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Repair ManualAudi A6 2005 ➤Fuel Injection and IgnitionEngine ID CCA

A

Edition 08.2010

Service

Service Department. Technical Information


List of Workshop Manual Repair GroupsList of Workshop ManualRepair GroupsList of Workshop Manual Repair Groups

Repai r Group24 - Fuel Injection System28 - Ignition/Glow Plug System

Technical information should always be available to the foremen and mechanics, because theircareful and constant adherence to the instructions is essential to ensure vehicle road-worthiness andsafety. In addition, the normal basic safety precautions for working on motor vehicles must, as amatter of course, be observed.

Service

All rights reserved.No reproduction without prior agreement from publisher.

Copyright © 2012 Audi AG, Ingolstadt D3E8016F7C1


Contents

24 - Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 Before Opening High Pressure Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 On Board Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.5 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.6 Lines, Routing and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.1 Component Locations Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.2 Air Filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.3 Lower Intake Manifold Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.4 High Pressure Pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222.5 Oxygen Sensors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253.1 Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253.2 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274.1 Wiring and Components, Checking with Test Box V.A.G 1598/42 . . . . . . . . . . . . . . . . . . 274.2 Fuel System, Performing Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284.3 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284.4 Fuel Pressure and Residual Pressure before High Pressure Pump, Checking . . . . . . . . . . 295 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335.1 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335.2 Intake Manifold, Lower Section, with Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355.3 Throttle Valve Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385.4 Control Valve Control Unit J808 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405.5 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405.6 High Pressure Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435.7 High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455.8 Heated Oxygen Sensor G39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475.9 Oxygen Sensor after Three Way Catalytic Converter G130 . . . . . . . . . . . . . . . . . . . . . . . . 495.10 Heated Oxygen Sensor 2 G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515.11 Oxygen Sensor 2 after Catalytic Converter G131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525.12 Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621.2 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642.1 Ignition Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663.1 Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663.2 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674.1 Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674.2 Knock Sensors G61 / G66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684.3 Camshaft Position Sensors G40 / G163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704.4 Engine Speed Sensor G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Audi A6 2005 ➤Fuel Injection and Ignition - Edition 08.2010

Contents i


5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73


ii Contents


24 – Fuel Injection System1 General Information⇒ “1.1 Safety Precautions”, page 1⇒ “1.2 Clean Working Conditions”, page 2⇒ “1.3 Before Opening High Pressure Fuel Injection System”,page 2⇒ “1.4 On Board Diagnostics”, page 4⇒ “1.5 Contact Corrosion”, page 5⇒ “1.6 Lines, Routing and Securing”, page 5

1.1 Safety PrecautionsIf it is necessary to use testing and measuring devices on roadtests, observe the following:

WARNING

Distraction and improperly secured test equipment can lead toaccidents.There is a risk that the passenger airbag could deploy in a col‐lision.• Operating testing and measuring equipment while driving

creates a distraction.• There is an increased risk of injury due to unsecured test‐

ing and measuring equipment.♦ Always secure testers on the rear seat with a strap and

have a second person on the rear seat to operate them.

Caution

♦ Always follow the instructions when disconnecting the bat‐tery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ;Removal and Installation .

Note the following when working on the fuel system:

WARNING

There is a risk of injury because the fuel is under very highpressure.♦ Before opening the high pressure area of the fuel injection

system, fuel pressure must be relieved to residual pres‐sure.

♦ To reduce the remaining residual pressure, lay a cleancloth around the connector and carefully loosen connec‐tor.

– Procedures before opening high pressure fuel injection sys‐tem. Refer to⇒ “1.3 Before Opening High Pressure Fuel Injection System”,page 2 .


1. General Information 1


To prevent personal injury and damage to the injection and igni‐tion system, observe the following:♦ Individuals with a pacemaker must not stay in the danger area

of high voltage systems, for example ignition systems, xenonlight.

♦ The ignition must be switched off before connecting or dis‐connecting injection and ignition system wiring or tester ca‐bles.

♦ Fuel lines must not be opened when engine is running.♦ Only clean engine with ignition switched off.♦ While testing it is possible that there may be some faults stored

in the engine control module. After completing all testing andrepairs, check the DTC memory. If a fault has been stored:

1.2 Clean Working ConditionsEven a little contamination can lead to faults. When working onthe fuel supply and fuel injection system, observe the followingguidelines for a clean working environment:♦ Before loosening, connections and surrounding areas must be

cleaned thoroughly with engine or brake cleaner, and thencleaned area must be dried completely.

♦ Plug open lines and connections immediately with appropriateprotective caps.

♦ Place parts that have been removed on a clean surface andcover them. Use lint-free cloths.

♦ Carefully cover over opened components or seal, if repairs arenot performed immediately.

♦ Install only clean parts: remove the replacement parts fromtheir packaging just before installing them. Do not use partsthat have been stored unpacked (for example in tool boxesetc.).

♦ When the system is open: do not work with compressed air.Do not move the vehicle unless absolutely necessary.

♦ Protect disconnected electrical connectors from dirt and mois‐ture and only connect if dry.

1.3 Before Opening High Pressure Fuel In‐jection System

Caution

♦ The fuel injection system is separated into a high-pressuresection (maximum approximately 120 bar) and a low-pressure section (approximately 6 bar).

♦ Before opening high pressure area, fuel pressure must bereduced to a residual pressure of approximately 6 bar. Theprocedure for this is as follows.

Special tools and workshop equipment required♦ Vehicle Diagnostic, Testing, and Information System -VAS

5051B-


2 Rep. Gr.24 - Fuel Injection System


Procedure– Connect the vehicle diagnosis tester.– Start engine and run at idle speed.– Select “Engine Electronics” in OBD.– Then select “Measured Values” read out.– Select measured value block 140.– With the engine running at idle, the fuel pressure will be dis‐

played in display field 3.• Specified value: between 35 and 45 bar.– Remove the right instrument panel cover. Refer to ⇒ Body

Interior; Rep. Gr. 70 ; Removal and Installation .




– Remove fuse 1 in the fuse carrier ST2 (brown) -2-.

Note

Ignore -1 and 3-.

– Follow the fuel pressure on the tester.• The fuel pressure decreases rapidly because the mechanical

high pressure pump is no longer supplied with fuel from thetransfer fuel pump -G6- .

– Switch off the ignition as soon as the fuel pressure has de‐creased to approximately 8 bar.

Note

The fuel pressure must not drop below 6 bar, because otherwisethe engine will shut off (risk of catalytic converter damage).

The fuel rail will continue to be filled with fuel, but it will no longerbe under high pressure.

WARNING

Do not let fuel come into contact with skin.♦ Wear protective eyewear and clothing when opening the

fuel system.♦ Lay clean cloths around the connection before opening

the high pressure area to collect any fuel that leaks out.

– After reducing fuel pressure, place a clean cloth around theconnection and open the high pressure system immediately.Escaping fuel must be absorbed.

Final Procedures– Install fuse 1 in the fuse carrier ST2 (brown).– Install the right instrument panel cover. Refer to ⇒ Body Inte‐

rior; Rep. Gr. 70 ; Removal and Installation .– Erase the DTC memory and generate the readiness code in

the engine control module in “Guided Functions”.

1.4 On Board Diagnostics♦ The engine control module is equipped with On Board Diag‐

nostics (OBD). Before repairs such as fault finding, check theDTC memory first. Also the vacuum hoses and connectionsmust be checked (unmetered air).

♦ Fuel hoses in engine compartment must only be secured withspring-type clips. The use of clamp or screw type clips is notpermissible.

♦ For the electric components to work properly, a voltage of atleast 11.5 Volts is required.

♦ Do not use sealants containing silicone. Particles of siliconedrawn into the engine, will not be burnt in the engine and dam‐age the oxygen sensor.




♦ The vehicles have a crash fuel shut-off. It reduces the risk offire in an accident because the fuel pump relay switches thefuel pump off.

1.5 Contact CorrosionContact corrosion can occur if incorrect fasteners (bolts, nuts,washers, etc.) are used.For this reason, only install connecting elements that are treatedwith a special coating.Also, rubber or plastic parts and adhesive consist of non-conduc‐tive materials.If there are doubts about the suitability of parts, generally use newparts. Refer to the electronic parts catalog ETKA.

Note

♦ Only original replacement parts are recommended, they arechecked and compatible with aluminum.

♦ Audi accessories are recommended.♦ Damage due to contact corrosion is not covered by warranty.

1.6 Lines, Routing and SecuringTo prevent mistakes and ensure the original installation locationis kept, mark the hydraulic lines, vacuum lines or electrical linesbefore removing them. If necessary, draw sketches or take pic‐tures.




