Manual Reparație Audi

Service
Workshop Manual
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.
Audi A3 2004 ➤
Audi A3 Sportback 2005 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-
valve common rail)
Engine ID
CBA CBA CBB CBE
A B B A
Edition 03.2018
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
23 - Mixture preparation - injection
28 - Glow plug system
Technical information should always be available to the foremen and mechanics, because their
careful and unless
constant adherence to AG
thedoesinstructions
not guarantee or is essential
any liability to ensure vehicle road-worthiness and
permitted authorised by AUDI AG. AUDI accept
safety. with
In respect
addition, the normal
to the correctness basic
of information in thissafety
document. precautions
Copyright by AUDI AG. for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Audi AG, Ingolstadt A0050478920

Audi A3 2004 ➤ , Audi A3 Sportback 2005 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail) - Edition 03.2018
Contents
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety precautions and rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when using testers and measuring instruments during a road test . . . . 1
1.2 Safety precautions for vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when working on the injection and glow plug system . . . . . . . . . . . . . . 3
1.5 Safety precautions when working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 System layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Exploded view - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5 Filling and bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.1 Exploded view - air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.3 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.4 Removing air cleaner (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.1 Exploded view - intake manifold with attached components . . . . . . . . . . . . . . . . . . . . . . . . 31
8.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.3 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.4 Removing and installing intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.5 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.1 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.1 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.2 Performing adaption of correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.3 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.4 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.5 Checking return flow rate of injectors at starter cranking speed . . . . . . . . . . . . . . . . . . . . 52
10.6 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
11.1 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
11.2 Installing high-pressure pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
11.3 Checking pressure retention valve in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
11.4 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.5 Checking fuel pressure (low pressure) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11.6 Checking delivery rate of fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.7 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 69
11.8 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
12 Protected
Lambda probe
by copyright. Copyingand exhaust
for private gas temperature
or commercial sensors
purposes, in part or in whole, is(CBAA,
not CBAB, CBBB) . . . . . . . . . . 76
12.1 Exploded view - Lambda probe and exhaust gas temperature
sensors .............. 76
12.2 Removing and installing Lambda probe G39 with Lambda probe heater Z19 . . . . . . . . . . 77
12.3 Removing and installing exhaust gas pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . 78
13 Lambda probe and exhaust gas temperature sensors (CBEA) . . . . . . . . . . . . . . . . . . . . . . 80
13.1 Exploded view - Lambda probe and exhaust gas temperature sensors . . . . . . . . . . . . . . 80
13.2 Removing and installing Lambda probe G39 with Lambda probe heater Z19 . . . . . . . . . . 83
13.3 Removing and installing Lambda probe after catalytic converter G130 with Lambda probe 1
heater after catalytic converter Z29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Contents i
13.4 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 87

13.5 Removing and installing exhaust gas pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . 88
13.6 Removing and installing control pipe for pressure sensors . . . . . . . . . . . . . . . . . . . . . . . . 89
13.7 Removing and installing control pipe for exhaust gas pressure sensor 1 G450 . . . . . . . . 92
14 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
14.1 Wiring and component check with test box V.A.G 1598/42 . . . . . . . . . . . . . . . . . . . . . . . . 95
14.2 Renewing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1 ...................................................................... 101
1.1 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.2 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 105
1.3 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.4 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
ii Contents
23 – Mixture preparation - injection

1 Safety precautions and rules for
cleanliness
(ARL005711; Edition 03.2018)
Overview
⇒ “1.1 Safety precautions when using testers and measuring in‐
struments during a road test”, page 1 by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
⇒ “1.2 Safety precautions for vehicles withtostart/stop
with respect the correctnesssystem”,
of information in this document. Copyright by AUDI AG.
page 1
⇒ “1.3 Safety precautions when working on the fuel system”, page
2
⇒ “1.4 Safety precautions when working on the injection and glow
plug system”, page 3
⇒ “1.5 Safety precautions when working on the exhaust system”,
page 4
⇒ “1.6 Checking vacuum system”, page 4
1.1 Safety precautions when using testers

and measuring instruments during a
road test
Please note the following if testers and measuring instruments
have to be used during a road test:
Risk of injury if test equipment is not secured
If an accident occurs and the front passenger's airbag is triggered,
test equipment which is not secured adequately may be catapul‐
ted through the vehicle with potentially serious consequences.
– Secure test equipment on the rear seat with a strap.
Or:
– Have a second mechanic operate test equipment on the rear
seat.
1.2 Safety precautions for vehicles with

start/stop system
When performing repairs on vehicles with start/stop system, note
the following:
Risk of injury - engine may start unexpectedly
The engine can start unexpectedly if the vehicle's start/stop sys‐
tem is activated. A message in the instrument cluster indicates
whether the start/stop system is activated.
– To deactivate the start/stop system, switch off the ignition.
1. Safety precautions and rules for cleanliness 1

1.3 Safety precautions when working on the

fuel system
When working on the fuel system note the following warnings:
Risk of fire due to escaping fuel
If the battery is connected, the door contact switch activates the
fuel pump when the driver's door is opened. Escaping fuel may
ignite, causing a fire.
– Before opening the fuel system, disconnect power supply to
fuel pump.
Risk of injury - fuel system operates under high pressure

The fuel system is pressurised. There is a risk of injury as fuel
may spray out.
Before opening the fuel system:
– Put on safety goggles.
– Put on protective gloves.
– Release pressure (wrap a clean cloth around connection and
open connection carefully).
If components of the fuel system between the fuel tank and the
high-pressure pump are removed or renewed, the fuel system
must be bled ⇒ page 24 .
Risk of irreparable damage to fuel pump
After working on the fuel system, the fuel pump may be irreparably
damaged if it is allowed to run while empty.
– Never allow fuel pump to run while it is empty.
– Fill/bleed fuel pump.
• Clean tools and workbench etc. before working on the injection

system.
• Clean connections and surrounding area thoroughly with en‐
gine cleaner or brake cleaner and dry cleaned area before
loosening.
• When removing components, plug all open connections im‐
mediately with suitable clean sealing caps.
• Do not remove sealing caps from components until immedi‐
ately prior to installation. Keep components that are to be re-
used in new, sealable plastic bags.
• Before installing, check the injectors and their surroundings
visually; they must be undamaged and clean. Make sure the
injector bores in the cylinder head are clean. Wipe out if nec‐
essary using a clean cloth, taking care not to cause damage.
Do not use sharp objects of any kind.
2 Rep. gr.23 - Mixture preparation - injection

