D3E8001FE53-Fuel Injection and Ignition PDF

Service
Repair Manual
Audi A4 2001 ➤
Audi A4 Cabriolet 2003 ➤
Fuel Injection and Ignition
Engine ID BGB BPG BUL BWE BWT BPJ BYK
Edition 05.2013
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
24 - Multiport Fuel Injection
28 - Ignition/Glow Plug System
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2014 Audi AG, Ingolstadt D3E8001FE53

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
Fuel Injection and Ignition - Edition 05.2013
Contents
24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Before Opening High Pressure Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Ignition System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 OnProtected
Boardby Diagnostics
copyright. Copying(OBD)
for privateGeneral
or commercialInformation . .in.whole,
purposes, in part or . . . is. .not. . . . . . . . . . . . . . . . . . . . . . 4
1.5 Safety Precautions,
permitted unless authorisedTest and
by AUDI AG. Measuring
AUDI AG does not Instruments during
guarantee or accept Test Drives . . . . . . . . . . . . . .
any liability 5
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Air Filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Component Location Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Fuel Injectors, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Fuel Rail Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 High Pressure Pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.6 Intake Manifold Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 Fuel Pressure and Residual Pressure before High Pressure Pump, Checking . . . . . . . . . . 24
4.2 Fuel Pressure Sensor G247 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4 Wiring and Components, Checking with Test Box Kit - 105 Pin Test Box Kit VAG1598/42
........................................................................ 30
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2 Combustion Chamber Seal (Teflon® Seal), Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.3 Engine Control Module J623 , Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.4 Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.5 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.6 Fuel Pressure Sensor G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.7 Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.8 Heated Oxygen Sensor G39 and Oxygen Sensor Heater Z19 before Catalytic Converter
........................................................................ 44
5.9 High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.10 Intake Flap Motor V157 with Intake Manifold Runner Position Sensor G336 . . . . . . . . . . 46
5.11 Intake Manifold with Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.12 Mass Airflow Sensor G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.13 Oxygen Sensor after Three Way Catalytic Converter G130 and Heater For Oxygen Sensor
1 after Catalytic Converter Z29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.1 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.1 Ignition System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.2 Ignition System, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1 Ignition Coils with Power Output Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Contents i
4.2 Knock Sensor 1 G61 and Knock Sensor 2 G66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
ii Contents
24 – Multiport Fuel Injection

1 General Information
(Edition 05.2013)
⇒ “1.1 Before Opening High Pressure Fuel Injection System”,
page 1
⇒ “1.2 Clean Working Conditions”, page 3
⇒ “1.3 Ignition System Safety Precautions”, page 3
⇒ “1.4 On Board Diagnostics (OBD) General Information”,
page 4
⇒ “1.5 Safety Precautions, Test and Measuring Instruments dur‐
ing Test Drives”, page 5
1.1 Before Opening High Pressure Fuel In‐

jection System
For safety reasons, if the battery is “not” disconnected, the Fuel
Pump Control Module - J538- fuse -28- must be removed before
opening fuel system. Otherwise, the fuel pump will be activated
by the driver door contact switch.
Note
♦ The fuse is located in the fuse carrier in the instrument panel.

♦ By removing fuse -28-, the voltage supply to “terminal 30” for
the Fuel Pump Control Module - J538- is interrupted.
Caution
The fuel injection system is divided into a high pressure section

(maximum approximately 110 bar (1595 psi)) and a low pres‐
sure system (approximately 6 bar (87 psi)).
Before opening high pressure parts, for example removing
high pressure pump, fuel rail, fuel injectors, fuel pipes or Fuel
Pressure Sensor - G247- , fuel pressure in high pressure area
must be reduced to a residual pressure of approximately 6 bar
(87 psi). The procedure for this is as follows.
High Fuel Pressure, Reducing
Special tools and workshop equipment required

♦ Elbow Assembly Tool - T10118-
1. General Information 1
– Use the Elbow Assembly Tool - T10118- to remove the elec‐

trical connector -2- from Fuel Pressure Regulator Valve -
N276- .
– Allow engine to idle approximately 10 seconds.
Note
♦ By removing the electrical connector from the Fuel Pressure

Regulator Valve - N276- in idle, the fuel pressure is reduced
from approximately 50 bar (725 psi) to approximately 6 bar (87
psi).
♦ Falling pressure can be observed if a Vehicle Diagnostic Test‐
er is connected and Engine Control Module (ECM) selected.
And select display group 140 under “Read measured value
block” function.
♦ Fuel pressure (actual value) is shown in display field 3.
– Switch off ignition.
WARNING
The fuel lines will continue to be filled with fuel, but will no lon‐
ger be under high pressure. To open fuel system, wear pro‐
tective eyewear and clothing to prevent injuries and contact
with skin.
Before opening the high pressure system, place a cloth around
the connection.
– After reducing high pressure, high pressure system can be

opened. To do this, place a clean cloth around connection to
reduce residual pressure in system to approximately 7 bar
(101.52 psi). Escaping fuel must be absorbed.
Note
If the high pressure line isProtected

not opened immediately,
by copyright. the
Copying for private fuel pres‐
or commercial purposes, in part or in whole, is not
sure can increase slightly. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Connect a Vehicle Diagnostic Tester and generate the readi‐

ness code in the ECM using “Guided Fault Finding”.
2 Rep. Gr.24 - Multiport Fuel Injection

1.2 Clean Working Conditions
WARNING
There is a risk of injury because the fuel is under very high

pressure.
♦ For safety reasons, if the battery is “not” disconnected, the
Fuel Pump Control Module - J538- fuse must be removed
before opening fuel system. Otherwise, the fuel pump will
be activated by the driver door contact switch.
♦ Fuel system is under pressure! Fuel pressure must be re‐
duced to a residual pressure before opening high pressure
area of injection system, refer to
⇒ “1.1 Before Opening High Pressure Fuel Injection Sys‐
tem”, page 1 .
♦ After reducing high pressure, connection should be
opened “immediately”. To do this, place a cloth around the
connection to reduce residual pressure (approximately 7
bar (101.52 psi)).
Caution
♦ Always follow the instructions when disconnecting the bat‐

tery, refer to ⇒ Electrical System; Rep. Gr. 27 ; Removal
and Installation .
Even a little contamination can lead to faults. When working on

the fuel supply and on the fuel injection system, observe the fol‐
lowing guidelines for a clean working environment:
♦ Before loosening, connections and surrounding areas must be
cleaned thoroughly with engine or brake cleaner, and then
cleaned area must be dried completely.
♦ Plug open lines and connections immediately with appropriate
protective caps.
♦ Place removed parts on a clean surface and cover them. Use
a lint-free cloth.
♦ Install only clean parts: remove the replacement parts from
their packaging just before installing them. Do not use parts
that have been stored unpacked (for example in tool boxes
etc.).
♦ When the system is open: do not work with compressed air.
Do not move vehicle unless absolutely necessary.
♦ Protect the disconnected connectors from dirt and moisture
and only connect when they are dry.
1.3 Ignition System Safety Precautions

To reduce the risk of personal injury and/or damage to the fuel
injection and ignition system, always observeofthe following:

with respect to the correctness information in this document. Copyright by AUDI AG.
♦ Individuals with a pacemaker must not stay in the danger area

of high voltage systems, for example ignition systems, xenon
light.
♦ Fuel lines must not be opened when engine is running.
♦ Only disconnect and reconnect wires for injection and ignition
system, including test leads, when ignition is switched off.
♦ If engine is to be cranked at starting RPM without starting (for

example for compression testing), disconnect connectors from
ignition coils and remove fuse for electric fuel pump.
♦ It is possible that the control module will recognize a malfunc‐
tion and store a Diagnostic Trouble Code (DTC) during some
tests. After completing all checks and repairs, check the DTC
memory and erase the memory, if necessary.
♦ If the DTC memory was erased, a new readiness code must
be generated.
♦ Cleaning the engine should only be performed with ignition
switched off.
♦ The Battery must only be disconnected and connected with
the ignition switched off, since the Engine Control Module
(ECM) can otherwise be damaged.
example for compression testing), disconnect the four con‐
nectors for ignition coils, using the Puller - Ignition Coil -
T40039- . Remove the fuse for the Fuel Pump Control Module
- J538- .
Note
By removing fuse, the voltage supply to “terminal 30” for the Fuel
Pump Control Module - J538- is interrupted, refer to ⇒ Wiring di‐
agrams, Troubleshooting & Component locations.
1.4 On Board Diagnostics (OBD) General

Information
♦ The Engine Control Module (ECM) is equipped with On Board
Diagnostics (OBD). Before repairs such as fault finding, check
the Diagnostic Trouble Code (DTC) memory first. Also the
vacuum hoses and connections must be checked (unmetered
air).
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. The use of clamp or screw type clips is not
permissible.
♦ For the electric components to work properly, a voltage of at
least 11.5 Volts is required.
♦ Do not use sealants containing silicone. Particles of silicone
drawn 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 of
fire in an accident because the fuel pump relay switches the
fuel pump off.
♦ This setup also makes it easier to start the engine. When the
driver-side door is opened, the fuel pump is activated for 2
seconds so that pressure builds in the fuel system, observe
safety measures, refer to
⇒ “1.5 Safety Precautions, Test and Measuring Instruments
during Test Drives”, page 5 .
♦ If it is difficult to disconnect the connectors, use a Reversing
Light Switch Connector Release Tool - T40138- .