2 Description and Operation⇒ “2.1 Component Locations Overview”, page 6⇒ “2.2 Air Filter Overview”, page 18⇒ “2.3 Lower Intake Manifold Section Overview”, page 19⇒ “2.4 High Pressure Pump Overview”, page 22⇒ “2.5 Oxygen Sensors Overview”, page 23

2.1 Component Locations OverviewEngine Compartment, Right

1 - Secondary Air Injection(AIR) Pump Motor -V101-

❑ Component location, re‐fer to⇒ Fig. ““Installed Loca‐tion Secondary Air In‐jection Pump Motor -V101- ”“ , page 16

2 - Charge Air Pressure Sen‐sor -G31- / Intake Air Temper‐ature Sensor -G72-

❑ Component location, re‐fer to⇒ Fig. ““Installed Loca‐tion Charge Air Pres‐sure Sensor -G31- / In‐take Air TemperatureSensor -G72- ”“ ,page 16

3 - Ignition Coils, CylinderBank 1

❑ Ignition coil 1 with poweroutput stage -N70-



❑ Removing and instal‐ling, refer to⇒ “4.1 Ignition Coils”,page 67

4 - Right Electrohydraulic En‐gine Mount Solenoid Valve -N145-

❑ Component location⇒ Fig. ““Installed Loca‐tion Left Electrohydraulic Engine Mount Solenoid Valve -N144- and Right Electrohydraulic Engine MountSolenoid Valve -N145- ”“ , page 15

5 - Heated Oxygen Sensor -G39- with Oxygen Sensor Heater -Z19-❑ 55 Nm❑ Component location, refer to ⇒ Fig. ““Oxygen Sensors Location, Cylinder Bank 1 (right)”“ , page 12❑ Connector location, refer to

⇒ Fig. ““Connectors on the Plenum Chamber Bulkhead (right bracket)”“ , page 11❑ Removing and installing, refer to ⇒ “5.8 Heated Oxygen Sensor G39 ”, page 47




6 - Camshaft Adjustment Valve 1 -N205-❑ Component location, refer to

⇒ Fig. ““Camshaft Position Sensor and Exhaust Camshaft Control Valve Cylinder Bank 1 (right)”“ , page13

7 - Engine Control Module -J623-❑ Component location, refer to ⇒ Fig. ““Installed Location Engine Control Module -J623- ”“ , page 10❑ Removing and installing, refer to ⇒ “5.12 Engine Control Module”, page 54

8 - Right Holder for Connectors❑ Connector locations, refer to

⇒ Fig. ““Connectors on the Plenum Chamber Bulkhead (right bracket)”“ , page 119 - Oxygen Sensor after Three Way Catalytic Converter -G130- with Heater for Oxygen Sensor 1 after CatalyticConverter -Z29-

❑ 55 Nm❑ Component location, refer to ⇒ Fig. ““Oxygen Sensors Location, Cylinder Bank 1 (right)”“ , page 12❑ Connector location, refer to

⇒ Fig. ““Connectors on the Plenum Chamber Bulkhead (right bracket)”“ , page 11❑ Removing and installing, refer to

⇒ “5.9 Oxygen Sensor after Three Way Catalytic Converter G130 ”, page 4910 - Secondary Air Injection Sensor 1 -G609-

❑ Component location, refer to ⇒ Engine Mechanical; Rep. Gr. 26 ; Description and Operation11 - Throttle Valve Control Module -J338-

❑ Component location, refer to⇒ Fig. ““Installed Location Throttle Valve Control Module -J338- ”“ , page 16

❑ Removing and installing, refer to ⇒ “5.3 Throttle Valve Control Module”, page 38❑ After replacement, adapt in “Guided Functions” operating mode under “adapting throttle valve control

module”.12 - EVAP Canister Purge Regulator Valve 1 -N80-13 - Control Valve Control Unit -J808-

❑ Component location, refer to⇒ Fig. ““Installed Location Control Valve Control Unit -J808- ”“ , page 16

❑ Removing and installing, refer to ⇒ “5.4 Control Valve Control Unit J808 ”, page 40❑ After replacement, adapt in “Guided Functions” operating mode under “adapting control valve control

module”.14 - Knock Sensor 1 -G61-

❑ Component location, refer to⇒ Fig. ““Installed Location under the Intake Manifold, Cylinder Bank 1 (right)”“ , page 15

❑ Connector location, refer to ⇒ Fig. ““Electrical Connectors on Left Rear of Engine”“ , page 1215 - Fuel Injectors, Cylinder Bank 1

❑ Cylinder 1 Fuel Injector -N30-❑ Cylinder 2 Fuel Injector -N31-❑ Cylinder 3 Fuel Injector -N32-❑ Removing and installing, refer to ⇒ “5.5 Fuel Injectors”, page 40

16 - Intake Manifold Runner Position Sensor -G336-❑ Component location, refer to

⇒ Fig. ““Installed Location Intake Manifold Runner Position Sensor 2 -G512- ”“ , page 1317 - Camshaft Position Sensor -G40-

❑ Component location, refer to⇒ Fig. ““Camshaft Position Sensor and Exhaust Camshaft Control Valve Cylinder Bank 1 (right)”“ , page13

18 - Fuel Metering Valve -N290-❑ Component location, refer to ⇒ Fig. ““Installed Location on the High Pressure Pump”“ , page 14


2. Description and Operation 7


19 - Low Fuel Pressure Sensor -G410-❑ Component location, refer to ⇒ Fig. ““Installed Location on the High Pressure Pump”“ , page 14

20 - Fuel High Pressure Pump❑ Component location, refer to ⇒ Fig. ““Installed Location on the High Pressure Pump”“ , page 14❑ Removing and installing, refer to ⇒ “5.7 High Pressure Pump”, page 45

Engine Compartment, Left

1 - Fuel Pressure Sensor -G247-

❑ Component location, re‐fer to⇒ Fig. ““Installed Loca‐tion under the IntakeManifold, Cylinder Bank2 (left)”“ , page 15

2 - Knock Sensor 2 -G66-❑ Component location, re‐

fer to⇒ Fig. ““Installed Loca‐tion under the IntakeManifold, Cylinder Bank2 (left)”“ , page 15

❑ Connector location, re‐fer to⇒ Fig. ““Electrical Con‐nectors on Left Rear ofEngine”“ , page 12

3 - Fuel Injectors, CylinderBank 2

❑ Cylinder 4 fuel injector -N33-



❑ Removing and instal‐ling, refer to⇒ “5.5 Fuel Injectors”,page 40

4 - Intake Air TemperatureSensor -G42- / Manifold Abso‐lute Pressure Sensor -G71-

❑ Component location, re‐fer to⇒ Fig. ““Installed Location Intake Air Temperature Sensor -G42- / Manifold Absolute Pressure Sensor -G71- ”“ , page 14

5 - Secondary Air Injection Solenoid Valve -N112-❑ Component location, refer to

⇒ Fig. ““Installed Location Secondary Air Injection Solenoid Valve -N112- / Intake Manifold Runner Con‐trol Valve -N316- / Secondary Air Injection Solenoid Valve 2 -N320- ”“ , page 14

6 - Intake Manifold Runner Control Valve -N316-❑ Component location, refer to





7 - Secondary Air Injection Solenoid Valve 2 -N320-❑ Component location, refer to


8 - Engine Speed Sensor -G28-❑ Component location, refer to ⇒ Fig. ““Installed Location Engine Speed Sensor -G28- ”“ , page 15

9 - Oxygen Sensor 2 after Three Way Catalytic Converter -G131- with Heater for Oxygen Sensor 2 after CatalyticConverter -Z30-

❑ 55 Nm❑ Component location, refer to ⇒ Fig. ““Oxygen Sensors Location, Cylinder Bank 2 (left)”“ , page 12❑ Connector allocation and installation location, refer to

⇒ Fig. ““Connectors on the Plenum Chamber Bulkhead (left bracket)”“ , page 11❑ Removing and installing, refer to

⇒ “5.11 Oxygen Sensor 2 after Catalytic Converter G131 ”, page 5210 - Engine Malfunction Lamp

❑ Inside the instrument cluster11 - Accelerator Pedal Position Sensor -G79- / Accelerator Pedal Position Sensor 2 -G185-

❑ In accelerator pedal module, component location, refer to⇒ Fig. ““Installed Location Accelerator Pedal Position Sensor -G79- / Accelerator Pedal Position Sensor2 -G185- ”“ , page 11

12 - Brake Lamp Switch -F- / Brake Pedal Switch -F47-❑ Component location, refer to

⇒ Fig. ““Installed Location Brake Light Switch -F- / Brake Pedal Switch -F47- ”“ , page 1113 - Relay Box14 - Left Holder for Connectors

❑ Connector locations, refer to⇒ Fig. ““Connectors on the Plenum Chamber Bulkhead (left bracket)”“ , page 11

15 - Camshaft Adjustment Valve 2 -N208-Component location, refer to⇒ Fig. ““Camshaft Position Sensor and Exhaust Camshaft Control Valve Cylinder Bank 2 (left)”“ , page 13

16 - Heated Oxygen Sensor 2 -G108- with Oxygen Sensor 2 Heater -Z28-❑ 55 Nm❑ Component location, refer to ⇒ Fig. ““Oxygen Sensors Location, Cylinder Bank 2 (left)”“ , page 12❑ Connector location, refer to

⇒ Fig. ““Connectors on the Plenum Chamber Bulkhead (left bracket)”“ , page 11❑ Removing and installing, refer to ⇒ “5.10 Heated Oxygen Sensor 2 G108 ”, page 51

17 - Left Electrohydraulic Engine Mount Solenoid Valve -N144-❑ Component location, refer to

⇒ Fig. ““Installed Location Left Electrohydraulic Engine Mount Solenoid Valve -N144- and Right Elec‐trohydraulic Engine Mount Solenoid Valve -N145- ”“ , page 15

18 - Ignition Coils, Cylinder Bank 2❑ Ignition coil 4 with power output stage -N292-❑ Ignition coil 5 with power output stage -N323-❑ Ignition coil 6 with power output stage -N324-❑ Removing and installing, refer to ⇒ “4.1 Ignition Coils”, page 67

19 - Oil Pressure Regulation Valve -N428-❑ Component location, refer to

⇒ Fig. ““Installed Location Oil Pressure Regulation Valve -N428- ”“ , page 1320 - Charge Air Coolant Pump -V188-

❑ Component location, refer to⇒ Fig. ““Installed Location Charge Air Cooling Pump -V188- ”“ , page 17




21 - After-Run Coolant Pump -V51-❑ Depending on country❑ Component location, refer to ⇒ Fig. ““Installed Location After-Run Coolant Pump -V51- ”“ , page 17

22 - Intake Air Temperature Temperature Sensor 2 -G430- / Charge Air Pressure Sensor 2 -G447-❑ Component location, refer to

⇒ Fig. ““Installed Location Charge Air Pressure Sensor -G31- / Intake Air Temperature Sensor -G72- ”“ ,page 16

23 - Camshaft Position Sensor 2 -G163-❑ Component location, refer to

⇒ Fig. ““Camshaft Position Sensor and Exhaust Camshaft Control Valve Cylinder Bank 2 (left)”“ ,page 13

24 - Intake Manifold Runner Position Sensor 2 -G512-❑ Component location, refer to

⇒ Fig. ““Installed Location Intake Manifold Runner Position Sensor 2 -G512- ”“ , page 13❑ After replacing, perform an “Adaptation” in “Guided Functions”. Use a vehicle tester.