• If the high-pressure fuel lines are to be re-used, you must mark

them before removal. High-pressure pipes must always be re-
installed on the same cylinder.
• Take care not to damage the injectors when removing the old
copper seals.
• Check all new O-rings for damage before installing. Lubricate
O-rings with engine oil or assembly oil before installing.
• Position high-pressure pipes so they are free of stress. Tighten
all unions lightly to start with before tightening to final torque.
• Never attempt to bend high-pressure fuel lines to shape.
• When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
• Press the fuel return hoses onto the injectors by hand from
above so that they engage audibly on each injector (do not
press in the release pins when doing this). Then press down
the release pin after connecting the return line. Check that the
fuel return hoses are seated securely by pulling them by hand
from above. Also check that they seal properlyProtected
(fuel pressure
by copyright. Copying for private or commercial purposes, in part or in whole, is not
in return line as far as pressure retention valve: permitted
between 8 and
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
10 bar).
• Do not dismantle individual common rail components. If there

is a fault, the complete components must be renewed.
• When the engine is running, do not perform any repairs to the
common rail system.
• Do not bleed the common rail system by unfastening high-
pressure components after the engine has been started.
• All cable ties which are released or cut open when removing
must be refitted in the same position when installing.
• When the fuel system is open: Do not work with compressed
air if this can be avoided. If possible, do not move vehicle.
• Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.

injection and glow plug system
To prevent injuries to persons and/or damage to the fuel injection
and glow plug system, note the following:
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as
piezo systems and xenon headlights.
♦ Always switch off the ignition before connecting or discon‐
necting tester cables or electrical wiring for the injection or
glow plug system.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off ignition before washing engine.
♦ Certain tests may lead to faults being detected and stored by
the engine control units. Therefore the event memory must be
interrogated after completing all tests and repair work (“Inter‐
rogate event memory”).


exhaust system
Do not dismantle exhaust gas temperature sender - risk of injury.
Risk of injury when disconnecting the exhaust system
There is a risk of eye irritation caused by soot particles in the air.
– Put on safety goggles.
Danger from toxic exhaust gases

Auxiliary/supplementary heater produces toxic exhaust gases.
There is a risk of poisoning and of damage to the respiratory tract.
– In enclosed spaces, only switch on the auxiliary/supplemen‐
tary heater if there is an exhaust extraction system.
– In enclosed spaces without an exhaust extraction system,
switch off the auxiliary/supplementary heater.
Risk of damage to flexible joint

The flexible joint can be damaged or develop leaks if it is handled
incorrectly.
– Do not bend flexible joint more than 10°.
– Install flexible joint so that it is not under tension.
1.6 Checking vacuum system

Special tools and workshop equipment required
♦ Hand vacuum pump - VAS 6213-
Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites
♦ Kinked or crushed lines

♦ Porous or leaking lines

– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
– If a fault is stored in the event memory, check all vacuum lines
leading to the corresponding component, and also check the
remaining vacuum lines leading to other components.
– If it is not possible to build up pressure with the hand vacuum
pump - VAS 6213- or if the pressure drops again immediately,
check the hand vacuum pump and connecting hoses for leaks.

2 Overview of fitting locations - injec‐

tion system
Components A to N are not shown on the exploded view.
1 - Pressure sensor
❑ On vehicles with engine
codes CBAA, CBAB
and CBBB, the compo‐
nent's designation is ex‐
haust gas pressure sen‐
sor 1 - G450-
❑ Removing and installing
⇒ page 87
❑ On vehicles with engine
code CBEA, the compo‐
nent's designation is
pressure differential
sender - G505-
⇒ page 87
❑ Fitting location
⇒ page 14
❑ Adaption must be per‐
formed after renewing
this component
2 - Hall sender - G40-
⇒ page 14
⇒ page 106
❑ 10 Nm
3 - Lambda probe - G39- with
Lambda probe heater - Z19-
⇒ page 16
⇒ page 77

(CBEA) ⇒ page 83
❑ 50 Nm
4 - Engine control unit - J623-
❑ Fitting location ⇒ page 10
❑ Removing and installing ⇒ page 95
5 - Injectors
6 - Position sender for charge pressure positioner - G581-
7 - Pressure retention valve
❑ The pressure retention valve maintains a residual pressure of approx. 10 bar in the return lines
❑ This residual pressure is required for the control function of the injectors
❑ The pressure retention valve may only be renewed together with the fuel return lines
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system
❑ Checking pressure retention valve ⇒ page 63
8 - Fuel pressure regulating valve - N276-
❑ Checking ⇒ page 65
❑ 80 Nm
9 - Charge pressure control solenoid valve - N75-
❑ Electrical connector for exhaust gas temperature sender 3 - G495-
10 - Electrical connector
❑ For exhaust gas temperature sender 4 - G648-
❑ For exhaust gas temperature sender 1 - G235-
❑ For Lambda probe - G39-
11 - Air mass meter - G70-
12 - Coolant temperature sender - G62-
❑ Removing and installing ⇒ Rep. gr. 19
13 - Engine speed sender - G28-
❑copyright.
Protected by Fitting location
Copying ⇒ page
for private 15 purposes, in part or in whole, is not
or commercial
❑ to4.5
with respect Nm
the correctness of information in this document. Copyright by AUDI AG.
14 - Component on side of intake manifold

❑ Variable intake manifold motor - V183- (engine codes CBAA, CBAB, CBBB only)
❑ Intake manifold flap motor - V157- (engine code CBEA only)
15 - Exhaust gas recirculation cooler change-over valve - N345-
❑ Engine codes CBAA, CBAB, CBBB only
16 - Pump for exhaust gas recirculation cooler - V400-
2. Overview of fitting locations - injection system 7