1.5 Safety Precautions, Test and Measuring

Instruments during Test Drives
If special testing equipment is required during road test, note the
following:
WARNING
Improperly secured testing and measuring equipment and dis‐

traction during a road test increase the risk
Protected of anCopying
by copyright. accident.
for private or commercial purposes, in part or in whole, is not
The passenger airbag could pose awithrisk if ittodeploys
respect in aof colli‐
the correctness information in this document. Copyright by AUDI AG.
sion.
• Operating testing equipment while driving causes it to shift
position.
• There is an increased risk of injury due to unsecured test‐
ing equipment.
♦ Always secure testers on the rear seat with a strap and
have a second person on the rear seat operate them.
2 Description and Operation

⇒ “2.1 Air Filter Overview”, page 6
⇒ “2.2 Component Location Overview”, page 7
⇒ “2.3 Fuel Injectors, Cleaning”, page 15
⇒ “2.4 Fuel Rail Overview”, page 16
⇒ “2.5 High Pressure Pump Overview”, page 17
⇒ “2.6 Intake Manifold Overview”, page 20
2.1 Air Filter

Protected Overview
by copyright. Copying for private or commercial purposes, in part or in whole, is not
1 - Not Installed
2 - Air Guide Hose
❑ To turbocharger
❑ Check the air duct hose
for dirt and leaves
3 - Hose Clamp
4 - Mass Airflow Sensor - G70-
❑ Removing and instal‐
ling, refer to
⇒ “5.12 Mass Airflow
Sensor G70 ”,
page 52
5 - Bolt
❑ 1.5 Nm
6 - Air Guide
❑ To lock carrier
7 - Bolt
❑ 1.5 Nm
❑ On the lock carrier
8 - Air Guide
❑ To air filter housing
❑ Clean the air guide
channel of debris and
leaves
9 - Expanding Clip
10 - Bolt
❑ 1.5 Nm
11 - Upper Air Filter Housing
Section
❑ Clean salt, dirt and
leaves from the upper section of the air filter.
12 - Heat Shield
13 - Bolt
❑ 1.5 Nm
14 - Air Filter
❑ Always use an original air filter.
❑ Removing and installing, refer to ⇒ “5.1 Air Filter”, page 32 .
❑ Follow the replacement intervals, refer to ⇒ Maintenance Intervals; Rep. Gr. 03 .

15 - Lower Air Filter Housing Section

❑ Clean the lower section of the air filter from salt, dirt and leaves.
❑ Clean out the water drain, which is the small hole in the air filter housing lower section, using compressed
air.
16 - O-Ring
❑ Replace if damaged
17 - Not Installed
2.2 Component Location Overview

Components A through R are not depicted in the exploded view
illustration.
1 - Mass Airflow Sensor - G70-

❑ Refer to
⇒ Fig. ““ Mass Airflow
Sensor -G70- -1-”“ ,
page 11
2 - Heated Oxygen Sensor -
G39- and Oxygen Sensor
Heater - Z19-
❑ Refer to
⇒ Fig. ““ Engine Coolant
Temperature Sensor -
G62- -1-”“ , page 13
ling, refer to
⇒ “5.8 Heated Oxygen
Sensor G39 and Oxy‐
gen Sensor Heater Z19
before Catalytic Con‐
verter”, page 44
3 - Oxygen Sensor after Three
Way Catalytic Converter -
G130- and Heater For Oxygen
Sensor 1 After Catalytic Con‐
verter - Z29-
❑ Refer to
⇒ Fig. ““Oxygen Sen‐
sors”“ , page 12
ling, refer to
⇒ “5.13 Oxygen Sensor
after Three Way Cata‐
lytic Converter G130
and Heater For Oxygen
Sensor 1 after Catalytic
Converter Z29 ”,
2. Description and Operation 7

page 53
4 - Engine Coolant Temperature Sensor - G62-
❑ Refer to ⇒ Fig. ““ Engine Coolant Temperature Sensor -G62- -1-”“ , page 13
5 - Camshaft Adjustment Valve 1 - N205-
❑ Refer to
⇒ Fig. ““ Camshaft Adjustment Valve 1 -N205- -1- and Fuel Pressure Regulator Valve -N276- -2-”“ , page
11
❑ Removing and installing, refer to ⇒ Engine Mechanical; Rep. Gr. 15 ; Removal and Installation
6 - Fuel Pressure Regulator Valve - N276-
❑ Refer to
⇒ Fig. ““ Camshaft Adjustment Valve 1 -N205- -1- and Fuel Pressure Regulator Valve -N276- -2-”“ , page
11
7 - High Pressure Pump
❑ Removing and installing, refer to ⇒ “5.9 High Pressure Pump”, page 45
8 - Low Fuel Pressure Sensor - G410-
❑ 15 Nm
9 - Intake Flap Motor - V157- with Intake Manifold Runner Position Sensor - G336-
❑ It is necessary to adapt the Intake Manifold Runner Position Sensor - G336- to the Engine Control Module
- J623- after removing or replacing the fuel rail. Use a Vehicle Diagnostic Tester .
❑ Removing and installing, refer to
⇒ “5.10 Intake Flap Motor V157 with Intake Manifold Runner Position Sensor G336 ”, page 46
10 - Engine Speed Sensor - G28-
❑ Refer to ⇒ Fig. ““Connectors”“ , page 14
11 - 6-Pin Connector
❑ For Heated Oxygen Sensor - G39- and Oxygen Sensor Heater - Z19- (black), refer to
⇒ Fig. ““Connectors”“ , page 12
12 - 6-Pin Connector
❑ Oxygen Sensor after Three Way Catalytic Converter - G130- and Heater For Oxygen Sensor 1 After
Catalytic Converter - Z29- (brown connector), refer to ⇒ Fig. ““Connectors”“ , page 12
13 - EVAP Canister Purge Regulator Valve 1 - N80-
14 - Engine Control Module - J623-
❑ Removing and installing, refer to ⇒ “5.3 Engine Control Module J623 , Replacing”, page 36
15 - Charge Air Pressure Sensor - G31-
❑ Refer to ⇒ Fig. ““ Charge Air Pressure Sensor -G31- -1-”“ , page 14
❑ Removing and installing, refer to ⇒ Engine Mechanical; Rep. Gr. 21 ; Removal and Installation
16 - Throttle Valve Control Module - J338- , EPC Throttle Drive - G186-
❑ EPC throttle drive permitted
angle unless
sensor 1 - G187-
authorised by AUDI and EPC
AG. AUDI AG throttle drive angle
does not guarantee or acceptsensor
any liability2 - G188-
❑ After replacing the Throttle Valve Control Module - J338- , it must be adapted to the Engine Control
Module - J623- again (basic setting, display group 60) see Vehicle Diagnostic Tester “Guided Functions”
❑ Refer to
⇒ Fig. ““ Intake Air Temperature Sensor -G42- -1- Throttle Valve Control Module -J338- -2-”“ ,
page 11
17 - Intake Air Temperature Sensor - G42-
❑ Refer to
⇒ Fig. ““ Intake Air Temperature Sensor -G42- -1- Throttle Valve Control Module -J338- -2-”“ ,
page 11

18 - Fuel Pressure Sensor - G247-

❑ 22 Nm
❑ Removing and installing, refer to ⇒ “5.6 Fuel Pressure Sensor G247 ”, page 42 .
❑ Checking, refer to ⇒ “4.2 Fuel Pressure Sensor G247 , Checking”, page 27 .
❑ Refer to ⇒ Fig. ““ Fuel Pressure Sensor -G247- -1-”“ , page 10
19 - Camshaft Position Sensor - G40- (camshaft position sensor)
❑ Refer to ⇒ Fig. ““ Camshaft Position Sensor -G40- -1-”“ , page 11
20 - Ignition Coils with Power Output Stages
❑ Ignition Coil 1 with Power Output Stage - N70-
❑ The ignition coils must be pulled out of the cylinder head using the Puller - Ignition Coil - T40039-
❑ Removing and installing, refer to ⇒ “4.1 Ignition Coils with Power Output Stages”, page 61
21 - Turbocharger Recirculation Valve - N249-
❑ Installed directly on turbocharger, refer to ⇒ Fig. ““Components on Turbocharger”“ , page 15
❑ Removing and installing, refer to ⇒ Engine Mechanical; Rep. Gr. 21 ; Description and Operation
22 - Wastegate Bypass Regulator Valve - N75-
❑ Installed directly on turbocharger, refer to ⇒ Fig. ““Components on Turbocharger”“ , page 15
❑ Removing and installing, refer to ⇒ Engine Mechanical; Rep. Gr. 21 ; Description and Operation .
A - Data Link Connector
Protected(DLC)
❑ In knee bolsterwith
onrespect
driver's
to theside
correctness of information in this document. Copyright by AUDI AG.
B - Fuel Pump Control Module - J538-

❑ Refer to ⇒ Fig. ““ Fuel Pump Control Module -J538- -1-”“ , page 12
❑ If the Fuel Pump Control Module - J538- or fuel pump is replaced, an adaptation must be performed
“Initiate basic setting” display group 103
❑ Fuel Pump Control Module - J538- , Checking, refer to ⇒ Fuel Supply System; Rep. Gr. 20 ; Diagnosis
and Testing .
C - Electronic Power Control “EPC” Malfunction Indicator Lamp
❑ Inside the instrument cluster
D - Exhaust Malfunction Indicator Lamp “MIL”
❑ Inside the instrument cluster
E - 8-Pin Connector for Fuel Injectors
❑ Refer to ⇒ Fig. ““Component Locations Beneath Intake Manifold”“ , page 14
F - Connector
❑ For Camshaft Position Sensor - G40- and Fuel Pressure Sensor - G247-
G - Brake Lamp Switch - F- and Brake Pedal Switch - F63-
❑ Refer to
⇒ Fig. ““Component Location of Brake Lamp Switch -F- and Brake Pedal Switch -F47- , Clutch Pedal
Switch -F36- ”“ , page 13
H - Accelerator Pedal Position Sensor - G79- and Accelerator Pedal Position Sensor 2 - G185-
❑ On accelerator pedal (both sensors are stored in one housing)
I - Clutch Pedal Switch - F36-
❑ Refer to
⇒ Fig. ““Component Location of Brake Lamp Switch -F- and Brake Pedal Switch -F47- , Clutch Pedal
Switch -F36- ”“ , page 13

J - Relay and Fuse Carrier in E-Box

❑ Refer to ⇒ Fig. ““Installed Location in 4-Socket Relay Carrier, Plenum Chamber E-Box”“ , page 13
K - Coolant Fan Control Module - J293-
❑ Installed in left coolant fan, when facing driving direction
L - Fuel Injectors
❑ Inside the fuel rail
❑ Cylinder 1 Fuel Injector - N30-
❑ Removing and installing, refer to ⇒ “5.5 Fuel Injectors”, page 40 .
Fuel injectors referred to here are high pressure fuel injectors. They inject fuel directly into the cylinder under
high pressure (max. approximately 120 bar).
M - Knock Sensor 1 - G61-