25 - Engine Coolant Temperature Sensor -G62-❑ Component location, refer to

⇒ Fig. ““Installed Location Engine Coolant Temperature Sensor -G62- ”“ , page 14

Installed Location Engine Control Module -J623-♦ In the E-box in engine compartment, right




Installed Location Accelerator Pedal Position Sensor -G79- / Ac‐celerator Pedal Position Sensor 2 -G185-♦ In accelerator pedal module -arrow-.

Note

The accelerator pedal position sensor and accelerator pedal po‐sition sensor 2 are integrated in the gas pedal module and cannotbe replaced individually.

Removing and installing, refer to ⇒ Fuel Supply System; Rep.Gr. 20 ; Removal and Installation .

Installed Location Brake Light Switch -F- / Brake Pedal Switch -F47-♦ On pedal mount -arrow-.

Note

To ensure that they are absolutely securely seated, the switchesmay only be installed once.

Removing and installing, refer to ⇒ Brake System; Rep. Gr. 46 ;Removal and Installation .

Connectors on the Plenum Chamber Bulkhead (right bracket)1 - For the heated oxygen sensor -G39- with oxygen sensor

heater -Z19-2 - For oxygen sensor after three way catalytic converter -

G130- with heater for oxygen sensor 1 after catalytic con‐verter -Z29-

Connectors on the Plenum Chamber Bulkhead (left bracket)1 - For the heated oxygen sensor 2 -G108- with oxygen sensor

2 heater -Z28-2 - For oxygen sensor 2 after three way catalytic converter -





Oxygen Sensors Location, Cylinder Bank 1 (right)1 - oxygen sensor after three way catalytic converter -G130-

with heater for oxygen sensor 1 after catalytic converter -Z29-

2 - heated oxygen sensor -G39- with oxygen sensor heater -Z19-

Oxygen Sensors Location, Cylinder Bank 2 (left)1 - Heated oxygen sensor 2 -G108- with oxygen sensor 2 heat‐

er -Z28-2 - oxygen sensor 2 after three way catalytic converter -G131-


Electrical Connectors on Right Rear of Engine1 - To knock sensor 1 -G61-2 - To the fuel injectors, cylinder bank 1

Electrical Connectors on Left Rear of Engine1 - To cylinder bank 2 fuel injectors and to fuel pressure sensor

-G247-2 - To knock sensor 2 -G66-




Installed Location Intake Manifold Runner Position Sensor 2 -G512-♦ At the front on the left lower section of the intake manifold.

Note

The intake manifold runner position sensor -G336- is installed asa mirror image.

Camshaft Position Sensor and Exhaust Camshaft Control ValveCylinder Bank 1 (right)1 - Camshaft adjustment valve 1 -N205-2 - Camshaft position sensor -G40-

Camshaft Position Sensor and Exhaust Camshaft Control ValveCylinder Bank 2 (left)1 - Camshaft position sensor 2 -G163-3 - Camshaft Adjustment Valve 2 -N208-

Installed Location Oil Pressure Regulation Valve -N428-4 - Oil pressure regulation valve -N428-♦ Left side, underneath on the engine.Removing and installing, refer to ⇒ Engine Mechanical; Rep. Gr. 17 ; Removal and Installation .




Installed Location Engine Coolant Temperature Sensor -G62-1 - Engine coolant temperature sensor -G62-♦ At front on engine.

Installed Location Secondary Air Injection Solenoid Valve -N112- / Intake Manifold Runner Control Valve -N316- / SecondaryAir Injection Solenoid Valve 2 -N320-1 - Secondary air injection solenoid valve -N112-2 - Intake manifold runner control valve -N316-3 - Secondary air injection solenoid valve 2 -N320-♦ Behind, on the supercharger with the charge air cooler.

Installed Location Intake Air Temperature Sensor -G42- / Mani‐fold Absolute Pressure Sensor -G71-1 - Intake air temperature sensor -G42- / manifold absolute

pressure sensor -G71-♦ Behind, on the supercharger with the charge air cooler.

Installed Location on the High Pressure Pump1 - Low fuel pressure sensor -G410-2 - Fuel metering valve -N290-♦ At right side of the cylinder head




Installed Location Left Electrohydraulic Engine Mount SolenoidValve -N144- and Right Electrohydraulic Engine Mount SolenoidValve -N145-♦ On the left and right engine mounts -arrow-.

Installed Location under the Intake Manifold, Cylinder Bank 1(right)1 - Cylinder 1 fuel injector -N30-2 - Cylinder 2 fuel injector -N31-3 - Cylinder 3 fuel injector -N32-4 - Knock sensor 1 -G61-

Installed Location under the Intake Manifold, Cylinder Bank 2 (left)1 - Cylinder 6 fuel injector -N84-2 - Cylinder 5 fuel injector -N83-3 - Cylinder 4 fuel injector -N33-4 - Fuel pressure sensor -G247-5 - Knock sensor 2 -G66-

Installed Location Engine Speed Sensor -G28-♦ At front left of transmission housing -arrow-.




Installed Location Throttle Valve Control Module -J338-♦ Behind, on the supercharger

Installed Location Control Valve Control Unit -J808-4 - Control valve control unit -J808-♦ Behind, on the supercharger

Installed Location Charge Air Pressure Sensor -G31- / Intake AirTemperature Sensor -G72-♦ On the right side, on the supercharger with the charge air

cooler.

Note

The intake air temperature temperature sensor 2 -G430- / chargeair pressure sensor 2 -G447- are arranged as mirror image ofeach other.

Removing and installing, refer to ⇒ Engine Mechanical; Rep. Gr. 21 ; Removal and Installation .

Installed Location Secondary Air Injection Pump Motor -V101-♦ Under the right headlamp.Removing and installing, refer to ⇒ Engine Mechanical; Rep. Gr. 26 ; Description and Operation .




Installed Location Charge Air Cooling Pump -V188-♦ Under left headlamp.Removing and installing, refer to ⇒ Engine Mechanical; Rep. Gr. 19 ; Removal and Installation .Removal and Installation

Installed Location After-Run Coolant Pump -V51-♦ Left side, at the front, on the engineRemoving and installing, refer to ⇒ Engine Mechanical; Rep. Gr. 19 ; Removal and Installation .




2.2 Air Filter Overview

1 - Secondary Air Hose❑ To secondary air injec‐

tion pump2 - Air Filter Lower Section

❑ Removing and instal‐ling, refer to⇒ “5.1 Air Filter”,page 33

❑ Clean off dirt, leavesand salt residue

3 - Rubber Grommet4 - Spreader Clip5 - Air Duct

❑ To lock carrier❑ Clean off dirt, leaves

and salt residue6 - Bolt

❑ 1.5 Nm❑ 2 pieces

7 - Air Duct❑ Clean off dirt, leaves

and salt residue8 - Hose Clamp

❑ Must be appropriate forthe model type, refer tothe electronic parts cat‐alog ETKA

9 - Air Guide Hose❑ To throttle valve control

module -J338-❑ With resonator

10 - Hose Clamp❑ Depending on country❑ Must be appropriate for the model type, refer to the electronic parts catalog ETKA

11 - Hose❑ For crankcase ventilation

12 - Hose Clamp❑ Must be appropriate for the model type, refer to the electronic parts catalog ETKA

13 - Air Filter Upper Section❑ Removing and installing, refer to ⇒ “5.1 Air Filter”, page 33❑ Clean off dirt, leaves and salt residue

14 - Wiring Router15 - O-ring

❑ Replace16 - Connection17 - Bolt

❑ 1.5 Nm




❑ For securing air filter insert -19-❑ 2 pieces

18 - Air Duct❑ Clipped into the upper section of the air filter❑ Clean off dirt, leaves and salt residue

19 - Air Filter❑ Use an original air filter, refer to the electronic parts catalog ETKA❑ Maintenance interval, refer to Maintenance Intervals Rep. Gr. 03 and Maintenance Procedures Rep. Gr.

03❑ Removing and installing, refer to ⇒ “5.1 Air Filter”, page 33❑ Clean the snow screen, if equipped

20 - O-ring❑ Replace

21 - Grommet22 - Water Drain

❑ Check for dirt, clean if necessary

2.3 Lower Intake Manifold Section Overview

1 - Bolts❑ 2.5 Nm

2 - Intake Manifold Runner Po‐sition Sensor

❑ Left intake manifold run‐ner position sensor 2 -G512- , right intakemanifold runner positionsensor -G336-

3 - Seal❑ Replace if damaged❑ Lift out with screwdriver

to replace❑ Press in by hand

4 - Sleeve5 - Fuel Pressure Sensor -G247-

❑ 22 Nm❑ Lubricate the thread.