17 - Component on front of intake manifold

❑ Intake manifold flap motor - V157- with throttle valve potentiometer - G69- (engine codes CBAA, CBAB,
CBBB only)
❑ Throttle valve module - J338- (engine code CBEA only)
❑ Exploded view - intake manifold ⇒ page 31
18 - Charge pressure sender - G31-
❑ Combined with intake air temperature sender - G42-
19 - Glow plugs
❑ Glow plug 1 - Q10-
❑ Removing and installing ⇒ page 102 by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
20 - Fuel temperature sender - G81- in with
fuelrespect
supplyto theline
correctness of information in this document. Copyright by AUDI AG.
21 - Exhaust gas recirculation
❑ Exhaust gas recirculation valve - N18- with exhaust gas recirculation potentiometer - G212- (engine
codes CBAA, CBAB, CBBB only)
❑ Exhaust gas recirculation control motor - V338- with exhaust gas recirculation potentiometer - G212-
(engine code CBEA only)
22 - Fuel return line connection to fuel filter
23 - Fuel supply line connection (high-pressure pipe) to fuel rail (high-pressure reservoir)
24 - High-pressure fuel pump with fuel metering valve - N290-
❑ Do not open fuel metering valve - N290-
❑ After renewing, first fuel filling MUST be performed (it is important not to allow pump to run while it is still
empty) ⇒ page 24
25 - Fuel pressure sender - G247-
❑ 100 Nm
26 - Radiator outlet coolant temperature sender - G83-
❑ Fitting location (engine codes CBAA, CBAB, CBBB only) ⇒ page 15
❑ Fitting location (engine code CBEA only) ⇒ page 15
27 - Supplementary fuel pump - V393-
28 - Fuel filter
❑ Exploded view - fuel filter ⇒ Rep. gr. 20
❑ Renewing fuel filter ⇒ Rep. gr. 20
A - Low heat output relay - J359- and high heat output relay - J360-
❑ Fitting location ⇒ Current flow diagrams, Electrical fault finding and Fitting locations

B - Brake light switch - F- and brake pedal switch - F47-

❑ In footwell on brake pedal
C - Clutch position sender - G476-
❑ Only fitted on vehicles with manual gearbox
D - Accelerator position sender - G79- and accelerator position sender 2 - G185-
E - Exhaust gas recirculation temperature sensor - G98- (engine code CBEA only)
❑ Is screwed into housing for exhaust gas recirculation
❑ Electrical connector ⇒ page 16
F - Exhaust gas recirculation control motor - V338- with exhaust gas recirculation potentiometer 2 - G466-
❑ Is screwed into housing for exhaust gas recirculation
G - Exhaust gas pressure sensor 1 - G450- (engine code CBEA only)
H - Exhaust gas temperature sender 1 - G235-
❑ Exploded view - Lambda probes and exhaust gas temperature sensors ⇒ page 76
I - Exhaust gas temperature sender 2 - G448- (engine code CBEA only)
❑ Fitting location of electrical connector ⇒ page 13
J - Exhaust gas temperature sender 3 - G495-
❑ permitted
Removing and installing
unless authorised by AUDI AG. ⇒AUDI
Rep. gr. not
AG does 26guarantee or accept any liability
K - Exhaust gas temperature sender 4 - G648-
L - Lambda probe after catalytic converter - G130- (engine code CBEA only)
❑ Fitting location of electrical connector ⇒ page 17
M - Exhaust flap control unit - J883- (engine code CBEA only)
N - Particulate filter
❑ Fitted on underbody
❑ Combined with a catalytic converter
❑ Adaption must be performed after renewing this component

Fitting location of engine control unit - J623-

Removing and installing ⇒ page 97
Accelerator position sender - G79- and accelerator position send‐

er 2 - G185-
Removing and installing ⇒ Rep. gr. 20
Note
The accelerator position sender - G79- and accelerator position

sender 2 - G185- are integrated in the accelerator pedal module
and cannot be renewed individually.
Brake light switch - F- and brake pedal switch - F47- -1-

♦ On brake master cylinder

Clutch position sender - G476-

♦ On clutch master cylinder -arrow-.
Integrated functions: clutch pedal switch for engine start - F194-
and clutch pedal switch - F36- (manual gearbox only)
Fuel system pressurisation pump - G6-

Charge pressure sender - G31- with intake air temperature send‐

er - G42- -1-

Fitting locations
3 - (Engine codes CBAA, CBAB, CBBB) variable intake manifold
motor - V183- with variable intake manifold position sender -
G513-
3 - (Engine code CBEA) intake manifold flap motor - V157- with
intake manifold flap potentiometer - G336-
4 - (Fitting location only applies for engine codes CBAA, CBAB,
CBBB) exhaust gas recirculation cooler changeover valve - N345-
5 - (Engine codes CBAA, CBAB, CBBB) intake manifold flap mo‐
tor - V157- with throttle valve potentiometer - G69-
5 - (Engine code CBEA) throttle valve module - J338-
6 - Exhaust gas recirculation valve - N18- with exhaust gas recir‐
culation potentiometer - G212-
6 - (Engine code CBEA) exhaust gas recirculation control motor
- V338- with exhaust gas recirculation potentiometer - G212-
7 - Fuel temperature sender - G81-
8 - Fuel metering valve - N290-
Components at front of engine

1 - Electrical connector for Hall sender - G40-
2 - (Fitting location only applies for engine codes CBAA, CBAB,
CBBB) exhaust gas recirculation cooler changeover valve - N345-
3 - (Engine codes CBAA, CBAB, CBBB) variable intake manifold
motor - V183-
3 - (Engine code CBEA) intake manifold flap motor - V157-
Components on engine
1 - (Engine codes CBAA, CBAB, CBBB)
permitted exhaust gasbypressure
unless authorised AUDI AG. AUDI AG does not guarantee or accept any liability
sensor 1 - G450- with respect to the correctness of information in this document. Copyright by AUDI AG.
1 - (Engine code CBEA) pressure differential sender - G505-

2 - Position sender for charge pressure positioner - G581-
4 - Injectors (N30 to N32)

Injectors
1 - Injector, cylinder 1 - N30-
Fitting locations and connectors (engine codes CBAA, CBAB,

CBBB)
1 - For charge pressure control solenoid valve - N75-
2 - For exhaust gas temperature sender 4 - G648-
4 - For Lambda probe - G39-
For fitting locations for vehicles with engine code CBEA, see next
illustration.
Fitting locations and connectors (engine code CBEA)

1 - For charge pressure control solenoid valve - N75-
4 - For Lambda probe - G39-

Pump for exhaust gas recirculation cooler - V400-
Hall sender - G40-
Pressure sensor
On vehicles with engine codes CBAA, CBAB and CBBB, the
component's designation is exhaust gas pressure sensor 1 -
G450-
On vehicles with engine code CBEA, the component's designa‐
tion is pressure differential sender - G505-
Exhaust gas pressure sensor 1 - G450- -3- (engine code CBEA)

Radiator outlet coolant temperature sender - G83- (engine codes

CBAA, CBAB, CBBB)
Radiator outlet coolant temperature sender - G83- (engine code

CBEA)
Coolant temperature sender - G62- -2-

Engine speed sender - G28- -arrow-

Electrical connectors
1 - Exhaust gas recirculation temperature sensor - G98-
2 - Crankcase breather hose
3 - Heating element for crankcase breather - N79-
4 - Bolt
Components at rear of engine