❑ For cylinder 1 and 2
❑ Tightening specification: 20 Nm
❑ Removing and installing, refer to ⇒ “4.2 Knock Sensor 1 G61 and Knock Sensor 2 G66 ”, page 62 .
N - Knock Sensor 2 - G66-
❑ For cylinder 3 and 4
❑ Removing and installing, refer to ⇒ “4.2 Knock Sensor 1 G61 and Knock Sensor 2 G66 ”, page 62 .
❑ Refer to ⇒ Fig. ““Component Locations
permittedBeneath Intake
unless authorised Manifold”“
by AUDI AG. AUDI AG , page
does not14
guarantee or accept any liability
O - Oil Pressure Switch - F1-
❑ Refer to ⇒ Fig. ““Connectors”“ , page 14
❑ Oil Pressure Switch, checking and removing and installing, refer to ⇒ Engine Mechanical; Rep. Gr. 17 ;
Diagnosis and Testing .
P - Oil Level Thermal Sensor - G266-
❑ Refer to ⇒ Fig. ““ Oil Level Thermal Sensor -G266- ”“ , page 14
Q - Leak Detection Pump - V144-
❑ Only installed on engine code BPG
R - Left Electrohydraulic Engine Mount Solenoid Valve - N144-
❑ Only installed on vehicles with automatic transmission
Fuel Pressure Sensor - G247- -1-

• Tightening specifications of connection “30 Nm” must be
checked before installing Fuel Pressure Sensor - G247-

Camshaft Position Sensor - G40- -1-
Mass Airflow Sensor - G70- -1-
Camshaft Adjustment Valve 1 - N205- -1- and Fuel Pressure

Regulator Valve - N276- -2-
Intake Air Temperature Sensor - G42- -1- Throttle Valve Control

Module - J338- -2-

Fuel Pump Control Module - J538- -1-

• If the Fuel Pump Control Module - J538- or fuel pump is re‐
placed, an adaptation must be performed “Initiate basic set‐
ting” display group 103
• Fuel Pump Control Module - J538- , Checking, refer to ⇒ Fuel
Supply System; Rep. Gr. 20 ; Diagnosis and Testing .
Connectors
1 - Heated Oxygen Sensor - G39- and Oxygen Sensor Heater -
Z19- (black connector)
2 - Oxygen Sensor after Three Way Catalytic Converter - G130-
and Heater For Oxygen Sensor 1 After Catalytic Converter - Z29-
(brown connector)
Oxygen Sensors
1 - Oxygen Sensor after Three Way Catalytic Converter - G130-
and Heater For Oxygen Sensor 1 after Catalytic Converter - Z29-
2 - Heated Oxygen Sensor - G39- and Oxygen Sensor Heater -
Z19-
Installed Location of Engine Control Module - J623-

Engine Coolant Temperature Sensor - G62- -1-
Component Location of Brake Lamp Switch - F- and Brake Pedal

Switch - F47- , Clutch Pedal Switch - F36-
1- Brake Lamp Switch - F- , Brake Pedal Switch - F47-
2- Clutch Pedal Switch - F36-
Note
To ensure that they are absolutely securely seated, the switches

may only be installed once.
Installed Location in 4-Socket Relay Carrier, Plenum Chamber E-

Box
1.1 - Not assigned
1.2 - Starting Interlock Relay - J207-
2 - Motronic Engine Control Module Power Supply Relay - J271-
3 - Engine Component Power Supply Relay - J757-
Installed Location on 9-Socket Relay Carrier in Driver Footwell

Arrow - Fuel Pump Relay - J17-

Connectors
1 - Oil Pressure Switch - F1-
2 - 3-pin connector (gray) for Engine Speed Sensor - G28-
3 - Engine Speed Sensor - G28-
Component Locations Beneath Intake Manifold

1 - Knock Sensor 1 - G61-
3 - Oil Pressure Switch - F1- in the oil filter bracket
4 - 3-pin connector (gray) for Engine Speed Sensor - G28-
5 - Electrical connector for Camshaft Position Sensor - G40- and
Fuel Pressure Sensor - G247-
6 - 8-Pin Connector for fuel injectors
Charge Air Pressure Sensor - G31- -1-

– Replace O-ring
– Tighten to 5 Nm.
Removing and installing, refer to ⇒ Engine Mechanical; Rep. Gr.
21 ; Removal and Installation .
Oil Level Thermal Sensor - G266-

Components on Turbocharger
1 - Turbocharger
2 - Tighten the Wastegate Bypass Regulator Valve - N75- to 3
Nm
3 - Tighten the Turbocharger Recirculation Valve - N249- to 7 Nm
(observe installation location, next illustration)
Observe Installed Position of Turbocharger Recirculation Valve -

N249-
2.3 Fuel Injectors, Cleaning

♦ Ultrasonic Cleaning Unit - VAS6418-
♦ Mounting Plate for Injection Modules - VAS6418/1-
♦ Cleaning Fluid - VAS6418/2-
Cleaning
– Remove the fuel injectors, refer to
⇒ “5.5 Fuel Injectors”, page 40 .
Note
Follow the safety precautions and the instructions for the ultra‐
sonic device.
– The ultrasonic device must be filled with Cleaning Fluid -

VAS6418/2- .
Note
Fill the ultrasonic device up to the upper edge of the holes with
cleaner (see the magnified area of the illustration).

– Install the fuel injectors -1- until stop in the Mounting Plate for
Injection Modules - VAS6418/1- -2- while doing this dip the fuel
injectors in the cleaner.
– Adjust the temperature to 50 degrees using the knob -4-.
– Set a cleaning time of 30 minutes using the knob -5-.
– Switch the ultrasonic device on with the button -3-.
Note
The time begins counting down once the cleaning temperature

reaches 50 degrees.
– Replace the combustion chamber seal (Teflon® seal) after

cleaning each fuel injector, refer to
⇒ “5.2 Combustion Chamber Seal (Teflon® Seal), Replacing”,
page 33 .
– Install the fuel injectors, refer to
⇒ “5.5 Fuel Injectors”, page 40 .
2.4 Fuel Rail Overview with respect to the correctness of information in this document. Copyright by AUDI AG.
1 - Radial Adjustment
❑ Replace if damaged
2 - Fuel Injector
❑ With combustion cham‐
ber seal (Teflon® seal),
always replace
❑ Replace O-rings
❑ Note correct installation
position
ling, refer to
⇒ “5.5 Fuel Injectors”,
page 40
3 - Support Ring
4 - Fuel Rail
ling, refer to
⇒ “5.7 Fuel Rail”,
page 43 .
5 - Fuel Pressure Sensor -
G247-
❑ 22 Nm
❑ Tighten connections to
30 Nm
6 - Low Fuel Pressure Sensor
- G410-
❑ 15 Nm
7 - Fuel Pressure Regulator
Valve - N276-
❑ with Fuel Pressure Reg‐
ulator Valve - N276- and

Low Fuel Pressure Sen‐

sor - G410-
❑ An electrical fuel pump, located in the fuel tank, supplies fuel to the mechanical high-pressure pump at
a pressure of approximately 6 bar (87 psi).
❑ When installing, make sure that no dirt enters the fuel system.
❑ The fuel system must be without pressure to install the high-pressure pump, releasing fuel pressure,
refer to ⇒ “1.1 Before Opening High Pressure Fuel Injection System”, page 1 .
❑ Install the fuel lines free of tension
❑ Removing and installing, refer to ⇒ “5.9 High Pressure Pump”, page 45 .
9 - EVAP Canister Purge Regulator Valve 1 - N80-
❑ With EPC Throttle Drive Angle Sensor 1 - G187- and EPC Throttle Drive Angle Sensor 2 - G188-
Module - J623- again (basic setting, display group 60) see “Guided Fault Finding”
11 - Intake Air Temperature Sensor 2 - G299-
❑ Tighten to 5 Nm.
12 - Intake Manifold Bolts
❑ 9 Nm
13 - Intake Manifold
❑ Removing and installing, refer to ⇒ “5.11 Intake Manifold with Fuel Rail”, page 48 .
❑ Adapt the Intake Manifold Runner Position
with respect Sensorof- information
to the correctness G336- -item 10- to the
in this document. Engine
Copyright Control
by AUDI AG. Module - J623-
if it has been removed or replaced. Use a Vehicle Diagnostic Tester “Guided Functions”
2.5 High Pressure Pump Overview
WARNING
Fuel system is under high pressure! Before opening the sys‐

tem, perform the procedure for releasing fuel pressure, refer to
page 1 .

1 - Channel Separating Plate

❑ Removable
❑ Check for damages and
correct positioning
2 - Sleeve
❑ Remains inserted in cyl‐
inder head after remov‐
ing the high-pressure
pump, removable
❑ When installing the high
pressure pump, the
sleeve must be at the
lowest point (rotate the
camshaft as needed)
ling, refer to
⇒ “5.9 High Pressure
Pump”, page 45 .
3 - O-Ring
❑ Replace
❑ An electrical fuel pump,
located in the fuel tank,
supplies fuel to the me‐
chanical high-pressure
pump at a pressure of
approximately 6 bar (87
psi).
❑ When installing, make
sure that no dirt enters
the fuel system.
❑ The fuel system must be
without pressure, re‐
leasing fuel pressure,
refer to

⇒ “1.1 Before Opening

High Pressure Fuel Injection System”, page 1
❑ Install the fuel lines free of tension.
❑ When installing the high pressure pump, the sleeve must be at the lowest point (rotate the camshaft as
needed).
❑ Removing and installing, refer to ⇒ “5.9 High Pressure Pump”, page 45 .
5 - Fuel Pressure Regulator Valve - N276-
6 - Low Fuel Pressure Sensor - G410-
❑ 15 Nm
7 - High-Pressure Pump Bolts
❑ 9 Nm
❑ TORX® bolts (Qty. 3)
8 - Connection for Fuel Return Line to Fuel Tank
❑ Replace bolt
❑ Tighten the connection to 40 Nm. Check the line torque every time before installing the fuel line.
❑ Do not install the fuel line with tension and make sure it is clean. Tightening specification: 25 Nm
9 - Fuel Supply Line To Fuel Rail
❑ Do not install the fuel line with tension and make sure it is clean. Tightening specification: 30 Nm
10 - Hole In Cylinder Head For High-Pressure Pump
11 - Fuel Injectors
❑ Replace O-rings
❑ Note correct installation position
❑ Removing and installing, refer to ⇒ “5.5 Fuel Injectors”, page 40