6 - Bracket7 - Bolt

❑ 9 Nm8 - High-Pressure Lines

❑ 27 Nm




WARNINGThere is a risk of injurybecause the fuel is undervery high pressure.♦Before opening highpressure components ofthe fuel injection system,pressure must be re‐lieved to residual pres‐sure.

❑ Reduce the fuel pressure in the high pressure area, refer to⇒ “1.3 Before Opening High Pressure Fuel Injection System”, page 2 .

❑ Connectors should not show any signs of damage❑ Do not change bent shape❑ Removing and installing, refer to ⇒ “5.6 High Pressure Line”, page 43❑ Counterhold the connecting pieces when loosening and tightening fuel line❑ Tighten fuel line connecting pieces before installing the fuel line

9 - Bolt❑ 9 Nm

10 - Nut❑ 9 Nm

11 - Bolt❑ 9 Nm

12 - Bolt❑ 2.5 Nm

13 - Retaining Bracket for Fuel Rail14 - Threaded Connection

❑ 40 Nm15 - Fuel Rail16 - Gasket

❑ Replace17 - Intake Manifold Lower Section

❑ Removing and installing, refer to ⇒ “5.2 Intake Manifold, Lower Section, with Fuel Rail”, page 3518 - Gasket

❑ Replace19 - Support Ring

❑ Make sure it is seated properly❑ The fuel rail wields force via the support ring to hold the fuel injector tightly in the cylinder head.

20 - O-ring❑ Replace❑ Coat with clean engine oil

21 - Spacer Ring❑ Replace if damaged

22 - Fuel InjectorRemoving and installing, refer to ⇒ “5.5 Fuel Injectors”, page 40




23 - Upper Sealing Washer24 - Lower Sealing Washer25 - Circlip26 - Combustion Chamber Seal

❑ Replacing, refer to ⇒ “5.5 Fuel Injectors”, page 40 .27 - Seal

❑ Replace if damaged❑ Lift out with screwdriver to replace❑ Press in by hand

28 - Actuator Lever❑ For the vacuum actuator

29 - Vacuum Hose❑ To intake manifold runner control valve -N316-

30 - Intake Manifold Runner Control Vacuum Actuator

Lower Intake Manifold Section - Tightening Specification and Se‐quence– Tighten the bolts and nuts -arrows- diagonally on the intake

manifold lower section and in steps.• 10 Nm




2.4 High Pressure Pump Overview

1 - Low Fuel Pressure Sensor-G410-

❑ 15 Nm2 - Seal

❑ Replace3 - Bolt

❑ Tighten by hand in a di‐agonal sequence andthen tighten to 5 Nm

❑ Final tightening specifi‐cation: 20 Nm

❑ Do not tilt the high pres‐sure pump

4 - High Pressure Pump❑ With fuel metering valve

-N290-❑ Removing and instal‐

ling, refer to⇒ “5.7 High PressurePump”, page 45

❑ Do not disassemble5 - Threaded Connection

❑ Connectors should notshow any signs of dam‐age

❑ Tighten using a 14 mmopen end spanner insert-V.A.G 1331/9-

❑ 27 Nm6 - Fuel Supply Hose

❑ Low pressure side7 - High Pressure Fuel Line

WARNINGDo not let fuel come intocontact with skin.♦Before opening highpressure area of the fuelinjection system, fuelpressure must be re‐lieved to residual pres‐sure.

❑ Reduce the fuel pressure in the high pressure area⇒ “1.3 Before Opening High Pressure Fuel Injection System”, page 2 .

❑ Removing and installing, refer to ⇒ “5.6 High Pressure Line”, page 43❑ 27 Nm

8 - Gasket❑ Replace

9 - Housing10 - Camshaft Position Sensor -G40-

❑ Removing and installing, refer to ⇒ “4.3 Camshaft Position Sensors G40 / G163 ”, page 70




11 - Bolt❑ Tightening specifications -item 1- ⇒ Item 1 (page 64)

12 - O-ring❑ Replace❑ Lubricate O-rings with clean engine oil before installing

13 - Protective Plate❑ For high pressure line

14 - Nut❑ 9 Nm

15 - Stud❑ 9 Nm

16 - Roller Tappet❑ Can be installed in one position only❑ Lubricate O-rings with clean engine oil before installing

17 - O-ring❑ Replace❑ Lubricate O-rings with clean engine oil before installing

2.5 Oxygen Sensors OverviewHeated Oxygen Sensor Connectors (cylinder bank 1)1 - for the Heated Oxygen Sensor -G39- with Oxygen Sensor

Heater -Z19-2 - for Oxygen sensor after three way catalytic converter -

G130- with Heater for oxygen sensor 1 after catalytic con‐verter -Z29-

Heated Oxygen Sensor Connectors (cylinder bank 2)1 - For the heated oxygen sensor 2 -G108- with oxygen sensor

2 heater -Z28-2 - For oxygen sensor 2 after three way catalytic converter -





Installed Location, Oxygen Sensors, Cylinder Bank 11 - Oxygen sensor after three way catalytic converter -G130-


2 - Heated oxygen sensor -G39- with oxygen sensor heater -Z19-

• Tightening specifications: 55 Nm

Component Location, Oxygen Sensors, Cylinder Bank 21 - Heated oxygen sensor 2 -G108- with oxygen sensor 2 heat‐

er -Z28-2 - Oxygen sensor 2 after three way catalytic converter -G131-


• Tightening specifications: 55 Nm

Note

♦ New oxygen sensors are coated with assembly paste; thepaste must not get into slots of oxygen sensor body.

♦ For a used oxygen sensor, only coat threads with hot boltpaste. This paste must not come into contact with oxygensensor slots. Hot bolt paste, refer to the electronic parts cata‐log ETKA

♦ Wiring connection of oxygen sensor must always be securedin the same position when installing so that contact with theexhaust pipe is avoided.

Heated oxygen sensor -G39- and oxygen sensor heater -Z19- ,removing and installing, refer to⇒ “5.8 Heated Oxygen Sensor G39 ”, page 47 .Oxygen sensor after three way catalytic converter -G130- andheater for oxygen sensor 1 after catalytic converter -Z29- , re‐moving and installing, refer to⇒ “5.9 Oxygen Sensor after Three Way Catalytic Converter G130”, page 49 .Heated oxygen sensor 2 -G108- with oxygen sensor 2 heater -Z28- , refer to⇒ “5.10 Heated Oxygen Sensor 2 G108 ”, page 51 .Oxygen sensor 2 after three way catalytic converter -G131- withheater for oxygen sensor 2 after catalytic converter -Z30- , referto⇒ “5.11 Oxygen Sensor 2 after Catalytic Converter G131 ”, page52




3 Specifications⇒ “3.1 Test Data”, page 25⇒ “3.2 Fastener Tightening Specifications”, page 25

3.1 Test Data3.0L TFSI Engine

Engine idle speed Cannot be adjusted, it is regu‐lated by idle stabilization

Fuel pressure before high-pressure pump

3.0 to 6.0 bar pressure

Fuel pressure after high-pres‐sure pump

30 to 120 bar pressure

3.2 Fastener Tightening SpecificationsComponent Fastener Size NmActuator for Intake Manifold Change-Over - 2.5Air Duct to Lock Carrier - 1.5Air Filter Upper Section - 1.5Bracket for High-Pressure Line - 9Fuel Pressure Sensor - 22Fuel Supply Hose Low Pressure Side Threaded Connection to Pump - 27Heated Oxygen Sensor - 55High Pressure Line Connections - 27High Pressure PumpTighten by hand in a diagonal sequence and then tighten to - 5Final tightening - 20Housing, Stud - 9Intake Manifold Runner Position Sensor - 2.5Low Fuel Pressure Sensor - 15Oxygen Sensor - 55Protective Plate for High Pressure Line, Nut and Stud - 9Retaining Bracket for Fuel RailBolt - 2.51

Nut - 91

Bolt - 91

Threaded Support for Fuel Rail - 40Threaded Support2 - 27• 1 For bolt tightening clarification, refer to ⇒ “2.3 Lower Intake Manifold Section Overview”, page 19 and

see items -10, 11 and 12-• 2 For bolt tightening clarification, refer to ⇒ “2.4 High Pressure Pump Overview”, page 22 and see item

-5-


3. Specifications 25


Lower Intake Manifold Section - Tightening Specification and Se‐quence– Tighten the bolts and nuts -arrows- diagonally on the intake

manifold lower section and in steps.• 10 Nm




4 Diagnosis and Testing⇒ “4.1 Wiring and Components, Checking with Test Box V.A.G1598/42 ”, page 27⇒ “4.2 Fuel System, Performing Leak Test”, page 28⇒ “4.3 Vacuum System, Checking”, page 28⇒ “4.4 Fuel Pressure and Residual Pressure before High Pres‐sure Pump, Checking”, page 29

4.1 Wiring and Components, Checking withTest Box -V.A.G 1598/42-

Special tools and workshop equipment required♦ Adapter Cable -V.A.G 1598/39-1-♦ Adapter Cable -V.A.G 1598/39-2-♦ Test Box -V.A.G 1598/42-

Note

♦ The -V.A.G 1598/42- is designed with 105 terminals. It can beconnected to one of the engine control modules via 2 differentadapter cables.