1- Exhaust gas temperature sender 1 - G235-
2- Exhaust gas temperature sender 4 - G648-
3- Vacuum unit for exhaust gas recirculation cooling system
Components in particulate filter (engine codes CBAA, CBAB,

CBBB)
1 - Exhaust gas temperature sender 3 - G495-
3 - Lambda probe - G39-
Components in particulate filter (engine code CBEA)

1 - Lambda probe - G39-
3 - Exhaust gaspermitted
temperature sender
unless authorised 3 - AG.
by AUDI G495-
AUDI AG does not guarantee or accept any liability
4 - Exhaust gas pressure sensor 2 - G451-

Exhaust flap control unit - J883- (engine code CBEA)
Fitting locations and connectors (engine code CBEA)

2 - Bracket
3 - Lambda probe after catalytic converter - G130-
Exhaust gas temperature sender 4 - G648- -1-
Electrical wiring -arrow- of Lambda probe after catalytic converter

- G130- (engine code CBEA)

3 System layout
WARNING
♦ Always read rules for cleanliness and instructions for

working on fuel system ⇒ page 2 .
♦ Follow these instructions and rules for cleanliness before
starting work and while working on the fuel system.
Caution
The high-pressure fuel pump has very close tolerances and

must not be allowed to run without fuel. To prevent this and to
enable the engine to start quickly after parts have been re‐
newed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank
and the high-pressure fuel pump are removed or renewed,
the first fuel filling must be performed.
♦ If a fuel pump,
permitted fuel
unless line (between
authorised by AUDI AG. fuel tank
AUDI AG and
does high-pres‐
not guarantee or accept any liability
sure fuelwithpump) orthefuel
respect to filter ofisinformation
correctness removed ordocument.
in this renewed, the by AUDI AG.
Copyright
fuel system must be bled before the engine is started for
the first time.
♦ If the high-pressure fuel pump is removed or renewed, the
the first time.
Procedure for first fuel filling ⇒ page 24
Note
The high-pressure pump will be damaged if the first fuel filling

procedure is not performed.

1 - Fuel tank
❑ With fuel system pres‐
surisation pump - G6-
2 - Fuel filter
❑ Exploded view - fuel fil‐
ter ⇒ Rep. gr. 20
❑ Renewing fuel filter ⇒
Rep. gr. 20
3 - Supplementary fuel pump -
V393-
4 - Filter strainer
5 - Fuel temperature sender -
G81-
6 - High-pressure pump
❑ After renewing, first fuel
filling operation MUST
be performed (it is im‐
portant not to allow
pump to run while it is
still empty) ⇒ page 24
⇒ page 45
7 - Fuel metering valve - N290-
❑ Do not unscrew
8 - Fuel pressure regulating
valve - N276-
❑ 80 Nm
❑ Cannot be re-installed
⇒ page 69
9 - Fuel rail
❑ 100 Nm
11 - Pressure retention valve
❑ The pressure retention valve maintains a residual pressure of approx. 10 bar in the return lines.
❑ This residual pressure is required for the control function of the injectors
❑ The pressure retention valve may only be renewed together with the fuel return lines.
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system
valve ⇒
❑ Checking pressure retention Protected by page 63
copyright. Copying for private or commercial purposes, in part or in whole, is not
12 - Injectors with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Injector, cylinder 1 - N30-
3. System layout 19
4 Exploded view - fuel system
WARNING

Caution
The high-pressure fuel pump has very close tolerances and

must not be allowed to run without fuel. To prevent this and to
enable the engine to start quickly after parts have been re‐
newed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank
and the high-pressure fuel pump are removed or renewed,
the first fuel filling must be performed.
♦ If a fuel pump, fuel line (between fuel tank and high-pres‐
sure fuel pump) or fuel filter is removed or renewed, the
the first time.
♦ If the high-pressure fuel pump is removed or renewed, the
the first time.
Procedure for first fuel filling ⇒ page 24
Note
The high-pressure pump will be damaged if the first fuel filling

procedure is not performed.

1 - Bolt
❑ 10 Nm
2 - High-pressure pipe
❑ 25 Nm
❑ Between high-pressure
pump and fuel rail
3 - Fuel return lines
❑ To fuel tank
❑ Fuel return line must not
be kinked, damaged or
clogged
❑ The fuel return lines
must not be dismantled;
if necessary they must
be renewed complete
with pressure retention
valve.
❑ The pressure retention
valve maintains a resid‐
ual pressure of approx.
10 bar in the return lines.
❑ This residual pressure is
required for the control
function of the injectors
❑ Checking pressure re‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
tention valve
⇒ page 63
❑ After replacement, en‐
gine must be run at
idling speed for approx.
2 minutes to bleed fuel
system; then check fuel
return lines for leaks
4 - Bolt
❑ 10 Nm
5 - High-pressure pipes
❑ 25 Nm
❑ Between fuel rail and injectors
❑ Do not interchange
❑ Install free of stress
Note
♦ Note identification marks for cyl‐

inder allocation when re-instal‐
ling high-pressure pipes.
♦ The high-pressure pipes can be
re-used after performing the fol‐
lowing checks:
♦ Check taper seats of high-pres‐
sure pipes for deformation and
cracks.
♦ The bore of the pipe must not be
distorted, restricted or otherwise
damaged.
♦ Corroded pipes must not be
used again.
4. Exploded view - fuel system 21


❑ Cannot be re-installed
❑ Remove and install using open-end spanner insert, 30 mm - T10553-
❑ 80 Nm
7 - Fuel rail
8 - Fuel supply line
9 - High-pressure pump
❑ With fuel metering valve - N290- (do not open)
10 - Bolt
❑ Renew
❑ 20 Nm
❑ Turn long bolts 180° further Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Turn short bolts 45° further with respect to the correctness of information in this document. Copyright by AUDI AG.
11 - Bolt
❑ 20 Nm
12 - High-pressure pump sprocket
13 - Nut
❑ 95 Nm
14 - Hub
❑ With sender wheel
❑ Use counterhold tool - T10051- to loosen and tighten
❑ To remove, use puller - T40064-
❑ Always renew after removing
❑ 100 Nm
16 - Bolt
❑ 22 Nm
17 - Clamping piece
❑ Renew
18 - Hexagon flange nut
❑ For clamping piece
❑ 10 Nm
19 - Cover for injector
20 - Bolt
❑ 5 Nm
21 - Injector
❑ Use a coloured pen to mark injectors and corresponding high-pressure pipes and cylinder for re-instal‐
lation; pay attention to markings when installing
❑ Always renew copper seal when removing and installing
❑ To remove carbon deposits from the injector sealing surface, clean the injector bore in the cylinder head
with cleaning kit - VAS 6811- (it is important to do this to avoid leaks)

Installation position of clamping piece
4. Exploded view - fuel system 23

5 Filling and bleeding fuel system

♦ Vehicle diagnostic tester
If components of the fuel system between the fuel tank and the
high-pressure pump are removed or renewed, the fuel system
must be bled.
Risk of irreparable damage to fuel pump
After working on the fuel system, the fuel pump may be irreparably
damaged if it is allowed to run while empty.
– Never allow fuel pump to run while it is empty.
– Fill/bleed fuel pump.
Proceed as follows to fill high-pressure pump with fuel.