2.6 Intake Manifold Overview
1 - Intake Air Temperature

Sensor 2 - G299- Bolt
❑ 5 Nm
2 - Intake Air Temperature
Sensor 2 - G299-
3 - Intake Manifold
ling, refer to
⇒ “5.11 Intake Manifold
with Fuel Rail”,
page 48
❑ Adapt the Intake Mani‐
fold Runner Position
Sensor - G336-
-item 10- to the Engine
Control Module - J623- if
it has been removed or
replaced. Use a Vehicle
Diagnostic Tester “Gui‐
ded Functions”
4 - EVAP Canister Purge Reg‐
ulator Valve 1 - N80-
5 - High Pressure Pump Bolt
❑ 10 Nm
❑ Quantity: 3
6 - Fuel Pressure Regulator
Valve - N276-
❑ With fuel pressure regu‐
lator valve - N276- and
low fuel pressure sensor
- G410-
❑ An electrical fuel pump,

located in the fuel tank,

supplies fuel to the mechanical high-pressure pump at a pressure of approximately 6 bar (87 psi).
❑ When installing, make sure that no dirt enters the fuel system.
❑ The fuel system must be without pressure, releasing fuel pressure, refer to
⇒ “1.1 Before Opening High Pressure Fuel Injection System”, page 1 .
❑ Install the fuel lines free of tension
❑ Removing and installing, refer to ⇒ “5.9 High Pressure Pump”, page 45
8 - Connection for Fuel Return Line to Fuel Tank
❑ Replace bolt
❑ Do not install fuel line with tension (be aware of cleanliness)
9 - Fuel Supply Line to Fuel Rail
❑ Do not install fuel line with tension (be aware of cleanliness)
10 - Intake Flap Motor - V157- with Intake Manifold Runner Position Sensor - G336-
❑ Adapt the Intake Manifold Runner Position Sensor - G336- to the Engine Control Module - J623- after
the fuel rail has been removed or replaced. Use a Vehicle Diagnostic Tester “Guided Functions”.
❑ Removing and installing, refer to
⇒ “5.10 Intake Flap Motor V157 with Intake Manifold Runner Position Sensor G336 ”, page 46 .
11 - Bolt for Intake Flap Motor - V157- with Intake Manifold Runner Position Sensor - G336-
❑ 7 Nm
❑ Quantity: 3
12 - Intake Manifold Support
13 - Intake Manifold Support Bolt
❑ 23 Nm
❑ With EPC Throttle Drive Angle Sensor 1 - G187- and EPC Throttle Drive Angle Sensor 2 - G188-
Module - J623- again (basic setting, display group 60) see “Guided Fault Finding”
15 - Throttle Valve Control Module - J338- Bolt
❑ 7 Nm
❑ Quantity: 4
16 - Intake Manifold Support Nut
❑ 10 Nm
17 - Seal
❑ Replace
18 - Fuel Rail
❑ Removing and installing, refer to ⇒ “5.7 Fuel Rail”, page 43 .
❑ Adapt the Intake Manifold Runner Position Sensor - G336- to the Engine Control Module - J623- after
the fuel rail has been removed or replaced. Use a Vehicle Diagnostic Tester “Guided Functions”.
19 - Fuel Pressure Sensor - G247-
❑ 22 Nm

3 Specifications
⇒ “3.1 Fastener Tightening Specifications”, page 22
⇒ “3.2 Technical Data”, page 22
3.1 Fastener Tightening Specifications

Component Fastener Size Nm
Air duct to lock carrier bolt - 1.5
Fuel line to fuel rail bolt - 22
Fuel pressure sensor bolt - 22
Fuel pressure sensor connection bolt - 30
Fuel return line to fuel tank, bolt1 - 25
Fuel return line to fuel tank connection - 40
Fuel supply line to fuel rail connection - 30
Heat shield bolt - 1.5
High-pressure pump bolt - 10
Intake Air Temperature (IAT) sensor 2 bolt - 5
Intake flap motor with intake manifold runner position sensor bolt - 7
Intake manifold bolt - 9
Intake manifold support
- Bolt - 23
- Nut - 10
Knock sensor bolt - 20
Low fuel pressure sensor bolt - 15
Mass air flow sensor bolt - 1.5
Oxygen sensor bolt - 55
Single-piston high-pressure pump
permitted unlessbolt
authorised by AUDI AG. AUDI AG does not guarantee or accept any - liability 10
Throttle valve control module bolt - 7
Turbocharger Recirculation Valve bolt - 7
Upper section of air filter housing bolt - 1.5
Wastegate Bypass Regulator Valve bolt - 3
• 1 Always replace
3.2 Technical Data

Engine Data 2.0L / 125 kW / 147 kW / 162 kW
Turbo FSI Engine
Idle speed cannot be adjusted, it is 640 to 800 RPM
regulated by idle stabilization
Engine speed limitation via fuel in‐ 6500 RPM:
jector shut-off
Fuel pressure Fuel supply-pressure up to approximately 6 bar (87 psi) pressure with
high-pressure pump, (is ignition on
produced by an electric fuel
pump in the fuel tank)

Engine Data 2.0L / 125 kW / 147 kW / 162 kW

Turbo FSI Engine
Fuel high pressure (pro‐ Approximately 50 bar (725 psi) positive
duced by a mechanical sin‐ pressure at idle
gle-piston pump) at approx‐ Approximately 110 bar (1595 psi) positive
imately 85 degree coolant pressure at certain operating points.
temperature
3. Specifications 23
4 Diagnosis and Testing

⇒ “4.1 Fuel Pressure and Residual Pressure before High Pres‐
sure Pump, Checking”, page 24
⇒ “4.2 Fuel Pressure Sensor G247 , Checking”, page 27
⇒ “4.3 Vacuum System, Checking”, page 29
⇒ “4.4 Wiring and Components, Checking with Test Box Kit - 105
Pin Test Box Kit VAG1598/42 ”, page 30
4.1 Fuel Pressure and Residual Pressure

before High Pressure Pump, Checking
♦ Fuel Injection Gauge Kit - VAG1318-
♦ Fuel Injection Gauge Kit - CO Adapter - VAG1318/11-
♦ Injection Rate Comparison Meter Kit - Remote Cable -
VAG1348/3A- with Injection Rate Kit - Remote Cable -
VAG1348/3-3-
♦ Measuring container, fuel-resistant
Test Conditions:
• Battery voltage at least 12.5 V.
• Fuse 28 (On Fuse Panel) - S228- (position 28) OK.
• Fuel Pump Control Module - J538- is OK; check.

• Fuel filter is OK.
• Fuel tank minimum 1/4 full.
Test Sequence
Sedan:
– Remove carpeting in luggage compartment.
– Fold forward the right backrest of rear seat, if necessary.
Wagon:
– Remove left 1/3 backrest, refer to ⇒ Body Interior; Rep. Gr.
72 ; Removal and Installation .
– Remove the left luggage compartment side trim panel and the
dirt tray, refer to ⇒ Body Interior; Rep. Gr. 70 ; Removal and
Installation .

All:
– Unbolt cover for locking flange -arrows-.
– Disconnect the connector -arrow- from the locking flange.
– Connect the Injection Rate Comparison Meter Kit - Remote

Cable - VAG1348/3A- and Injection Rate Kit
Protected by copyright. - Remote
Copying for privateCable
or commercial purposes, in part or in whole, is not
- VAG1348/3-3- with the Connector Test
permitted unless Set - by
authorised VAG1594D-
AUDI AG. AUDI AG to does not guarantee or accept any liability
contact -1-. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Using insulating tape, tape over the second contact of Injection

Rate Kit - Remote Cable - VAG1348/3-3- to prevent a short
circuit -arrow-.
– Connect contact -4- to vehicle Ground (GND) using a jumper
cable from the Connector Test Set - VAG1594D- .
– Connect alligator clip to vehicle battery (positive).
– Remove the fuel cap from the fuel filler tube.

– Remove engine cover -arrows-.
WARNING
Fuel system is under pressure! Before opening system, place

clean rags around the connection. Then release pressure by
carefully loosening the connection.
4. Diagnosis and Testing 25

– Disconnect fuel supply line -arrow-.
– Connect the Fuel Injection Gauge Kit - VAG1318- with Fuel

Injection Gauge Kit - CO Adapter - VAG1318/11- and Fuel In‐
jection Gauge Kit - VAG1318/12- to the fuel supplyProtected
line. by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Connect the adapter hose -arrow- to the Fuel InjectionwithGauge
respect to the correctness of information in this document. Copyright by AUDI AG.
Kit - VAG1318- and hold it in the container.

– Open shut-off valve on Fuel Injection Gauge Kit - VAG1318- .
The lever points in the direction of flow.
– Bleed fuel system by pressing remote control briefly.
– Close shut-off valve on Fuel Injection Gauge Kit - VAG1318- .

Lever stands perpendicular to direction of flow -arrow-.
– Press remote control switch until pressure increase is no lon‐
ger observed on Fuel Injection Gauge Kit - VAG1318- .
• Specified value: approximately 5 bar (72.51 psi) (3 to 7 bar
(43.51 to 101.52 psi))
If the specification is not obtained:
– Check fuel pump delivery rate, refer to ⇒ Fuel Supply System;
Rep. Gr. 20 ; Diagnosis and Testing .
Holding Pressure, Checking
– Check for leaks and residual pressure by watching for the
pressure on the Fuel Injection Gauge Kit - VAG1318- to de‐
crease.
• After 10 minutes there must be a residual pressure of at least
3 bar (43 psi).
If the residual pressure drops below 3 bar (43 psi):
♦ Check the connection between the Fuel Injection Gauge Kit -
VAG1318- and the fuel supply line for leaks.
♦ Check the Fuel Injection Gauge Kit - VAG1318- for leaks.
♦ Check fuel lines and their connections for leaks.
♦ Replace fuel filter with integrated fuel pressure regulator, refer
to ⇒ Fuel Supply System; Rep. Gr. 20 ; Removal and Instal‐
lation . Then repeat test.
♦ If the fuel filter is OK, replace fuel pump, refer to ⇒ Fuel Supply
System; Rep. Gr. 20 ; Removal and Installation .
Install in reverse order of removal. Note the following:

Note
Before disconnecting the pressure gauge, release the pressure

by opening the shut-off valve. Hold collecting container in front of
hose.
– Tighten fuel supply line (ensure cleanliness).