♦ For testing at the 60-pin harness connection, the -V.A.G1598/39-1- is connected to the test box with connector “A”.Components of the 60-pin harness connection ⇒ Wiring dia‐grams, Troubleshooting & Component locations.

♦ For testing at the 94-pin harness connection, the -V.A.G1598/39-2- is connected to the test box with connectors “A”and “B”. Components of the 94-pin harness connection ⇒ Wir‐ing diagrams, Troubleshooting & Component locations.

♦ The -V.A.G 1598/42- is designed so that it can be connectedsimultaneously to the engine control module harness and theengine control module itself.

♦ This is advantageous because electronic engine control re‐mains fully functional (for example measurement of signalswith engine running) when the test box is attached.

♦ The procedures will indicate whether the engine control mod‐ule (ECM) is to remain connected to the test box or not.

Procedure– Remove the ECM. Refer to

⇒ “5.12 Engine Control Module”, page 54 .

Caution

Risk of destroying electrical components.♦ Before connecting test leads, switch on respective meas‐

uring range and observe test conditions.


4. Diagnosis and Testing 27


– Connect -V.A.G 1598/42- to wiring harness with -V.A.G1598/39-1- or -V.A.G 1598/39-2- . Clamp test box Ground(GND) clip to battery negative terminal. The procedure will in‐dicate whether the ECM is to be connected to the test box ornot.

Note

The procedure will indicate whether the ECM is to be connectedto the test box or not.

– Perform test as described in respective repair procedure.Installing the ECMInstall in reverse order of removal.– Thereafter, the ECM must be equipped with the metal retainer.– Clean threaded holes for shear bolts of locking compound

residue. Cleaning can be performed with a thread cutter (tap).– Always use new shear bolts.– Check the DTC memory and, if necessary, erased. After DTC

memory is erased, a readiness code must be generated forthe engine control module using operating mode “GuidedFault-Finding”.

4.2 Fuel System, Performing Leak TestProceed as follows:– Let the engine run a few minutes at a moderate speed.– Switch off ignition.– Check the entire fuel system for leaks.– If there are leaks in spite of correct tightening specifications,

the corresponding component must be replaced.– Then perform a road test and depress the accelerator pedal

all the way at least one time.– Then check the high pressure area again for leaks.

4.3 Vacuum System, CheckingSpecial tools and workshop equipment required♦ Hand Vacuum Pump -VAS 6213-Procedure– Check all vacuum lines in the vacuum system for:♦ Cracks♦ Damage caused by animals♦ Crimps♦ Leaks and leakage– Check the vacuum line leading to and from the solenoid valve.– If there is a fault, check the vacuum lines for the named com‐

ponent, but also all the vacuum lines to the other components.– If using the -VAS 6213- and it does not produce any pressure

or if the pressure drops again right away, then check the handvacuum pump and the connection hoses for leaks.




4.4 Fuel Pressure and Residual Pressurebefore High Pressure Pump, Checking

Special tools and workshop equipment required♦ Fuel Inj. Pressure Gauge-CIS -V.A.G 1318-♦ Pressure Gauge Adapter -V.A.G 1318/10-12-♦ Remote Control -V.A.G 1348/3A- with Remote Control -V.A.G

1348/3-3-♦ Measuring container, fuel-resistantTest Conditions• Battery voltage at least 12.5 V.• Fuel filter OK.• Fuel tank at least 1/4 filled.

• Fuel pump control module -J538- OK; checking, refer to ⇒ Fuel Supply System; Rep. Gr. 20 ; Diagnosis and Testing .

• Ignition switched off.Fuel Pressure, Checking– Remove the rear bench seat. Refer to ⇒ Body Interior; Rep.

Gr. 72 ; Removal and Installation .– Remove the bolts -arrows- and remove the cover for the right

locking flange.

– Carefully release and disconnect electrical harness connector-arrow- at locking flange.




– Connect the -V.A.G 1348/3A- using the -V.A.G 1348/3-3- andcable from the connector test set -V.A.G 1594C- to the termi‐nal -5-.

– 2. Tape -V.A.G 1348/3-3- with insulating tape -arrow- to pre‐vent a short circuit.

– Route -V.A.G 1348/3A- toward front in engine compartment.– Connect alligator clip to ground (GND) point in engine com‐

partment.– Connect the contact -1- to the battery positive with a self-made

adapter cable.

Note

For safety reasons, install a fuse -A- in the cable.

– Remove the bolts -arrows-, remove the air guides -1- and-2-.

WARNING

There is a risk of injury because the fuel is under very highpressure.♦ Before opening high pressure area of the fuel injection


– Reduce fuel pressure in high pressure area. Refer to⇒ “1.3 Before Opening High Pressure Fuel Injection System”,page 2 .

– Remove the fuel supply hose from the high pressure pump-arrow- and free it up.




– Connect the -V.A.G 1318- with adapters -V.A.G 1318/11- and-V.A.G 1318/15- in the fuel line.

– Connect assisting hose -arrow- on pressure gauge and holdin a measuring container.

– Open the shut-off valve on the pressure gauge.• The lever points in the direction of flow.– Bleed fuel system by briefly pressing remote control.– Close the shut-off valve on the pressure gauge.

• Lever stands perpendicular to direction of flow -arrow-.– Press the remote control switch long enough until the pressure

gauge stops registering an increase in pressure.• Specified value: approximately 6 bar pressure.– If the specified value is not reached, check the fuel pump de‐

livery rate. Refer to ⇒ Fuel Supply System; Rep. Gr. 20 ;Diagnosis and Testing .

Residual Pressure, Checking– Check for leaks and constant pressure, watch the manometer

to see if there is a drop in pressure.• After 10 minutes there must be a residual pressure of at least

3 bar.If the holding pressure drops below 3 bar:♦ Check connection between pressure gauge and fuel line for

leaks.♦ Check the pressure gauge for leaks.♦ Check fuel lines and their connections for leaks.♦ Replace the fuel filter with an integrated fuel pressure regula‐

tor, refer to ⇒ Fuel Supply System; Rep. Gr. 20 ; Removaland Installation .

♦ Replace the fuel pump, refer to ⇒ Fuel Supply System; Rep.Gr. 20 ; Removal and Installation .

AssemblingAssembly is performed in reverse order of removal, noting thefollowing:

WARNING

There is a risk of injury because the fuel is under very highpressure.♦ Before disconnecting pressure gauge, release pressure

by opening shut-off valve. Hold a container under the con‐nection.




– Connect the fuel supply hose -arrow- to the high pressurepump. Make sure the hose is clean.

• Tightening specifications, refer to⇒ “2.4 High Pressure Pump Overview”, page 22

– Install the rear bench seat. Refer to ⇒ Body Interior; Rep. Gr. 72 ; Removal and Installation .

Note

Check fuel system for leaks.




5 Removal and Installation⇒ “5.1 Air Filter”, page 33⇒ “5.2 Intake Manifold, Lower Section, with Fuel Rail”,page 35⇒ “5.3 Throttle Valve Control Module”, page 38⇒ “5.4 Control Valve Control Unit J808 ”, page 40⇒ “5.5 Fuel Injectors”, page 40⇒ “5.6 High Pressure Line”, page 43⇒ “5.7 High Pressure Pump”, page 45⇒ “5.8 Heated Oxygen Sensor G39 ”, page 47⇒ “5.9 Oxygen Sensor after Three Way Catalytic Converter G130”, page 49⇒ “5.10 Heated Oxygen Sensor 2 G108 ”, page 51⇒ “5.11 Oxygen Sensor 2 after Catalytic Converter G131 ”, page52⇒ “5.12 Engine Control Module”, page 54

5.1 Air FilterRemove the Air Filter Upper Section.– Remove the bolts -arrows-, remove the air guides -1- and

-2-.

– Free up the fuel line -4- and hose connection -1- from theEVAP canister on the air filter housing and on the air guidetube.

– Remove the vacuum hose -2- from the air guide hose con‐nection.

– Remove the air guide pipe by loosening the hose clamp -3-and opening the clips -arrows-.


5. Removal and Installation 33


– Open the clips -arrows- and remove the air filter housing uppersection.

– Remove the bolts -arrows- and remove the air filter.Removing the Lower Section of the Air Filter




– Remove the pin from spreader clips -2-.– Remove the lower section of the air filter housing and then

disconnect the hose -1- for the secondary air injection pumpby pressing the release button.

Installing• Tightening specifications, refer to

⇒ “2.2 Air Filter Overview”, page 18 .

Note

♦ Always use an original air filter.♦ The hose connections and hoses in the intake area must be

free of oil and grease before installing. When installing, do notuse any lubricants containing silicone.

♦ Air filter housing must always be clean.♦ Secure all hose connections with hose clamps appropriate for

the model. Refer to the electronic parts catalog ETKA.♦ In order to be able to securely mount the air guide hoses on

their connectors, spray the screws on the previously usedclamps with a rust remover.

♦ When cleaning the air filter housing with compressed air, coverthe critical air flow components such as the mass air flow sen‐sor, air ducts, etc. with a clean cloth to prevent malfunctions.

♦ Observe disposal regulations!

– Clean the water drain hose (the small hole in the air filter lowersection) using compressed air.

– Clean air filter housing (upper and lower sections) of salt res‐idue, dirt or leaves (by extracting).

– Check the air guide hose (clean air side) for salt residue, dirtand leaves.

– Check air duct from lock carrier to air filter housing for dirt andleaves.

– Make sure the air filter is centered inside the lower section ofthe air filter when installing.

– Carefully position the upper section of the air filter hosing onthe lower section. Make sure the upper section of the air filterdoes not sit at an angle on top of the air filter (pay attention tothe sealing lip on the air filter).