• Check fuel gauge in instrument cluster; fuel gauge needle
must indicate that fuel is above reserve level.
– Connect a ⇒ Vehicle diagnostic tester.
– Switch on ignition.
– Select “Engine electronics” in vehicle self-diagnosis.
– Then select “Basic setting”.
– Select “Display group 35”.
– Press “activate” button.
– The fuel pumps start running.
– The fuel pumps must run for approx. 1 minute to ensure that
the high-pressure pump is filled with sufficient fuel.
– Start engine after filling fuel system.
– Run engine at moderate speed for several minutes and then
switch off.
– Check fuel system for leaks.
– Road-test vehicle and accelerate with full throttle at least once.
– Then check high-pressure system again for leaks.

6 Checking fuel system for leaks

– Run engine at idling speed for several minutes (do not press
accelerator) and then switch off. Fuel system will bleed itself
automatically.
– Check the entire fuel system for leaks.
Renew affected component if leakage still occurs after tightening
to correct torque.
– After completing the repair, road-test the vehicle. Accelerate
with full throttle at least once. Then check the high-pressure
section of the fuel system again for leaks.
Note
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the engine and erase the event memory. Then
continue the road test.
6. Checking fuel system for leaks 25

7 Air cleaner
Overview
⇒ “7.1 Exploded view - air cleaner”, page 26
⇒ “7.2 Removing and installing engine cover panel”, page 27
⇒ “7.3 Removing and installing air filter element”, page 28
⇒ “7.4 Removing air cleaner (bottom section)”, page 29
7.1 Exploded view - air cleaner
1 - Spring-type clip
2 - Air hose
❑ To turbocharger
❑ Check air intake hose
for dirt and leaves
3 - Air mass meter - G70-
❑ 1.5 Nm
⇒ page 61
4 - Bolts
❑ For air cleaner (top sec‐
tion)
❑ 1.5 Nm
5 - Bolts
❑ For air cleaner (top sec‐
tion)
❑ 1.5 Nm
6 - Air cleaner (top section)
❑ Clean any salt residue,
leaves and dirt out of air
cleaner (top section)
7 - Air filter element
❑ Always use genuine
part for air filter element
⇒ page 28
❑ Observe change inter‐
vals ⇒ Maintenance ;
Booklet 808
8 - Bolt
❑ For air cleaner (bottom
section)
❑ 8 Nm
9 - Snow screen
❑ Not installed in all vehicles
10 - Air cleaner (bottom section) permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Clean any salt residue, leaves and dirt out of air cleaner (bottom section)
❑ On vehicles for cold climates, air cleaner (bottom section) with hot air intake is installed
11 - Connection for water drain hose
❑ Clean connection

12 - Water drain hose

❑ Clean water drain hose
13 - Flutter valve
❑ Clean and re-install
14 - Intake air duct
❑ To lock carrier
❑ Clean any leaves and dirt out of intake air duct
7.2 Removing and installing engine cover

panel
Removing
– Carefully pull engine cover panel off retaining pins one after
the other “arrows”. Do not jerk the cover panel away, and do
not try to pull on one side only.
Installing
– To avoid damage, do not strike the engine cover panel with
your fist or with any kind of tool.
– Position engine cover panel on engine (note locations of oil
filler neck and oil dipstick).
– First
Protected pressCopying
by copyright. engine coveror panel
for private commercialinto rear rubber
purposes, in part or ingrommets
whole, is not and
permittedthen into
unless frontbyrubber
authorised AUDI AG.grommets
AUDI AG does with both hands.
not guarantee or accept any liability
7. Air cleaner 27
7.3 Removing and installing air filter ele‐

ment
Removing
– Unscrew bolts -arrows- from air cleaner (top section).
Note
Disregard items 1 to 3.
– Lift up air cleaner (top section) and take out air filter element.
Installing
To ensure the correct function of the air mass meter - G70- , it is
important to observe the following notes and instructions.
Note
♦ If the air filter element is very dirty or wet, dirt particles or water
can reach the air mass meter - G70- and falsify the detected
air mass values. This will cause a loss of power, as the cal‐
culated injection quantities will be too low.
♦ Always use genuine air filter elements (same as original equip‐
ment).
♦ Hose connections and charge air system hoses must be free
of oil and grease prior to fitting. Do not use any lubricants con‐
taining silicone when assembling.
♦ Both sections of the air cleaner housing must be clean.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue .
♦ To prevent malfunctions, cover all critical parts of the engine
air intake tract (air mass meter, intake pipes, etc.) with a clean
cloth when blowing out the air cleaner housing with com‐
pressed air.
♦ Please observe requirements for disposal.
– Remove and clean snow screen -1-.
Note
The snow screen is not installed in all vehicles.

– Clean water drain -arrow- and air cleaner (bottom section).

– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections); use a vacuum cleaner if necessary.
– Check air mass meter and air hose (engine intake side) for salt
residue, dirt and leaves.
– Check air duct leading from lock carrier to air cleaner housing
for dirt and leaves.
– When installing the air filter element, check that it is properly
centred in the retainer in the air cleaner (bottom section).
– Carefully fit air cleaner (top section) on air cleaner (bottom
section) without applying any force. Make sure the top section
of the air cleaner is fitted straight on the air filter element (note
position of sealing lip on air filter element).
– Make sure that air hose is correctly seated at air mass meter
- G70- .
The remaining installation steps are carried out in the reverse se‐
quence.
7.4 Removing air cleaner (bottom section)

Removing
– Unscrew bolts -arrows- from air cleaner (top section).
– Lift up air cleaner (top section) and take out air filter element.
– Remove air duct leading from lock carrier to air cleaner hous‐
ing -2 and 3-.
– Slacken bolt -1-.