Tightening Specification
Component Nm
Fuel line to fuel rail 22
4.2 Fuel Pressure Sensor - G247- , Check‐

ing
♦ Pressure Sensor Tester - VAS6394-
♦ Adapter - VAS6394/2-
♦ Vehicle Diagnostic Tester - Test Adapter - 3 Pin - VAS5570-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Vehicle Diagnostic Tester
Procedure
– Remove the engine cover.
WARNING
Fuel system is under pressure! Fuel pressure must be reduced

to a residual pressure before opening high pressure area of
injection system, refer to
page 1 .
– Remove the Fuel Pressure Sensor - G247- , refer to

⇒ “5.6 Fuel Pressure Sensor G247 ”, page 42 .
– In place of the Fuel Pressure Sensor - G247- , install the
Adapter - VAS6394/2- and tighten it to the Fuel Pressure Sen‐
sor - G247- tightening specification.
• Tightening specification: Fuel Rail Assembly Overview, refer
to ⇒ “2.4 Fuel Rail Overview”, page 16

– Remove the plug -2- on the Pressure Sensor Tester -

VAS6394- and install the removed Fuel Pressure Sensor -
G247- and tighten the sensor to the tightening specification.
– Use the Vehicle Diagnostic Tester - Test Adapter - 3 Pin -

VAS5570- to establish the electrical connection between the
vehicle and the Fuel Pressure Sensor - G247- .
– Connect the Vehicle Diagnostic Tester .
– Turn the ignition on. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Select “engine electronics” in n Board Diagnostics (OBD).
– Select “Measured values”.
– Select “Fuel pressure” from the list.
The current value is displayed in field, which the Fuel Pressure
Sensor - G247- reports to the Engine Control Module (ECM).
– Switch the Pressure Sensor Tester - VAS6394- on by pressing

the button -A- once briefly.
Note
Holding the button -A- for 2 seconds switches on the illumination

for 20 seconds.
The Pressure Sensor Tester - VAS6394/1- should display 0 bar;

if this is not the case, then press button -C- one time quickly to
set it back to zero.

– Connect the Pressure Sensor Tester - VAS6394- pressure line

to the Adapter - VAS6394/2- .
– Start the engine.
– Compare the pressure displayed on the Pressure Sensor
Tester - VAS6394/1- with the actual value displayed on the
Vehicle Diagnostic Tester .
• The pressures may have a maximum difference of 5 bar (72.5
psi).
– If the difference is greater than 5 bar (72.5 psi), test a new Fuel
Pressure Sensor - G247- .
WARNING

page 1 .
– Install a new Fuel Pressure Sensor - G247- in the Pressure

Sensor Tester - VAS6394/1- .
– Repeat the test with the new Fuel Pressure Sensor - G247-
and compare both measured values.
If the measured values do not now match again:
– Check the electrical connection between the Fuel Pressure
Sensor - G247- and the ECM, refer to ⇒ Wiring diagrams,
Troubleshooting & Component locations.
If the measured values now match:
– Install the new Fuel Pressure Sensor - G247- .
4.3 Vacuum System, Checking

♦ Hand Vacuum Pump - VAS6213-
Procedure
– Check all vacuum lines in the vacuum system for:
♦ Cracks
♦ Damage caused by animals
♦ Crimps
♦ Leaks
– Check the vacuum lines leading both to and from the solenoid
valve to the respective component.
– If there is a fault, check the vacuum lines for the
permitted named
unless com‐
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ponent, but also all the vacuum lines to thewith
other components.
respect to the correctness of information in this document. Copyright by AUDI AG.
– If using the Hand Vacuum Pump - VAS6213- does not produce

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

4.4 Wiring and Components, Checking with

Test Box Kit - 105 Pin Test Box Kit -
VAG1598/42-
♦ Adapter Cable, 60-pin - VAG1598/39-1-
♦ Test Box Kit - 94 Pin Adapter - VAG1598/39-2-
♦ Test Box Kit - 105 Pin Test Box Kit - VAG1598/42-

Note
♦ The test box has 105 terminals. The connection cable can be
separated from the test box. This means that as new Engine
Control Module (ECM) connectors are introduced in the future,
only a new cable must be designed and no longer the entire
test box.
♦ The smaller of the two connectors on the ECM is assigned with
terminals 1 to 60. The larger of the two connectors is assigned
with terminals 1 to 94.
♦ For testing at the 60-pin harness connection, the Adapter Ca‐
ble, 60-pin - VAG1598/39-1- is connected to the test box with
connector -A-. Components on the 60-pin harness connection,
refer to ⇒ Wiring diagrams, Troubleshooting & Component lo‐
cations.
♦ For testing at the 94-pin harness connection, the Test Box Kit
- 94 Pin Adapter - VAG1598/39-2- is connected to the test box
with connectors -A and B-. Components on the 94-pin harness
connection, refer to ⇒ Wiring diagrams, Troubleshooting &
Component locations.
♦ The Test Box Kit - 105 Pin Test Box Kit - VAG1598/42- is de‐
signed so that Protected
it can be connected
by copyright. Copyingsimultaneously to purposes,
for private or commercial the ECM in part or in whole, is not
harness and the ECMunless
permitted itself.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ This is advantageous because electronic engine control re‐
mains fully functional (for example measurement of signals
with engine running) when the test box is attached.
♦ The procedures will indicate whether the ECM is to remain
connected to the test box or not.
♦ To connect testers (for example. Voltage Tester -
VAG1527B- , Analog/Digital Multimeter - FLU83III- , etc.),
always use the Connector Test Set - VAG1594C- .
WARNING
To avoid damaging electronic components, switch to the cor‐

responding measuring range and observe all test conditions
before connecting the test leads.
– Remove the engine control module, refer to

⇒ “5.3 Engine Control Module J623 , Replacing”, page 36 .
– Connect Test Box Kit - 105 Pin Test Box Kit - VAG1598/42- to
wiring harness connector. Attach the ground clip on the test
box to the battery negative cable. The procedures will indicate
whether the ECM is to be connected to the test box.
– Perform test as described in relevant repair sequences.
Installing the ECM
Install 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 Diagnostic Trouble Code (DTC) memory and erase
if necessary.

5 Removal and Installation

⇒ “5.1 Air Filter”, page 32
page 33
⇒ “5.3 Engine Control Module J623 , Replacing”, page 36
⇒ “5.4 Engine Cover”, page 40
⇒ “5.5 Fuel Injectors”, page 40
⇒ “5.6 Fuel Pressure Sensor G247 ”, page 42
⇒ “5.7 Fuel Rail”, page 43
⇒ “5.8 Heated Oxygen Sensor G39 and Oxygen Sensor Heater
Z19 before Catalytic Converter”, page 44
⇒ “5.9 High Pressure Pump”, page 45
⇒ “5.10 Intake Flap Motor V157 with Intake Manifold Runner Po‐
sition Sensor G336 ”, page 46
⇒ “5.11 Intake Manifold with Fuel Rail”, page 48
⇒ “5.12 Mass Airflow Sensor G70 ”, page 52
⇒ “5.13 Oxygen Sensor after Three Way Catalytic Converter
G130 and Heater For Oxygen Sensor 1 after Catalytic Converter
Z29 ”, page 53
5.1 Air Filter

Removing
– Disconnect the connector -1- from the Mass Airflow Sensor -
G70- .
– Unscrew both bolts -arrows- of the air duct at the lock carrier.
– Disconnect air duct -2- from air filter housing.
– Open the hose clamp on air duct hose to turbocharger and pull
it off at Mass Airflow Sensor - G70- .

– Unscrew both bolts -1- at upper part of air filter and lift the
upper part of air filter upward and out.
– Remove the old filter element.
Installing
For problem-free operation of the Mass Airflow Sensor - G70- it
is very important to observe the following notes and procedures.
Note
♦ If the air filter is very dirty or soaked, dirt particles or moisture

may have contaminated the Mass Airflow Sensor - G70- and
may be causing false mass airflow values. This results in a
reduction of power, since a lower injection quantity is calcula‐
ted.
♦ Always use an original air filter.
♦ Hose connections and charge air system hoses must be free
of oil and grease before installing. When installing, do not use
any lubricants containing silicone.
♦ The air filter housings must be absolutely clean.
♦ Secure all hose connections using hose clamps appropriate
for the model type, refer to the Parts Catalog.
♦ Note the following when cleaning the air filter housing with
pressurized air: To prevent malfunctions, cover the critical air
flow components, such as the Mass Airflow Sensor - G70- , air
intake pipes, etc., with a clean cloth.
♦ Observe disposal regulations!
– Clean
Protected out the
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is not
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authorised section,
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not guarantee or accept
– Clean air filter housing (upper and lower sections) of salt res‐
idue, dirt or leaves (use vacuum cleaner if necessary).
– Check the Mass Airflow Sensor - G70- and air duct hose (in‐
take air side) for salt residue, dirt, and leaves.
– Check the air duct from lock carrier to air filter housing for dirt
and leaves.
– Make sure that air filter is properly centered when placed in
the mounting of the air filter housing lower section.
– Set the upper part of air filter housing onto lower part of air
filter housing, without using much force. When doing this,
make sure that the upper part of air filter housing is not placed
crooked onto the air filter (observe sealing lip of air filter).
– Make sure the air duct hose is securely seated on Mass Airflow
Sensor - G70- .
5.2 Combustion Chamber Seal (Teflon®

Seal), Replacing
Note
The combustion chamber seal must always be replaced before

re-installing the fuel injector.
5. Removal and Installation 33

– The illustration shows the fuel injector.