Further installation is performed in reverse order.

5.2 Intake Manifold, Lower Section, withFuel Rail

Special tools and workshop equipment required♦ Torque Wrench 5-50 Nm -V.A.G 1331-♦ Ring Spanner Insert -V.A.G 1331/2-♦ Hand Vacuum Pump -VAS 6213-




Removing

Note

The following removal and installation procedure is for the left in‐take manifold lower section. The procedure for the other side isidentical.

WARNING

There is a risk of injury because the fuel is under very highpressure.♦ The fuel pressure must be reduced to residual pressure

before opening the high pressure area of the fuel injectionsystem. Refer to⇒ “1.3 Before Opening High Pressure Fuel Injection Sys‐tem”, page 2 .


– Remove the supercharger. Refer to ⇒ Engine Mechanical;Rep. Gr. 21 ; Removal and Installation .

– Push the vacuum hoses to the side.




– Disconnect the fuel pressure sensor -G247- connector -4-.– Remove the union nut -1- while counterholding the threaded

connection.

Note

Before removing the lower intake on the drivers side disconnectthe connector for Cam Position Sensor 2.

– Remove the bolts and nuts -arrows- and remove the lower in‐take manifold section and fuel rail.

– Disconnect the connector -2- on the intake manifold runnerposition sensor and remove the vacuum hose -3-.

Caution

The engine could be destroyed.♦ Cover the intake channels with a clean cloth to prevent

small particles from getting into the engine through the in‐take channels in the cylinder heads.

InstallingInstallation is performed in reverse order of removal, noting thefollowing:

Note

♦ If a fuel injector was removed from the cylinder head, then theTeflon seal must be replaced.

♦ Replace seals and O-rings.♦ Lubricate the fuel injector O-rings lightly with clean engine oil.

Move the intake manifold flaps in direction of -arrow- when instal‐ling the intake manifold lower section.




– Connect -VAS 6213- to intake manifold runner control vacuumactuator, as shown in illustration.

– Generate vacuum using hand vacuum pump.• The intake flaps are opened.

Note

If the intake flaps are not opened, they could have seized wheninstalling the lower section of the intake manifold in the cylinderhead.

– Press the intake manifold lower section evenly on the fuel in‐jectors.

– Tighten the bolts and nuts diagonally on the intake manifoldlower section according to the tightening specification.

• Tightening specification for the intake manifold lower section⇒ page 21

– Remove hand vacuum pump from intake manifold runner con‐trol vacuum actuator.

– Connect the fuel pressure sensor -G247- connector -4-.– Counterhold the threaded connection and tighten the union

nut -1-.– Make sure the high pressure line is free of tension.– Install the supercharger. Refer to ⇒ Engine Mechanical; Rep.

Gr. 21 ; Removal and Installation .

5.3 Throttle Valve Control ModuleRemoving– Remove the rear engine cover -2- upward.







– Disconnect the connector -1-.– Remove bolts -arrows- and remove throttle valve control mod‐

ule -J338- with the intermediate flange.

Caution

The engine could be destroyed.♦ Cover the intake channel with a clean cloth to prevent

small particles from getting into the supercharger.


Note

Replace O-rings.

– Install the intermediate flange -2- and new O-rings into the su‐percharger -1- -left arrows-.

– Install the throttle valve control module -3- on the intermediateflange -right arrows-.

• Tightening specification: 10 Nm.– After replacing, perform an “Adaptation” in “Guided Func‐

tions”.




5.4 Control Valve Control Unit -J808-Removing– Remove the rear engine cover -2- upward.

– Disconnect the connector -3- from the control valve controlunit.

– Remove the bolts -5- and -6-.– Remove the bypass connection -1- with the adapter -2- and

control valve control unit -4-.InstallingInstallation is performed in reverse order of removal, noting thefollowing:

Note

Replace O-rings.

– Install the bypass connection -1- with the adapter -2- and con‐trol valve control unit -4-. Use new O-rings.

– Install the bolts -5- and -6- hand-tight.– First tighten the bolts -6- to the tightening specification.• Tightening specifications: 10 Nm– Then tighten the bolts -5- to the same tightening specification.– Connect the connector -3-.– Perform an “Adaptation” in “Guided Functions” after replacing

the control valve control module.

5.5 Fuel InjectorsSpecial tools and workshop equipment required♦ Tool Set -T10133-




Removing

WARNING





– Remove the affected intake manifold lower section. Refer to⇒ “5.2 Intake Manifold, Lower Section, with Fuel Rail”,page 35 .

– Guide the puller -T10133/2A- in the groove on the fuel injector.– Mount the removal tool -T10133/16- on the puller, turn the

screw -1- and remove the fuel injector.Disassemble the Fuel Injector.

– Remove the support ring -4-, O-ring -3- and spacer ring -2-from the fuel injector -1-.

– Remove the circlip -7- and upper sealing washer -5- and lowersealing washer -6-.

– Carefully remove the old combustion chamber seal -8- by cut‐ting the sealing ring with a knife and prying it open with a smallscrewdriver.

– Make sure that the groove of the fuel injector does not becomedamaged. If the groove is damage, the fuel injector must bereplaced.

Installing

Note

♦ Replace combustion chamber seal and O-ring.♦ Replace spacer ring if damaged.♦ Lightly coat the fuel injector O-rings with clean engine oil.♦ Install the cylinder at same cylinder.




– Clean bore in cylinder head with nylon cylinder brush -T10133/4- .

– Place assembly cone -T10133/5- with new combustion cham‐ber seal -1- from the repair kit onto the fuel injector -2-.

– Slide combustion chamber seal as far possible onto -T10133/5- using assembly sleeve -T10133/6- .

– Turn -T10133/6- around and slide combustion chamber sealinto groove.

Note

When pushing the combustion chamber seal onto the fuel injec‐tor, the seal spreads open. Therefore after pushing it on, it mustbe tightened again in 2 steps, as follows.

– Press the sizing sleeve -T10133/7- with a slight turning motion(approximately 180°) onto the fuel injector until it stops.

– Pull the -T10133/7- off again, turning it in the opposite direc‐tion.




– Press the sizing sleeve -T10133/8- with a slight turning motion(approximately 180°) onto the fuel injector until it stops.

– Pull the -T10133/8- off again, turning it in the opposite direc‐tion.

– Install the parts form the repair kit on the injector valve -1-:2 - Spacer ring3 - O-ring4 - Support ring5 - Upper sealing washer - note installation position6 - Lower sealing washer - note installation position7 - Circlip - do not overstretch– Coat the new O-ring with clean engine oil before installing.

Note

The combustion chamber seal -8- must not be oiled.

– Press the fuel injector by hand into the bore in the cylinderhead (free of oil and grease) until it stops. Make sure fuel in‐jectors are positioned correctly in cylinder head.

Note

♦ The fuel injector must not be difficult to install. If necessary,wait as the combustion chamber seal continues to pull itselftogether.

♦ Check fuel injectors for correct seating and installation positionin cylinder head.

♦ If it is difficult to install the fuel injector by hand use the puller-T10133/2A- -2- with the hammer -T10133/3- .

• The electrical connection of the fuel injector must engage inthe intended recess of the cylinder head.

Further installation is performed in reverse order of removal, not‐ing the following:– Install the lower intake manifold section. Refer to

⇒ “5.2 Intake Manifold, Lower Section, with Fuel Rail”,page 35 .

– Install the supercharger. Refer to ⇒ Engine Mechanical; Rep.Gr. 21 ; Removal and Installation .

5.6 High Pressure LineSpecial tools and workshop equipment required




♦ Torque Wrench 5-50 Nm -V.A.G 1331-♦ Tool Insert, AF 17 -V.A.G 1331/6-Removing

WARNING





– Remove the front secondary air hose -arrow- from its bracketand disconnect it; to do so press the release buttons.

– Remove the bolts -arrows- and move the intake manifold run‐ner position sensor -G336- and the intake flap vacuum actua‐tor to the side.

Note

♦ Ignore -1-.♦ Cylinder bank 2 (left) is shown in the illustration.




– Remove the bolts -arrows- and threaded connection -1-.– Remove the union nuts -2- and -3- while counterholding the

threaded connection.

Note

Do not change the bend shape of the high pressure line.


⇒ “2.3 Lower Intake Manifold Section Overview”, page 19 ,⇒ “2.4 High Pressure Pump Overview”, page 22 .

Note

♦ High pressure line connections must not show any signs ofdamage.

♦ Do not change the bent shape of the high pressure line.

– First tighten the union nut by hand making sure that it contactthe high pressure line free-of-stress.

– Counterhold the fuel rail using an open-end wrench on thethreaded connection and tighten the union nut using a torquewrench -V.A.G 1331- and a -V.A.G 1331/6- .

– First tighten the bolt of the retaining strap, after that, the highpressure line is tightened.


5.7 High Pressure PumpSpecial tools and workshop equipment required♦ Torque Wrench 5-50 Nm -V.A.G 1331-♦ Ratchet, Reversible -V.A.G 1331/1-♦ 14 mm Open End Spanner Insert -V.A.G 1331/9-Removing

WARNING







– Remove bolts -arrows-.– Remove the air ducts -1- and -2-.

– Remove the nuts -arrows- and the protective plate -1-.

– Disconnect electrical connectors -1- and -6-.– Remove the threaded connections -2- and -5-.– Remove the bolt -3- on the retaining clamp.– Remove the bolts -arrows- and pry the end cover up carefully.

Note

♦ Do not change bent shape.♦ Ignore -4-.

