2">
You've now got everything disconnected and are ready to pull the fuel rail. First you have to unbolt it from the manifold. There are 4 allen bolts that hold it down. I forget the size of the key to use. Regardless, remove the bolts and set aside.
<img src="http://audifahrer.com/aw/injector_r&r/020.jpg" border="2">
At this point, you can remove the fuel rail by lifting up. It might be on there tight! Quit being a sissy and it will come out. Don't drop any o-rings into the injector ports - might want to cover them with something clean.
You'll have your fuel rail in hand in no time.
<img src="http://audifahrer.com/aw/injector_r&r/021.jpg" border="2">
The last thing will be to remove your injectors from the rail. Each injector is secured in place by a clip that slides into grooves in the injector, and around the port lip on the rail. Just pop the clips off and pull the injectors from the rail. They might be in there tight. Again, just pull and you'll get it.
<img src="http://audifahrer.com/aw/injector_r&r/022.jpg" border="2">
<img src="http://audifahrer.com/aw/injector_r&r/023.jpg" border="2">
Installation of new injectors is the opposite or removal. Note that thenew o-rings mightbe a little "stiff," and it might be helpful to lube them up a little to get everything to slide in the way it should.
If you're adding stage III fueling, enjoy the new power, and hit yourself in the head for ever going stage "three minus" like a jerkoff. What were you thinking!!