1 - Radial compensation, replace if damaged
2 - Combustion chamber sealing ring (Teflon® sealing ring), re‐
place, the ring must not be greased or handled with any other
lubricants when installing.
3 - Groove on fuel injector
4 - Spacer Ring (replace if damaged)
5 - O-ring (replace, coat lightly with clean engine oil when instal‐
ling)
6 - Support ring (via this support ring, fuel rail utilizes the force to
hold the fuel injector in place in the cylinder head).
– Carefully remove the old Teflon® seal with the appropriate tool
(for example with cut the seal open with a razor and spread
seal open with a small screwdriver and pull it forward and off.)
When doing this, make sure not to damage the groove and
circumferential rib in the groove base.
Note
If the groove is damage, the fuel injector must be replaced.
– Before installing the new Teflon seal, the seal groove and the
shaft of the fuel injector must be cleaned of combustion resi‐
due using a clean rag.
Note
A fuel injector with “angled connector” is shown in the illustration.

Do not pay attention to this for the remainder of the procedure,
because it is unrelated to replacement of the combustion chamber
seal.
– Place the Assembly Cone - T10133/5- with the new Teflon®

seal -1- onto the fuel injector -2-.

– Using the Assembly Sleeve - T10133/6- , push the Teflon®

seal further onto the Assembly Cone - T10133/5- until the Tef‐
lon® seal is engaged in the seal groove. When doing this, do
not use any lubricants.
Note
By pushing the Teflon® seal onto the fuel injector, the Teflon®
seal is expanded. For this reason, the Teflon® seal must be con‐
tracted again, once it has been pushed on. This is done in two
steps. The procedure for this is as follows.
The first step of calibrating (adapting) the Teflon® seal is per‐

formed using the Calibrating Sleeve - T10133/7- .
– Using a rotating motion (approximately 180°) and light pres‐

sure, push the Calibrating Sleeve - T10133/7- over the fuel
injector up to the stop. Pull off Calibrating Sleeve - T10133/7-
again using turning motion in opposite direction.
The second step of calibrating (adapting) the Teflon® seal is per‐
formed using the Calibrating Sleeve - T10133/8- .
– Using a rotating motion (approximately 180°) and light pres‐

sure, push the Calibrating Sleeve - T10133/8- over the fuel
injector up to the stop. Pull off Calibrating Sleeve - T10133/8-
againwithusing
respectturning motionof in
to the correctness opposite
information in thisdirection.
document. Copyright by AUDI AG.
– Replace the O-ring on the fuel injector. Coat the O-ring with
clean engine oil before installing it.
– The Teflon® seal must not be oiled.
– Using the included Nylon Brush - T10133/4- , thoroughly clean

the bores for the high-pressure fuel injectors in the cylinder
head before installing the fuel injectors.
Note
Possibly an opened intake valve hinders the cleaning. In this

case, engine must be turned further by hand using a bolt wrench
on the crankshaft.
– Install fuel injector again with support ring -1- and clip in radial
compensation -2- on support ring.
– Press the fuel injector by hand into the bore in the cylinder
head (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 itself
together.
♦ Check fuel injectors for correct seating and installation position
in cylinder head.
♦ If it is difficult to install the fuel injector by hand, use the Puller
- T10133B/2A- -2- with the Sliding Hammer - T10133A/3- to
guide in the fuel injector.
– Further installation is in the reverse sequence to removal.

– Install intake manifold with fuel rail, refer to
⇒ “5.7 Fuel Rail”, page 43 .
5.3 Engine Control Module - J623- , Replac‐

ing
♦ Wiring Harness Repair Set - Hot Air Blower - VAS 1978/14A-
with nozzle attachment from the Wiring Harness Repair Set -
VAS1978B- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Commercially available pliers permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Vehicle Diagnostic Tester
Removing
– If the Engine Control Module (ECM) was replaced, then select
“replace engine control module” in “Guided Functions” using
a Engine Control Module - J623- .
– Turn off the ignition and remove the key.
– Pull off rubber seal of plenum chamber cover in direction of
-arrow-.
– Remove plenum chamber cover -1- toward front.
– Pry off both covers -3- using a screwdriver.

– Loosen hex-nuts -4- by several turns.

– Tilt the wiper arm -2- slightly to loosen it from the wiper arm
axle.
– Remove the nuts and the wiper arms.
– Remove securing clips -1- and remove cowl -5-.
– Remove cover for E-Box in plenum chamber, by removing the

bolts -arrows-.
– Carefully pry off the retainer bar with a screwdriver -arrow-.

– To increase the difficulty with which the ECM connectors can

be accessed, the ECM -1- is secured in a metal housing -5-
with retaining tabs -2- and shear bolts -3 and 4-.
WARNING
To prevent damages (burning) of wire and harness connec‐

tions, insulation and control modules, perform the following
work procedures exactly! Observe operating instructions for
heat gun.
– The threads of the shear bolts -4- (that are not screwed into
the ECM) are coated with a locking compound. For this rea‐
son, the threads must be heated with the heat gun to remove
both bolts.
– The threads of both shear bolts -3- (that are screwed into the
ECM) are not coated with a locking compound. The threads in
the ECM housing must not be heated and do not require to be
heated (unintentional heating of the ECM).

– Set the adjustment on the heat gun as shown in the illustration,

with the temperature potentiometer -2- set to maximum heat
and the two-stage airflow switch -3- set to level 3.
Note
♦ Then, the shear bolts are heated with the heat gun. During this
step, the holding effect that the locking compound has on the
shear bolt threads is reduced, thereby allowing the shear bolts
to be unscrewed easier.
♦ Cover all painted components to prevent damage that may be
caused by the heat gun or the locking pliers.
WARNING
By heating the shear bolts, parts of the protective housing are

heated intensely. Do not burn yourself on this! Make sure that
only the shear bolts are heated as much as possible, and not
any of the surrounding parts. Possibly cover these parts.
– Direct the heat gun nozzle at the shear bolt of the retaining
tab.
– Switch on heat gun and heat bolt for approximately 20 to 25

seconds.
– Then grab the bolt head with the locking pliers and unscrew
the shear bolt.
The procedure for the second shear bolt is exactly the same.
– Both bolts that are installed in the ECM do not require heating.
They can be removed without heat.
Then, the ECM can be separated from the protective housing.

– Disengage the connector retainers -arrows- and disconnect

the connectors -1 and 2- from ECM.
– Remove old ECM and install the ECM.
Installing
Install in reverse order of removal. Note the following:
– Afterwards, the Engine Control Module - J623- must be equip‐
ped with the metal retainer again.
– Clean threaded holes for shear bolts of locking compound
residue. Cleaning can be performed with a thread cutter (tap).
– Always use new shear bolts.
Perform the following step after installing a new ECM:
– Activate the ECM in “Guided Functions” under “replace engine
control module”. Use a Vehicle Diagnostic Tester for this.
5.4 Engine Cover

Removing
– Carefully remove engine cover from retaining pins. Do not re‐
move the engine cover on one side or in a jerking manner.
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– In order to prevent causing damage, do notwith
hitrespect
the engine cov‐ of information in this document. Copyright by AUDI AG.
to the correctness
er with your fist or tool.
– Position the engine cover (observe oil filler tube and oil dip‐
stick) on the engine.
– Using both hands, press the engine cover into the rubber
sleeves.
5.5 Fuel Injectors

Removing
Remove the intake manifold and fuel rail, refer to
⇒ “5.11 Intake Manifold with Fuel Rail”, page 48 .
Removing fuel injectors, in the event that they are stuck in the fuel
rail
Carefully pull the fuel injectors out of the fuel rail.
Removing fuel injectors, in the event that they are stuck in the
cylinder head
♦ Injector/Combustion Chamber Seal Tool Set - T10133B-
Note
The Puller - T10133/2- has been changed and has a new identi‐
fication Puller - T10133/2A- . If the new tool is not available, it is
possible to make the change yourself.
Modify the Puller - T10133/2- to create the Puller - T10133/2A- .

♦ Round file approximately 6 mm

– File the semicircle as shown in the illustration. The semicircle

allows the tool to slide farther onto the fuel injector, thus pro‐
viding the tool with a larger contact surface.
– Mark the modified tool with an “A” at the end of the tool num‐
ber.
Remove intake manifold and fuel rail, refer to
The illustration shows the fuel injector.

1 - Radial compensation, replace if damaged
2 - Combustion chamber sealing ring (Teflon® sealing ring), re‐
place, the ring must not be greased or handled with any other
lubricants when installing.
3 - Groove on fuel injector
4 - Spacer Ring (replace if damaged)
5 - O-ring (replace, coat lightly with clean engine oil when instal‐
ling)
6 - Support ring (via this support ring, fuel rail utilizes the force to
hold the fuel injector in place in the cylinder head).
Note
With fuel injector installed, the radial adjustment -1- is clipped into
the support ring -6-. To remove the fuel injector, the support ring
must be separated from the fuel injector in order to install the
Puller - T10133/2- into the indentation on the fuel injector -3-.
– Cover open intake channels with a clean cloth.

– Disconnect electrical harness connector at fuel injector that is
to be removed.
– Bend retaining tabs of radial compensation to the side using

a screwdriver and pull off support ring from fuel injector.

– Position the Puller - T10133/2A- in the groove on the fuel in‐

jector.
– Then position the Injector/Combustion Chamber Seal Tool Set
- 16A - T10133/16A- and remove the fuel injector by loosening
the bolt -1-.
Note
The combustion chamber seal must always be replaced before

re-installing the fuel injector, refer to
page 33 .
5.6 Fuel Pressure Sensor - G247-

♦ Socket - 27mm - T40218- or a commercially available 27 mm
socket
Removing
– Remove the engine cover.
WARNING

⇒ “1.1 Before Opening High Pressure FuelProtected
Injection System”,
page 1 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove the coolant line bolt -arrow- from the intake manifold.
– Disconnect the connector from the Fuel Pressure Sensor -

G247- using the Elbow Assembly Tool - T10118- .
– Remove the Fuel Pressure Sensor - G247- using the Socket
- 27mm - T40218- .
Installing
– Install in reverse order of removal.
– Check the connection tightening specification before installing
the Fuel Pressure Sensor - G247- .
• Fuel Pressure Sensor - G247- tightening specification: Over‐
view - Fuel Rail , refer to
⇒ “2.4 Fuel Rail Overview”, page 16

5.7 Fuel Rail

Adapt the Intake Manifold Runner Position Sensor - G336- to the
Engine Control Module - J623- after removing or replacing the
fuel rail. Use a Vehicle Diagnostic Tester “Guided Functions”.
– Remove the intake manifold, refer to
– Remove hoses from Evaporative Emission (EVAP) canister.
– To do this, open hose clamp -1-.
– Remove both bolts -arrows- from fuel rail.
– Pull the hose connection -1- off from intake manifold and re‐
move both bolts “arrows”.
– Unbolt both fuel lines -2 and 3-.