– Remove the high pressure pump and roller tappet.Installing• Tightening specifications, refer to

⇒ “2.2 Air Filter Overview”, page 18 ,⇒ “2.4 High Pressure Pump Overview”, page 22 .

Installation is performed in reverse order of removal, noting thefollowing:

Note

Replace O-ring.

Note

♦ High pressure line connections must not show any signs ofdamage.

♦ Do not bend the high pressure line to a different angle.




– Check the plunger -1- for damage and replace it if necessary.– Coat the plunger with oil and insert it with the tab -arrow A- in

the guide -arrow B-.– Rotate the crankshaft in the direction of engine rotation at the

vibration damper bolt while pressing the roller tappet into thecylinder head until it reaches the deepest point.

– Only lift the high pressure line slightly to insert the high pres‐sure pump.

– Tighten the bolts on the high pressure pump hand-tight.– Tighten the bolts crosswise with the required torque.• Tightening specifications, refer to

⇒ “2.4 High Pressure Pump Overview”, page 22– Install the high pressure line -2- and -5-. Refer to

⇒ “5.6 High Pressure Line”, page 43 .

– Connect the connectors -1- and -6-.– Remove the bolt -3- on the clamp.

Note

Check fuel system for leaks.

5.8 Heated Oxygen Sensor -G39-Special tools and workshop equipment required♦ Ring Spanner 7-Piece Set -3337-Removing– Remove the rear engine cover -2- upward.









– Disconnect the electrical connector -1- for the heated oxygensensor and free up the wire.

Note

Ignore -2-.




– Remove the oxygen sensor -2- with the oxygen sensor probewrench -3337/7- .

Note

To provide a better illustration, component location is shown frombehind with engine removed.


Note




• Tightening specifications, refer to⇒ “2.5 Oxygen Sensors Overview”, page 23

5.9 Oxygen Sensor after Three Way Cata‐lytic Converter -G130-

Special tools and workshop equipment required♦ Ring Spanner 7-Piece Set -3337-Removing– Remove the rear engine cover -2- upward.









– Disconnect the electrical connector -2- for the oxygen sensorafter three way catalytic converter and free up the electricalwire.

Note

Ignore -1-.




– Remove the oxygen sensor -1- with the wrench -3337/1/2- .

Note



Note





5.10 Heated Oxygen Sensor 2 -G108-Special tools and workshop equipment required♦ Ring Spanner 7-Piece Set -3337-Removing– Remove the rear engine cover -2- upward.




– Remove bolt -arrow-.– Disconnect the electrical connector to the engine coolant level

warning switch -F66- on the bottom of the coolant reservoirand lay the reservoir aside with the coolant hoses -1- and -2-attached.

– Disconnect the electrical connector -1- for the heated oxygensensor 2 and free up the wire.

Note

Ignore -2-.

– Remove the oxygen sensor -1- with the oxygen sensor probewrench -3337/7- .

Note



Note





5.11 Oxygen Sensor 2 after Catalytic Con‐verter -G131-

Special tools and workshop equipment required♦ Ring Spanner 7-Piece Set -3337-




Removing– Remove the rear engine cover -2- upward.



– Disconnect the electrical connector -2- for the oxygen sensor2 catalytic converter and free up the electrical wire.

Note

Ignore -1-.

– Remove the noise insulation, to do this loosen the mountingfasteners -1, 2, arrow-.




– Remove the oxygen sensor -2- with the special wrench-3337/1- .

Note



Note





– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Description and Operation .

5.12 Engine Control ModuleSpecial tools and workshop equipment required♦ Puller -T10369-♦ Heat Gun 220 V/50 Hz -VAS 1978/14A- with nozzle attach‐

ment from the Wiring Harness Repair Kit -VAS 1978 B-♦ Small commercially available Locking Pliers




Note

♦ Some engine control modules are not equipped with a protec‐tive housing. The removal and installation of the protectivehousing depends on the engine and transmission combina‐tion.

♦ The Engine Control Module (ECM) -1- is bolted to a protectivehousing -5-. To make removing the shear bolts -4- for the re‐taining tabs -2- more difficult, the threads are coated withlocking compound.

♦ To disconnect the connectors from the ECM (for example toconnect the test box or to replace the ECM), the protectivehousing must be removed.

Removing– If the engine control module was replaced, select “Replacing

engine control module (ECM)” in “Guided Fault-Finding”. Usea vehicle diagnosis tester.

– Switch off ignition and remove ignition key.

– Remove the seal -1- and remove the plenum chamber cover-2-.

– Pry off the caps on the wiper arms with a screwdriver.– Loosen nuts -arrows- a few turns.




– Mount the puller for removing wiper arms -T10369/1- onto thewiper arm -1- as illustrated.

– Mount the pressure piece -2- on the wiper axle.– Turn the screw -3- clockwise until the wiper arm is pulled off

the wiper axle.– Remove the nuts and remove the wiper arms.

Caution

Danger of causing damage to the wind cowl.♦ To prevent the cowl grille -1- from tearing when removing,

coat transition between windshield and cowl grille with asoapy solution and pull grille up vertically out of fasteningstrip beginning at edge of window.

– Remove the screws -arrows- and remove the cowl panel trimfrom the windshield.

– Remove bolts -arrows- and remove cover for E-box at right inengine compartment.

WARNING

Risk of burning on heater pump valve unit (at left in front of Ebox).♦ Wear protective gloves when working near heater pump

valve unit.




– Carefully pry off the retaining clip with a screwdriver-arrows 1 and 2- and remove the ECM from the E-box.

Caution

Risk of damage (burning) from wiring and connectors, insula‐tion and control modules.♦ Follow the next steps exactly! Observe hot air gun oper‐

ating instructions.

– Set the adjustment on the heat gun as shown in the illustration,with the temperature potentiometer -2- set to maximum heatand the two-stage airflow switch -3- set to level “3”.

Note

Next, the thread of protective housing in which the shear bolts isthreaded in is heated using the heat gun. This step decreases thelocking effect of the locking compound on the thread of the shearbolts, thus allowing the shear bolts to be removed more easily.

WARNING

There is a risk of burns.♦ By heating the shear bolts, parts of the protective housing

are heated intensely. Ensure as much as possible thatonly the shear bolt is heated and not the adjacent parts.Possibly cover these parts.

– Perform the following work steps in order on both shear bolts-4-.




– Guide nozzle of hot air gun on to shear bolt of protective hous‐ing.

– Switch the heat gun on and heat the bolt for approximately 20to 25 seconds.

– Remove shear bolts with locking pliers -arrow-.

Note

The threads of both shear bolts -3-, that are screwed into theECM, are not coated with a locking compound. The threads in theECM housing must not be heated and do not require to be heated(unintentional heating of the ECM).

– Remove both shear bolts -3-.– Separate the retaining tab -2- of the control module connector.– Release and pull off connectors from ECM.

Note

When the connector is disconnected from the ECM, adaptationvalues are erased but the content of the DTC memory remainsintact.

InstallingInstallation is performed in the reverse order of removal, notingthe following:– After that, the engine control module -J623- must be equipped

with the metal retainer.– Clean threaded holes for shear bolts of locking compound

residue. Cleaning can be performed with a thread cutter (tap).– Use new shear bolts.Perform the following step after installing a new ECM:– Activate the engine control module in “Guided Functions” un‐

der “replace engine control module”. Use a vehicle diagnosistester for this.




6 Special ToolsSpecial tools and workshop equipment required♦ Adapter Cable -V.A.G 1598/39-1-♦ Adapter Cable -V.A.G 1598/39-2-♦ Test Box -V.A.G 1598/42-

♦ Hand Vacuum Pump -VAS 6213-

♦ Fuel Inj. Pressure Gauge-CIS -V.A.G 1318-

♦ Pressure Gauge Adapter -V.A.G 1318/10-12-


6. Special Tools 59


♦ Remote Control -V.A.G 1348/3A- with Remote Control -V.A.G1348/3-3-

♦ Torque Wrench 5-50 Nm -V.A.G 1331-

♦ Tool Set -T10133-

♦ Tool Insert, AF 17 -V.A.G 1331/6-




♦ Ratchet, Reversible -V.A.G 1331/1-

♦ Ring Spanner 7-Piece Set -3337-

♦ Puller -T10369-

♦ Heat Gun 220 V/50 Hz -VAS 1978/14A- -1- with nozzle at‐tachment -2- from the Wiring Harness Repair Kit -VAS 1978B-

♦ Small commercially available Locking Pliers -3-

♦ Ring Spanner Insert -V.A.G 1331/2-♦ 14 mm Open End Spanner Insert -V.A.G 1331/9-


6. Special Tools 61


28 – Ignition/Glow Plug System1 General Information⇒ “1.1 Safety Precautions”, page 62⇒ “1.2 Ignition System”, page 63

1.1 Safety PrecautionsIf it is necessary to use testing and measuring devices on roadtests, observe the following:

WARNING

Distraction and improperly secured test equipment can lead toaccidents.There is a risk that the passenger airbag could deploy in a col‐lision.• Operating testing and measuring equipment while driving

creates a distraction.• There is an increased risk of injury due to unsecured test‐

ing and measuring equipment.♦ Always secure testers on the rear seat with a strap and

have a second person on the rear seat operate them.

To prevent personal injury and damage to the injection and igni‐tion system, observe the following:♦ Individuals with a pacemaker must not stay in the danger area

of high voltage systems, for example ignition systems, xenonlight.

♦ The ignition must be switched off before connecting or dis‐connecting injection and ignition system wiring or tester ca‐bles.