– Carefully lift air cleaner (bottom section).
Installing
To ensure the proper function of the air mass meter - G70- it is
important to observe the following instructions.
Note
♦ Always use genuine air filter elements (same as original equip‐
ment). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Use a silicone-free lubricant when installing the intake hose.
7. Air cleaner 29
– Remove and clean snow screen -1-.
Note
The snow screen is not installed in all vehicles.
– Clean water drain -arrow- and air cleaner (bottom section).
– Disconnect water drain hose -arrow- from air cleaner (bottom

section) and clean any dirt or leaves out of connection and
hose.
– When installing the air filter element, check that it is properly
centred in the retainer in the air cleaner (bottom section).
– Carefully fit air cleaner (top section) on air cleaner (bottom
section) without applying any force. Make sure the top section
of the air cleaner is fitted straight on the air filter element (note
position of sealing lip on air filter element).
quence.

8 Intake manifold
Overview
⇒ “8.1 Exploded view - intake manifold with attached compo‐
nents”, page 31
⇒ “8.2 Removing and installing intake manifold”, page 32
⇒ “8.3 Removing and installing fuel rail”, page 36
⇒ “8.4 Removing and installing intake manifold flap motor V157
”, page 39
8.1 Exploded view - intake manifold with attached components
1 - Intake manifold
❑ With combined variable
intake manifold motor -
V183- and variable in‐
take manifold position
sender - G513- (engine
codes CBAA, CBAB,
CBBB only)
❑ With combined intake
manifold flap motor -
V157- and intake mani‐
fold flap potentiometer -
G336- (engine code
CBEA only)
❑ Must not be dismantled
⇒ page 32
2 - Bolt
❑ 8 Nm
3 - Gasket
❑ Renew
4 - Seal
❑ Renew
5 - Connecting pipe
❑ To exhaust gas recircu‐
lation cooler
6 - Bolt
❑ 9 Nm
7 - Gasket
❑ Renew
8 - Bolt
❑ 10 Nm
9 - Component
❑ Removing and installing intake manifold flap motor - V157- with throttle valve potentiometer - G69- (en‐
gine codes CBAA, CBAB, CBBB only) ⇒ page 39
❑ Removing and installing throttle valve module - J338- (engine code CBEA) only ⇒ page 42
❑
10 - Bolt
❑ 10 Nm
8. Intake manifold 31
11 - Bolt
❑ 10 Nm
12 - Oil dipstick
13 - Exhaust gas recirculation
❑ Exhaust gas recirculation valve - N18- with exhaust gas recirculation potentiometer - G212- (engine
codes CBAA, CBAB, CBBB only)
❑ Exhaust gas recirculation control motor - V338- with exhaust gas recirculation potentiometer - G212-
8.2 Removing and installing intake manifold

♦ Torque wrench - V.A.G 1331-
♦ Ratchet - V.A.G 1331/1-
♦ Pliers - 3314-

♦ Bit XZN 8 - T40159- for vehicles with aluminium intake mani‐

fold
♦ Socket T30 - T10405- for vehicles with plastic intake manifold
Removing
WARNING

– Remove engine cover panel ⇒ page 27 .
– Take noise insulation off cylinder head cover.
– Remove noise insulation -1- ⇒ Rep. gr. 66 .
– Loosen hose clip -2- and remove air hose.
Removing air hoses with plug-in connectors

– Release tab -A- on plug-in connector by lifting retaining clip
-arrow-.
– Disconnect air pipes and hoses by hand (do not use a tool).
– Remove bolts -1- and -3-.

– Loosen hose clip -5- and disconnect air pipe -2-, but leave in
position.
Note
Disregard -item 4-.
– Unplug electrical connectors -5- from glow plugs.

– Unscrew union nuts at high-pressure pump -6- and fuel rail
-1- and remove high-pressure fuel pipe.
– Remove bolts -arrows- securing retainers for high-pressure
fuel pipe.

– Release retaining clips -arrows- and move wiring harness

clear.
– Detach fuel return lines -1, 2 and 3-.

– Remove bolts securing brackets and take out return line.
– Remove bolt -4- from bracket.
– Unplug connectors -9- and -7-.

– Remove bolts -6- from connecting pipe for exhaust gas recir‐
culation.
Additional step for vehicles with plastic intake manifold:
– Remove fuel rail ⇒ page 36 .
Continued for all vehicles:
– Open hose clip -8- at air hose and disconnect hose down‐
wards.
– Remove bolt -9- on bracket for oil dipstick.
– Remove bolts securing intake manifold in diagonal sequence
starting from outside and working inwards.
– Remove intake manifold.
Installing
Installation is carried out in the reverse order; note the following:
– Renew seals and/or gaskets.
– Tighten bolts securing intake manifold in diagonal sequence
starting from outside and working inwards.
♦ Tightening torque for intake manifold: refer to exploded view
of intake manifold ⇒ Item 2 (page 31) .
– Install air pipe: Exploded view - charge air cooler ⇒ Rep. gr.
21 .
Installing air hoses with plug-in connectors
Note
♦ Renew seal if damaged.

♦ Make sure that the seal is correctly seated in the groove on
the complete circumference of the air pipe/hose.
♦ Apply a thin coating of silicon-free lubricant to the sealing area
and the seal.
– Release retaining clip (position -1-).

– Push air pipe/hose in as far as stop and press retaining clip to
lock -2-.
– Press air pipe/hose again and pull again to check that plug-in
connector is correctly engaged.
– Install noise insulation ⇒ Rep. gr. 66 .
8.3 Removing and installing fuel rail

♦ Ratchet - V.A.G 1331/1- with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Open end spanner insert, AF 17 - V.A.G 1331/6-
♦ Socket - T40055-
Removing
WARNING


-1- and remove high-pressure fuel pipe.
– Remove bolts -arrows- for high-pressure fuel pipe.
– Detach fuel return hose -3-. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Release retaining clips -arrows- and move wiring harness

clear.