– Carefully pry off linkage from Intake Flap Motor - V157- -4-.
– Unscrew Intake Flap Motor - V157- bolts -5-.

– Pry fuel rail over retaining tabs “arrows” from intake manifold.
– Remove the fuel rail from the intake manifold.
Installing
– Install the intake manifold, refer to
5.8 Heated Oxygen Sensor - G39- and Oxy‐

gen Sensor Heater - Z19- before Cata‐
lytic Converter
Removing
♦ Ring Wrench 7-Piece Set - 3337-
– Disconnect the connector -1- for the Heated Oxygen Sensor -
G39- and the Oxygen Sensor Heater - Z19- .
– Remove the Heated Oxygen Sensor - G39- -2- using a tool

from the Ring Wrench 7-Piece Set - 3337- .
Installing
Note the following when installing:
Note
♦ Coat new oxygen sensors with an assembly paste. This paste

must not come into contact with oxygen sensor slots.
♦ For a used oxygen sensor, only coat threads with hot bolt
paste. This paste must not come into contact with oxygen
sensor slots. Hot bolt paste, refer to the Parts Catalog.
♦ The oxygen sensor wire must always be attached at the same
location when installing. Do not the electrical wire connection
come in contact with the exhaust pipe.
♦ Tightening specification: 55 Nm

5.9 High Pressure Pump
WARNING
Fuel system is under high pressure! Before opening the sys‐

tem, perform the procedure for releasing fuel pressure, refer to
page 1 .
Note
♦ The high pressure pump can only be removed and installed

when the engine is cold.
♦ When installing, make sure that no dirt enters the fuel system.
♦ Catch escaping fuel with a cloth.
♦ Always replace the O-ring.
♦ Install the fuel high-pressure lines free of tension.
Removing
– Disconnect electrical connectors from Low Fuel Pressure Sen‐
sor - G410- and from Fuel Pressure Regulator Valve - N276-
-1 and 2-.
– Unscrew both fuel lines.

– Remove the 3 bolts -arrows-.

– Carefully pull out the high-pressure fuel pump. The sleeve may
remain inserted in the cylinder head.
Installing
– Insert the undamaged sleeve in the cylinder head.
– Then rotate the camshaft until the sleeve has reached the
lowest point. Put light pressure on the sleeve when doing this.
– Replace the O-ring for the high-pressure pump.
– Carefully insert the high pressure pump in the sleeve in the
cylinder head.
– Tighten the bolts in a diagonal sequence.
– Before installing the fuel lines, check the torque of the con‐
nections on the high-pressure pump.
Fuel return line connection tightening specification: 40 Nm
Fuel supply line connection tightening specification: 30 Nm
Note
Replace the bolt for the fuel return line
– Screw in the bolt for the fuel return line hand-tight. Align so it
is free of stress.
– Tighten the fuel supply line union nut by hand. Align so it is
free of stress.
♦ Fuel return line tightening specification: 25 Nm
♦ Fuel supply line tightening specification: 30 Nm
– Connect electrical connectors on Low Fuel Pressure Sensor -
G410- and for Fuel Pressure Regulator Valve - N276- .
Note
Check fuel system for leaks.

5.10 Intake Flap Motor - V157- with Intake

Manifold Runner Position Sensor -
G336-
For the installed location of the Intake Flap Motor - V157- , Over‐
view - Intake Manifold, refer to
⇒ “2.6 Intake Manifold Overview”, page 20 .
♦ Commercially available 1 / 4 inch ratchet

♦ TORX® 30
Removing
– Remove the engine cover, refer to
⇒ “5.4 Engine Cover”, page 40 .
– Remove the coolant expansion tank -arrow-.
– Open the open hose clamp on the charge air hose -2- and
remove the hose from the Throttle Valve Control Module -
J338- .
– Remove the bolt -1- from the coolant pipe.

– Open the cable ties on the wiring harness on the coolant pipe.

– Remove the bracket -arrows- from the coolant pipe.

– Carefully pry off linkage from Intake Flap Motor - V157- -4-.
– Disconnect all necessary electrical connectors and press the
coolant pipe far enough to the side so the Intake Flap Motor -
V157- bolts can be accessed.
– Unscrew Intake Flap Motor - V157- bolts -5-.
Note
The intake manifold is not shown in the illustration to make it eas‐

ier to see the Intake Flap Motor - V157- .
Installing
5.11 Intake Manifold with Fuel Rail

Adapt the Intake Manifold Runner Position Sensor - G336-
-item 10- to the Engine Control Module - J623- if it has been
removed or replaced. Use a Vehicle Diagnostic Tester “Guided
Functions”
Caution
Before opening a component of the high-pressure section, the

fuel pressure must be released. Pay absolute attention to the
procedure on page, refer to
page 1 .
Note
♦ To access the fuel injectors, the intake manifold and the fuel
rail with intake manifold runner control valve must be removed.
(Depending on version, more or fewer work steps may be re‐
quired).
♦ The combustion chamber seal (Teflon) and the O-ring must
always be replaced.
♦ Adapt the Intake Manifold Runner Position Sensor - G336- to
the Engine Control Module - J623- after removing or replacing
the fuel rail. Use a Vehicle Diagnostic Tester “Guided Func‐
tions”. with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Intake manifold, overview, refer to

⇒ “2.6 Intake Manifold Overview”, page 20 .


♦ Hose Clip Pliers - VAG1921-

♦ Torx Socket - T30 - T10347-
Removing
– Remove the engine cover, refer to
⇒ “5.4 Engine Cover”, page 40 .
– Disconnect all necessary electrical harness connectors.
– Disconnect the vacuum hose between intake manifold and
vacuum pump from intake manifold.
Note
This vacuum hose and the vacuum pump (attached to rear of cyl‐
inder head) are only installed on vehicles with automatic trans‐
mission.
– Disconnect the fuel line -arrow- (catch escaping fuel and plug
the open connections immediately).
– Disconnect hose connections -arrows- from valve cover.
– Remove both bolts -1 and 2- from coolant pipe.

– Remove bolt from oil line -1- and from coolant pipe -2-.
– Remove both fuel lines at high-pressure pump.

– Open the hose clamps and pull the intake hose off from the
Throttle Valve Control Module - J338- and intake manifold.
– Disconnect electrical connector -1- from Fuel Pressure Sensor

- G247- .
– Pull the oil dipstick out and remove the bolt -2- for oil dipstick
guide tube.

– Remove bolt -1- for oil line.
– Remove the nut -arrow- from the intake manifold support (if
necessary, remove Throttle Valve Control Module - J338- to
do this).

– Separate the oil dipstick guide tube -2- at the separation point
and remove the bolt -1- for intake manifold bracket.
– Remove the intake manifold bolts using Torx Socket - T30 -
T10347- .
Note
The Throttle Valve Control Module - J338- must be removed in

order to remove any inaccessible bolts when not using the Torx
Socket - T30 - T10347- .
– Remove the intake manifold and fuel rail from the cylinder
head.
Note
The fuel injectors could remain stuck in the fuel rail.
– Fuel rail, removing and installing ⇒ “5.7 Fuel Rail”, page 43

Installing
Tightening Specification Nm
Intake Manifold Bolts 9
Intake manifold support bolt 23
Intake manifold support nut 10
Fuel supply line to high pres‐ 30
sure pump Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Fuel return line to high pressure
permitted unless authorised by AUDI 25AG. AUDI AG does not guarantee or accept any liability
pump (replace) with respect to the correctness of information in this document. Copyright by AUDI AG.
Intake Flap Motor - V157- bolts 7
5.12 Mass Airflow Sensor - G70-

Removing
– Disconnect the connector -1- from the Mass Airflow Sensor -
G70- .

– Unscrew both bolts -arrows- of the air duct at the lock carrier.
– Disconnect air duct -2- from air filter housing.
– Open the hose clamp on air duct hose to turbocharger and pull
it off at Mass Airflow Sensor - G70- .
– Remove both bolts from Mass Airflow Sensor - G70- .
– Carefully pull the Mass Airflow Sensor - G70- out of the guide
from air filter housing.
Installing
For problem-free operation of the Mass Airflow Sensor - G70- it
is very important to observe the following notes and procedures.
Note
♦ If the air filter is very dirty or soaked, dirt particles or moisture

may have contaminated the Mass Airflow Sensor - G70- and
may be causing false mass airflow values. This results in a
reduction of power, since a lower injection quantity is calcula‐
ted.
♦ Always use an original air filter.
♦ Use a silicone-free lubricant for installing the air guide hose.
♦ Secure all hose connections using hose clamps appropriate
for the model type, refer to the Parts Catalog.
– Check the Mass Airflow Sensor - G70- and air duct hose (in‐
take air side) for salt residue, dirt, and leaves.
– Check the intake channels up to the air filter for dirt. If any
contaminants are discovered, clean the air filter housing (up‐
per and lower parts) of salt residue, dirt and leaves (if neces‐
sary, clean by washing or vacuuming). Air filter, removing and
installing, refer to ⇒ “5.1 Air Filter”, page 32 .
5.13 Oxygen Sensor after Three Way Cata‐

lytic Converter - G130-
permittedand Heater
unless authorised ForAG. AUDI AG does not guarantee or accept any liability
by AUDI
Oxygen Sensor 1 after Catalytic Con‐
verter - Z29-
Removing
– Disconnect electrical connector -2- (brown connector) on the
Oxygen Sensor after Three Way Catalytic Converter - G130- .