♦ Do not touch or remove ignition wires when engine is runningor turning at starter speed.

♦ Only clean engine with ignition switched off.♦ If engine is to be cranked at starting RPM without starting (for

example for compression testing), disconnect connectors fromignition coils and from fuel injectors. After performing work,check and erase DTC memory.

♦ While testing it is possible that there may be some faults storedin the engine control module. After completing all testing andrepairs, check the DTC memory. If a fault has been stored:

Caution

Risk of destroying electrical components when battery is dis‐connected.♦ Observe measures when disconnecting battery.

– Disconnect battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Removal and Installation .


62 Rep. Gr.28 - Ignition/Glow Plug System


1.2 Ignition System♦ The engine control module is equipped with On Board Diag‐

nostics (OBD).♦ For the electric components to work properly, a voltage of at

least 11.5 Volts is required.♦ While testing it is possible that there may be some faults stored

in the engine control module. After completing all testing andrepairs, check the DTC memory.

♦ If the engine only starts briefly and then turns off again aftertroubleshooting, repair or checking of the components, it maybe that the immobilizer is blocking the Engine Control Module(ECM). DTC memory must then be checked and if necessary,control module must be adapted.




2 Description and Operation⇒ “2.1 Ignition Overview”, page 64

2.1 Ignition Overview

1 - Bolt❑ 9 Nm

2 - Camshaft Position Sensor -G40-

❑ Removing and instal‐ling, refer to⇒ “4.3 Camshaft Posi‐tion Sensors G40 /G163 ”, page 70

3 - O-ring❑ Replace

4 - Knock Sensor❑ Knock sensor 1 -G61-

(right), Knock sensor 2 -G66- (left)

❑ Removing and instal‐ling, refer to⇒ “4.2 Knock SensorsG61 / G66 ”, page 68

5 - Bolt❑ 20 Nm

6 - Camshaft Adjustment Valve1 -N205-7 - Bolt

❑ 5 Nm8 - O-ring

❑ Replace9 - Spark Plug

❑ Change interval, refer toMaintenance IntervalsRep. Gr. 03

❑ Tightening specifica‐tions, refer to Maintenance Procedures Rep. Gr. 03

10 - Ignition Coil❑ Removing and installing, refer to ⇒ “4.1 Ignition Coils”, page 67

11 - Bolt❑ 5 Nm

12 - Wiring Harness13 - Camshaft Adjustment Valve 2 -N208-14 - Bolt

❑ 9 Nm15 - Engine Speed Sensor -G28-

❑ Removing and installing, refer to ⇒ “4.4 Engine Speed Sensor G28 ”, page 7116 - O-ring

❑ Replace




17 - Camshaft Position Sensor 2 -G163-❑ Removing and installing, refer to ⇒ “4.3 Camshaft Position Sensors G40 / G163 ”, page 70

18 - Bolt❑ 9 Nm




3 Specifications⇒ “3.1 Test Data”, page 66⇒ “3.2 Fastener Tightening Specifications”, page 66

3.1 Test Data3.0L TFSI Engine

Engine idle speed Cannot be adjusted, it is regulated by idle stabiliza‐tion

Ignition timing Not adjustable, regulated by control moduleIgnition/Glow Plug System Single coil ignition system with 6 ignition coils (out‐

put stages integrated) that are connected directly tospark plugs via the ignition cables.

Spark plugs Names ⇒ Data sheets for exhaust emission test Tightening Specifications Maintenance Procedures Rep. Gr. 03Ignition sequence 1-4-3-6-2-5

3.2 Fastener Tightening SpecificationsComponent Bolt Size NmCamshaft Adjustment Valve 2 5Camshaft Position (CMP) Sensor 9Camshaft Position (CMP) Sensor 2 9Engine Speed (RPM) Sensor 9Knock Sensor 20Wiring Harness 5




4 Removal and Installation⇒ “4.1 Ignition Coils”, page 67⇒ “4.2 Knock Sensors G61 / G66 ”, page 68⇒ “4.3 Camshaft Position Sensors G40 / G163 ”, page 70⇒ “4.4 Engine Speed Sensor G28 ”, page 71

4.1 Ignition CoilsSpecial tools and workshop equipment required♦ Ignition Coil Puller -T40039-Removing– Remove the engine covers -1- and -2- upward.








– Remove the bolts -arrows- and disconnect the connectors onthe ignition coils.

– Lay the electrical wiring harness down slightly.

Note

Ignore -1 and 2-.

Cylinder Bank 2 (left):– Remove bolt -arrow-.– Disconnect the electrical connector to the engine coolant level


– Remove the bolts -arrows- and disconnect the connectors onthe ignition coils.

– Lay the electrical wiring harness down slightly.

Note

Ignore -1, 2 and 3-.

Continued for Both Sides:– Remove the ignition coils with the -T40039- .Installing• Tightening specifications, refer to

⇒ “2.2 Air Filter Overview”, page 18 ,⇒ “2.1 Ignition Overview”, page 64 .

Installation is performed in reverse order.

4.2 Knock Sensors -G61- / -G66-Removing– Remove the supercharger. Refer to ⇒ Engine Mechanical;

Rep. Gr. 21 ; Removal and Installation .– Remove left and right lower intake manifold sections. Refer to

⇒ “5.2 Intake Manifold, Lower Section, with Fuel Rail”,page 35 .




– Pull the knock sensor 1 -G61- connector -1- out of the mountand disconnect it.

Note

Ignore -2- and -arrow-.

– Pull the knock sensor 2 -G66- connector -2- out of the leftmount and disconnect it.

Note

Ignore items -1, 3- and -arrows-.

– Remove the bolts -1- for knock sensor 1 -G61- and the bolt-2- for knock sensor 2 -G66- and remove the sensors.


⇒ “2.1 Ignition Overview”, page 64 .Installation is performed in reverse order of removal, noting thefollowing:– Install the left and right lower intake manifold sections. Refer

to⇒ “5.2 Intake Manifold, Lower Section, with Fuel Rail”,page 35 .





4.3 Camshaft Position Sensors -G40- / -G163-

Removing– Remove the front engine cover -1- upward.

– Disconnect the connector -1-.– Remove the bolt -arrow- and remove the camshaft position

sensor -G40- (right side).

– Disconnect the connector -1-.– Remove the bolt -arrow- and remove the camshaft position

sensor 2 -G163- (left side).Installing• Tightening specifications, refer to

⇒ “2.4 High Pressure Pump Overview”, page 22 ,⇒ “2.1 Ignition Overview”, page 64 .

Installation is performed in reverse order of removal, noting thefollowing:

Note

Replace O-rings.




4.4 Engine Speed Sensor -G28-Removing– Remove the rear engine cover -2- upward.



Note

To improve clarity, the work procedures in the following illustra‐tions are shown with the engine removed and viewed from therear.

– Remove electrical harness connectors -1- and -2- from brack‐et and disconnect.

– Free up the electrical wiring harnesses -arrow-.– Remove the nut -3- and free up the ground (GND) wire.– Remove the double bolt and bracket.




– Disconnect electrical connector -arrow-.– Remove the bolt and remove the engine speed sensor.Installing• Tightening specifications, refer to

⇒ “2.1 Ignition Overview”, page 64 .Installation is performed in reverse order.




5 Special ToolsSpecial tools and workshop equipment required♦ Ignition Coil Puller -T40039-

Edition 10 17 2012


5. Special Tools 73


Cautions & Warnings

=Page 1 of 3 © 2002 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher. Version 1.0

Please read these WARNINGS and CAUTIONS before proceeding with maintenance and repair work. You must answer that you have read and you understand these WARNINGS and CAUTIONS before you will be allowed to view this information.

•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we suggest you leave such repairs to an authorized Audi retailer or other qualified shop. We especially urge you to consult an authorized Audi retailer before beginning repairs on any vehicle that may still be covered wholly or in part by any of the extensive warranties issued by Audi.

•= Disconnect the battery negative terminal (ground strap)whenever you work on the fuel system or the electrical system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.

•= Audi is constantly improving its vehicles and sometimes these changes, both in parts and specifications, are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always check with your authorized Audi retailer parts department for the latest information.

•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).

•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.

•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and become inoperable, even if the correct code is used in a later attempt.

•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from starting the vehicle while you are under it.

•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from being fully alert.

•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.

•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear goggles, gloves and other protective clothing whenever the job requires working with harmful substances.

•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe injury could result.


Cautions & Warnings


•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.

•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust. Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.

•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be crushed by heavy parts.

•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the instructions thoroughly, do not attempt shortcuts. Use tools that are appropriate to the work and use only replacement parts meeting Audi specifications. Makeshift tools, parts and procedures will not make good repairs.

•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at once, but do not store the oily rags, which can ignite and burn spontaneously.

•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque listed.

•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is ignited, it will ignite gas trapped in the cells and cause the battery to explode.

•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that govern the disposal of wastes.

•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment, trained in related safety precautions, and familiar with regulations governing the discharging and disposal of automotive chemical refrigerants.

•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery negative terminal (ground strap) and the ABS control module connector.

•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase system pressure and may cause the system to burst.


Cautions & Warnings


•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these components is not separately fused, disconnect the control module connector(s).

•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device. Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal injury. To guard against personal injury or airbag system failure, only trained Audi Service technicians should test, disassemble or service the airbag system.

•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.

•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained Audi Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit must never be electrically tested while it is not installed in the vehicle.

•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the tire from the rim before attempting any repair.

•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.

I have read and I understand these Cautions and Warnings.

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