– To do so, unplug the following electrical connectors:

- Injectors
- Glow plugs
Caution
♦ Mark cylinder numbers on high-pressure pipes. They must

always be re-installed on the same cylinders.
♦ Observe rules for cleanliness when working on the injec‐
tion system.
♦ Plug open connections with suitable sealing caps imme‐
diately.
– Loosen union nuts for high-pressure pipes at injectors using

socket - T40055- , 17 mm.
– Loosen union nuts for high-pressure pipes at fuel rail using
open end spanner insert, AF 17 - V.A.G 1331/6- .
– After removal, lay high-pressure pipes on a clean cloth.
– Unscrew both bolts and remove fuel rail.
Installing
Installation is carried out in the reverse order; note the following:
– Install high-pressure pipes so they are free of tension.
Note
♦ Note identification marks for cylinder allocation when re-in‐

stalling high-pressure pipes.
♦ The high-pressure pipes can be re-used after performing the
following checks:
♦ Check taper seats of high-pressure pipes for deformation and
cracks.
♦ The bore of the pipe must not be distorted, restricted or oth‐
erwise damaged.
♦ Corroded pipes must not be used again.
• Tightening torques: refer to exploded view of fuel system

⇒ page 20 .
8.4 Removing and installing intake manifold

flap motor - V157-
RemovingProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Removewith
engine cover
respect to panel of-arrows-.
the correctness information in this document. Copyright by AUDI AG.

– Release tab -A- on plug-in connector by lifting retaining
Protected clip
-arrow-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability


position.
Note
Disregard -item 4-.
– Unplug electrical connector -3-.

Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Disregard -items 1, 2, 4- and -arrow-.
– Unscrew bolts -arrows- and detach intake manifold flap motor

- V157- .
Installing
Installation is carried out in reverse order; note the following:
Note
Renew O-ring.
21 .
Note

and the seal.
– Release retaining clip (position -1-).

lock -2-.
– Press air pipe/hose againauthorised
permitted unless and pull again
by AUDI to check
AG. AUDI AG doesthat plug-inor accept any liability
not guarantee
connector is correctly
with respectengaged.
to the correctness of information in this document. Copyright by AUDI AG.

Tightening torques:
♦ ⇒ “8.1 Exploded view - intake manifold with attached compo‐
nents”, page 31
8.5 Removing and installing throttle valve

module - J338-
Removing
– Remove engine cover panel -arrows-.


– Release tab -A- on plug-in connector by lifting retaining clip
-arrow-.

position.
Note
Disregard -item 4-.
– Unplug electrical connector -3-.
Note
Disregard -items 1, 2, 4- and -arrow-.
– Unscrew bolts -arrows- and detach throttle valve module -

J338- .
Installing
Note
Renew O-ring.
21 .
Note

and the seal.
– Release retaining clip
permitted (position
unless authorised-1-).
by AUDI AG. AUDI AG does not guarantee or accept any liability
lock -2-.
– Press air pipe/hose again and pull again to check that plug-in
connector is correctly engaged.
Tightening torques:
♦ ⇒ “8.1 Exploded view - intake manifold with attached compo‐
nents”, page 31

9 High-pressure pump
Overview
⇒ “9.1 Removing and installing high-pressure pump”, page 45
9.1 Removing and installing high-pressure

pump
Removing
Caution
♦ Always observe rules for cleanliness and instructions for

♦ Running when dry causes irreparable damage to high-
pressure pump.
♦ The high-pressure pump must first be filled with fuel before
the engine is started. The high-pressure pump must not
be allowed to run while still empty (performing first fuel
filling ⇒ page 24 ).
– Remove toothed belt from camshaft and high-pressure pump

⇒ Rep. gr. 15 .
– Unplug electrical connector -1- at fuel metering valve - N290- .
– Remove securing bolts for coolant line on intake manifold and
move coolant line to one side.
– Pull fuel pipe connections -2 and 3- off high-pressure pump.

-5- and remove high-pressure fuel pipe -4-.
Note
Do not bend fuel lines.
– Remove toothed belt sprocket from high-pressure pump.
9. High-pressure pump 45
– Counterhold hub of high-pressure pump using counterhold

tool - T10051- and unscrew securing nut -1-.
– Apply puller - T40064- with thrust piece - T40064/1- and pin -

T40064/2- as shown in illustration and pull hub off high-pres‐
sure pump. If necessary, counterhold using an open-end
spanner (24 mm).
– Unscrew securing bolts -arrows- for high-pressure pump.
– Carefully take out high-pressure pump.
Installing
Installation is carried out in reverse sequence.
⇒ page 20 .
– Install toothed belt for high-pressure pump ⇒ Rep. gr. 15 .
– Install high-pressure pipes ⇒ page 61 .
Caution
♦ The high-pressure pump must first be filled with fuel before

the engine is started. The high-pressure pump must not
be allowed to run while still empty. First fuel filling
⇒ page 24
♦ Running when dry causes irreparable damage to high-
pressure pump.

10 Injectors
Overview
⇒ “10.1 Checking injectors”, page 47
⇒ “10.2 Performing adaption of correction values for injectors”,
page 47
⇒ “10.3 Checking for injectors sticking open”, page 48
⇒ “10.4 Checking return flow rate of injectors with engine running”,
page 49
⇒ “10.5 Checking return flow rate of injectors at starter cranking
speed”, page 52
⇒ “10.6 Removing and installing injectors”, page 54
10.1 Checking injectors

There are four different tests for checking the operation of the
injectors.
• Checking adaption of “Injector delivery calibration values” and
“Injector voltage calibration values” ⇒ page 47
• Checking for injectors sticking open ⇒ page 48
• Checking return flow rate of injectors with engine running
⇒ page 49
• Checking return flow rate of injectors at starter cranking speed
⇒ page 52
Perform the following tests first if the engine does not start at all:
♦ Checking for injectors sticking open ⇒ page 48
♦ Checking return flow rate of injectors at starter cranking speed
⇒ page 52
♦ Checking fuel pressure regulating valve - N276- ⇒ page 65
10.2 Performing adaption of correction val‐

ues for injectors
The “Injector delivery calibration” and “Injector voltage calibration”
functions serve to correct the injection rates for each cylinder of
a common rail system individually across the entire operating
range.
The 7-digit
with respect adaption
to the correctness values -1-in(details
of information in illustration
an
this document. areAG.only
Copyright by AUDI
example) are marked separately on each injector. They may con‐
sist of letters and/or numbers (ASCII code).
10. Injectors 47
Reference table for reading out letters and/or numbers on each

injector
When a new injector is installed, the adaption value for the new
injector must be written into the engine control unit.
When the engine control unit is renewed, the appropriate “injector
delivery calibration” values with “injector voltage calibration” val‐
ues must be written into the new control unit.
Additionally, check that the “injector delivery calibration values”
are correctly entered for all the other injectors. Do NOT attempt
to re-enter these values if the correct values are already stored in
the engine control unit.
The adaption procedure is described in “Guided Fault Finding”.
(The procedure is also described under “Guided Functions”.)
10.3 Checking for injectors sticking open

♦ Hand vacuum pump - VAS 6213-
♦ Use a return line to make an -adapter-.
WARNING


– Clean all connections (with commercial cleaning
permitted solution
unless authorised or AG. AUDI AG does not guarantee or accept any liability
by AUDI
similar) before removing. with respect to the correctness of information in this document. Copyright by AUDI AG.