– Remove the Oxygen Sensor after Three Way Catalytic Con‐

verter - G130- -1- using a tool from the Ring Wrench 7-Piece
Set - 3337- .
Installing
Note the following when installing:
Note
♦ New oxygen sensors are coated with assembly paste; the

paste must not get into slots of oxygen sensor body.
♦ For a used oxygen sensor, only coat threads with hot bolt
paste. This paste must not come into contact with sensor slots.
Hot bolt paste, refer to the Parts Catalog.
♦ Wiring connection of oxygen sensor must always be secured
in the same position when installing so that contact with the
exhaust pipe is avoided.

6 Special Tools
♦ Injector/Combustion Chamber Seal Tool Set - T10133B-
♦ Torx Socket - T30 - T10347-
♦ Reversing Light Switch Connector Release Tool - T40138- .
6. Special Tools 55
♦ Socket - 27mm - T40218-
♦ Fuel Injection Gauge Kit - VAG1318-

♦ Injection Rate Comparison Meter Kit - Remote Cable -
VAG1348/3A- with Injection Rate Kit - Remote Cable -
VAG1348/3-3-
♦ Adapter Cable, 60-pin - VAG1598/39-1-

♦ Test Box Kit - 94 Pin Adapter - VAG1598/39-2-
♦ Test Box Kit - 105 Pin Test Box Kit - VAG1598/42-

♦ Hose Clip Pliers - VAG1921-
♦ Wiring Harness Repair Set - Hot Air Blower - VAS 1978/14A-

-1- with nozzle attachment -2- from the Wiring Harness Repair
Set - VAS1978B- .
♦ Commercially available pliers -3-

♦ Hand Vacuum Pump - VAS6213-
6. Special Tools 57
28 – Ignition/Glow Plug System

1 General Information
⇒ “1.1 Ignition System”, page 58
⇒ “1.2 Safety Precautions”, page 58
1.1 Ignition System

♦ The Engine Control Module (ECM) is equipped with On Board
Diagnostics (OBD).
♦ For the electric components to work properly, a voltage of at
least 11.5 Volts is required.
♦ It is possible that the control module will recognize a malfunc‐
tion and store a Diagnostic Trouble Code (DTC) during some
tests. After completing all checks and repairs, check the DTC
memory and erase the memory, if necessary.
♦ If the engine only starts briefly and then turns off again after
troubleshooting, repair or checking of the components, it may
be that the immobilizer is blocking the ECM. DTC memory
must then be checked and if necessary, control module must
be adapted.
1.2 Safety Precautions

If special testing equipment is required during road test, note the
following:
WARNING
Improperly secured testing and measuring equipment and dis‐

traction during a road test increase the risk of an accident.
The passenger airbag could pose a risk if it deploys in a colli‐
sion.
• Operating testing equipment while driving causes it to shift
position.
• There is an increased risk of injury due to unsecured test‐
ing equipment. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Always secure testers on the rear seat with a strapwith
and respect to the correctness of information in this document. Copyright by AUDI AG.
have a second person on the rear seat operate them.
To reduce the risk of personal injury and/or damage to the fuel

injection and ignition system, always observe the following:
♦ Do not touch or remove ignition wires when engine is running
or turning at starter speed.
♦ Always switch ignition off before disconnecting or reconnect‐
ing wires for the ignition system, including high voltage wiring
and test leads.
example for compression testing), disconnect connectors from
ignition coils and from fuel injectors. After performing work,
check and erase Diagnostic Trouble Code (DTC) memory.
♦ Cleaning the engine should only be performed with ignition
switched off.
58 Rep. Gr.28 - Ignition/Glow Plug System

2 Description and Operation

⇒ “2.1 Ignition System Overview”, page 59
2.1 Ignition System Overview
1 - Knock Sensor 1 - G61- and

Knock Sensor 2 - G66-
❑ Contacts gold plated
ling, refer to
⇒ “4.2 Knock Sensor 1
G61 and Knock Sensor
2 G66 ”, page 62 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Ignition Coil with Power with respect to the correctness of information in this document. Copyright by AUDI AG.
Output Stage - (N70, N127,

N291, N292)-
ling, refer to
⇒ “4.1 Ignition Coils with
Power Output Stages”,
page 61
❑ To remove, use the Pull‐
er - Ignition Coil -
T40039-
3 - Spark Plug
❑ 30 Nm
ling, refer to ⇒ Mainte‐
nance Procedures;
Rep. Gr. 03
4 - Bolt
❑ 20 Nm
❑ Tightening specifica‐
tions affect function of
Knock Sensors (KS)
5 - Bolt
❑ 10 Nm
6 - Camshaft Position Sensor -
G40-
❑ Contacts gold plated
7 - O-Ring
❑ If damaged, replace O-ring
8-

3 Specifications
⇒ “3.1 Fastener Tightening Specifications”, page 60
⇒ “3.2 Ignition System, Technical Data”, page 60
3.1 Fastener Tightening Specifications

Component Fastener Size Nm
Camshaft Position Sensor - 10
Knock Sensor - 20
Spark Plug - 30
3.2 Ignition System, Technical Data

Engine Data 2.0L / 125 kW / 147 kW / 162 KW
Turbo FSI Engine
Idle speed 640 to 800 RPM
Idle speed cannot be adjusted, it is regulated by
idle stabilization
RPM limited by switching off fuel injectors and approximately 6500 RPM
closing throttle valve
Ignition timing is regulated by control module. It is
not possible to adjust the ignition timing.
Ignition System Single coil ignition system with four ignition coils (output
stages integrated) that are connected directly to the
spark plugs via the spark plug connectors. The ignition
coils can be pulled out of the cylinder head using the
Puller - Ignition Coil - T40039- .
Ignition sequence 1-3-4-2

4 Removal and Installation

⇒ “4.1 Ignition Coils with Power Output Stages”, page 61
⇒ “4.2 Knock Sensor 1 G61 and Knock Sensor 2 G66 ”,
page 62
4.1 Ignition Coils with Power Output Stages

♦ Puller - Ignition Coil - T40039-
Removing
– Remove both bolts -1- of the connector strip.
– Pull all ignition coils approximately 30 mm out of spark plug

shaft using Puller - Ignition Coil - T40039- .
– Release the connectors and pull all connectors simultaneously

off from the ignition coils.
Installing
– Insert all ignition coils loosely into spark plugbyshaft.
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not

– Align the ignition coils to the connectors and then connect all
of the connectors simultaneously onto the ignition coils.
– Press the ignition coils uniformly onto the spark plugs by hand
(do not use any impact tools).
4.2 Knock Sensor 1 - G61- and Knock Sen‐

sor 2 - G66-
Removing
– Remove the intake manifold, refer to
Note
If necessary remove the thermostat.
– Disconnect the connector from each Knock Sensor (KS).
Note
The KS is located under the intake manifold.
Knock Sensors
– Remove each KS.
Installing
– Install intake manifold, refer to
Tightening specification
• Overview - ignition System, refer to
⇒ “2.1 Ignition System Overview”, page 59 .

5 Special Tools
♦ Puller - Ignition Coil - T40039-
Edition A0059205921 FU and LF 992808, 03/04/2014 - JLH
5. Special Tools 63
6 Revision History
Re Dat Job Type Feedback # Notes Editor
vi‐ e
sio
n
3
2
1 3/4/ 992808 N/A Jim
201 Harder
4

Cautions & Warnings
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.
=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
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.
=Page 2 of 3
Version 1.0
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.
=Page 3 of 3
Version 1.0

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Copyright © 2014 Audi AG, Ingolstadt D3E8001FE53

24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4.2 Knock Sensor 1 G61 and Knock Sensor 2 G66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

24 – Multiport Fuel Injection

1.1 Before Opening High Pressure Fuel In‐

♦ The fuse is located in the fuse carrier in the instrument panel.

The fuel injection system is divided into a high pressure section

High Fuel Pressure, Reducing

Special tools and workshop equipment required

– Use the Elbow Assembly Tool - T10118- to remove the elec‐

♦ By removing the electrical connector from the Fuel Pressure

– Switch off ignition.

– After reducing high pressure, high pressure system can be

If the high pressure line isProtected

– Connect a Vehicle Diagnostic Tester and generate the readi‐

2 Rep. Gr.24 - Multiport Fuel Injection

1.2 Clean Working Conditions

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

♦ Always follow the instructions when disconnecting the bat‐

Even a little contamination can lead to faults. When working on

1.3 Ignition System Safety Precautions

injection and ignition system, always observeofthe following:

♦ Individuals with a pacemaker must not stay in the danger area

♦ If engine is to be cranked at starting RPM without starting (for

1.4 On Board Diagnostics (OBD) General

4 Rep. Gr.24 - Multiport Fuel Injection

1.5 Safety Precautions, Test and Measuring

Improperly secured testing and measuring equipment and dis‐

2 Description and Operation

2.1 Air Filter

6 Rep. Gr.24 - Multiport Fuel Injection

15 - Lower Air Filter Housing Section

2.2 Component Location Overview

1 - Mass Airflow Sensor - G70-

2. Description and Operation 7

8 Rep. Gr.24 - Multiport Fuel Injection

18 - Fuel Pressure Sensor - G247-

B - Fuel Pump Control Module - J538-

2. Description and Operation 9

J - Relay and Fuse Carrier in E-Box

M - Knock Sensor 1 - G61-

Fuel Pressure Sensor - G247- -1-

10 Rep. Gr.24 - Multiport Fuel Injection

Camshaft Position Sensor - G40- -1-

Mass Airflow Sensor - G70- -1-

Camshaft Adjustment Valve 1 - N205- -1- and Fuel Pressure

Intake Air Temperature Sensor - G42- -1- Throttle Valve Control

2. Description and Operation 11

Fuel Pump Control Module - J538- -1-

Installed Location of Engine Control Module - J623-

12 Rep. Gr.24 - Multiport Fuel Injection

Engine Coolant Temperature Sensor - G62- -1-

Component Location of Brake Lamp Switch - F- and Brake Pedal

To ensure that they are absolutely securely seated, the switches

Installed Location in 4-Socket Relay Carrier, Plenum Chamber E-