Work Procedure

^ Open hood and remove engine cover.

PRE-CHECK

- On 1993 model year vehicles only check the color of the top of each injector





- If the tops of all injectors are black (as shown in illustration), no further work is required; reinstall engine cover and close hood

- If the tops of any of the injectors are gray, proceed to the following steps below

^ Remove fuse for fuel pump from fuse box
- Audi 90, Cabriolet - fuse # 13
- Audi 100/A6 - fuse # 17

^ Loosen gas filler cap to relieve pressure (if any), then tighten cap





^ Remove vacuum hose -A- between fuel pressure regulator and vacuum line "T"

^ Remove tie wrap -B- (if present) holding ignition cable # 5 to injector rail

^ Remove all ignition cables from cable holders -C-, then remove holders

^ Disconnect all harness connectors -D- to fuel injectors

WARNING - FIRE HAZARD!
DO NOT SMOKE, WORK NEAR HEATERS OR HAVE ANYTHING IN THE AREA THAT COULD IGNITE THE FUEL OR FUMES.

CAUTION:
Fuel supply lines are under pressure! BEFORE loosening lines cover the connection with a rag. Release pressure by slowly loosening the connection - being careful to catch all fuel.

^ Prior to disconnecting the fuel pressure and return lines, remove (2) plastic covers from the fuel line in the kit

^ Disconnect fuel pressure and return lines from fuel rail

^ Screw (2) plastic covers from new fuel line onto old fuel line





- Remove 4 screws (arrows) then lift engine cover brackets and fuel rail together with fuel injectors from intake manifold





- Audi 100/A6, use kit 078 133 651 J

Note:
Use new, clean engine oil as lubricant on lower injector O-rings prior to installation





- Audi 90 and Cabriolet, use kit 078 133 651 H

Note:
Use new, clean engine oil as lubricant on lower injector O-rings prior to installation

^ Install new fuel rail/injector assembly on intake manifold and push down on each injector until it snaps into position and is properly seated

^ Check for correct position and seating of the clips securing the injector to the fuel line

^ Reconnect electrical connectors to all injectors

^ Reinstall engine cover brackets using new screws from kit and torque to 10 Nm (7 ft lb)

^ Reconnect fuel pressure and return line and torque to 25 Nm (18 ft lb)

^ Install new vacuum hose from kit between fuel pressure regulator and vacuum line "T"

^ Reinstall ignition cable holding clips

^ Reinstall ignition cables into holding clips

^ Reinstall fuel pump fuse in fuse box

^ Start engine

^ Disconnect vacuum line to fuel pressure regulator and check for vacuum. Reconnect vacuum line after a maximum of 2 minutes, and check for fuel leaks at fuel line connections and injectors

^ Turn engine off, reinstall engine cover and close hood

^ Properly dispose of all removed parts