Note
♦ Make sure all parts are clean; no dirt must be allowed to enter
the fuel system.
♦ Check all cylinders in turn.
– Dry all components after cleaning.

Start with cylinder No. 1.
– Pull return line connections off injectors; to do so, press tabs
-1- and -2- down and at the same time pull release pin upwards
-arrow-.
– Connect adapter to return line connection of injector to be tes‐
ted after adapter has been cleaned and blown out.
– Generate a vacuum of -500 mbar using the hand vacuum
pump - VAS 6213- .
If the vacuum reading remains the same for 30 seconds, the in‐
jector is OK.
If the injector is faulty, the vacuum reading will fall back to 0 bar
within 2 to 3 seconds.
Repeat test if necessary; note drop in vacuum reading on hand
vacuum pump - VAS 6213- .
– Renew faulty injectors ⇒ page 54 .
Checking fuel system for leaks
automatically.
Renew the affected component if leakage occurs.
– Install engine cover panel ⇒ page 27 .
10.4 Checking return flow rate of injectors

with engine running
Checking return flow rate of all injectors
♦ Fuel-resistant measuring container
WARNING

starting work and while working by on
AUDIthe
AG. fuel system.
permitted unless authorised AUDI AG does not guarantee or accept any liability

– Remove noise insulation from injectors.
10. Injectors 49
– Disconnect hose connection downstream of pressure reten‐

tion valve -2- in fuel return lines.
– Seal off open return line connection with plug -1-.
– Hold the end of this hose -3- (lengthen if necessary) in a suit‐
able container to measure the total return flow rate.
– Start engine and let it idle for 2 minutes.
• Specification for 2 minutes: 0 ml to 50 ml
– If specification is attained, increase engine speed to 2000 ...
2500 rpm for approx. 2 minutes and then check return flow rate
again.
• Specification for 2 minutes: less than 250 ml
Note
1000 ml = 1 litre
If specification is exceeded, this indicates that one or more injec‐

tors are defective. Check return flow rate from each injector
individually.
Checking return flow rate of individual injectors

♦ Return flow meter - VAS 6684-
Each injector normally has a relatively low fuel return flow rate. If
the return flow rate at one injector is relatively high compared to
the other injectors, that injector is probably defective.
– Clean all return line connections (e.g. with commercial clean‐
ing solution etc.) before removing.
– Clamp off fuel return line downstream of pressure retention
valve using hose clamp up to 25 mm - 3094- .

– Pull return line connections off injectors; to do so, press both

tabs down and at the same time pull release pin upwards
-arrow-.
Note
No dirt must be allowed to get into the disconnected return lines

or the open connections on the injectors.
– Connect hoses onto return line connections of all 4 injectors.

– Run the 4 hoses into injection rate comparison meter - V.A.G
1348/2 B- .
– Start engine and let it idle for several minutes.
Caution
Risk of damage to injectors when return lines are disconnec‐

ted.
♦ Do NOT press the accelerator during this test; the engine
must only run at idling speed.
10. Injectors 51
– When the engine is warm and running at idling speed, the re‐
turn flow rates at each of the 4 return lines must not differ by
more than a small amount.
1- Injectors OK. Return flow rate approx. identical on all injec‐
tors.
2- Injector for cylinder 3 not OK. Return flow rate greater than
three times the volume of smallest measured return flow
rate.
Note
There is a mechanical fault at the injector if the return flow rate is

greater than three times the volume of the smallest measured
return flow rate.
– If one injector has a significantly higher return flow rate than

the others it must be renewed ⇒ page 54 .
Installing fuel return lines
– Check O-ring for fuel return line connection for damage and
deformation.
If O-ring is damaged or deformed, renew O-ring.
Note
Lubricate all seals with engine oil or assembly oil before installing.
– Push return line connections carefully
permitted over seals
unless authorised and
by AUDI AG.onto
AUDI AGin‐does not guarantee or accept any liability
jectors. The catch should engage audibly.
with respect Then press
to the correctness release
of information in this document. Copyright by AUDI AG.
pin down carefully.
automatically.
10.5 Checking return flow rate of injectors at

starter cranking speed
Only perform this test if the engine does not start at all.

♦ Return flow meter - VAS 6684-
WARNING

Each injector normally has a relatively low fuel return flow rate. If
the return flow rate at one injector is relatively high compared to
the other injectors, that injector is probably
Protected defective.
– Remove engine cover panel with

⇒ page
respect 27
to the. correctness of information in this document. Copyright by AUDI AG.

– Clean all return line connections (with commercial cleaning
solution or similar) before removing.
10. Injectors 53

-arrow-.
– Connect hoses of return flow meter - VAS 6684- to return line
connections of all four injectors.
– Run the 4 hoses into return flow meter - VAS 6684- .
– Operate starter three times (wait approx. 20 seconds each
time after operating starter to prevent it from overheating).
• Specification of return flow rate: 0 ml
– If fuel comes out of an injector, that injector must be renewed.
Installing fuel return lines
– Check O-ring for fuel return line connection for damage and
deformation.
Note
Lubricate all seals with engine oil or assembly oil before installing.
– Push return line connections carefully onto injectors. The

catch should engage audibly. Then press release pin down
carefully.
automatically.
10.6 Removing and installing injectors

♦ Cleaning kit - VAS 6811-

♦ Socket - T40055-
♦ Puller - T10055- with adapter - T10055/1-
10. Injectors 55
♦ Assembly sleeve - T10377-
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
WARNING


Caution
♦ Mark cylinder numbers on injector units. They must al‐

ways be re-installed on the same cylinders.
♦ Observe rules for cleanliness when working on the injec‐
tion system.
♦ Plug open connections with suitable sealing caps imme‐
diately.

-arrow-.
Note
Should you not be able to pull the return line connection upwards,
open the connection by turning it with a small screwdriver.

– Unplug electrical connectors -1- at injectors which are to be

removed.
– Loosen union nuts for high-pressure pipes at injectors using
socket - T40055- , 17 mm.
– Loosen union nuts for high-pressure pipes at fuel rail using
open end spanner insert, AF 17 - V.A.G 1331/6- .
– Unbolt covers for injectors -arrows-.

– Pull covers upwards and turn them 1/4 turn (90°).
Caution with respect to the correctness of information in this document. Copyright by AUDI AG.
When removing the securing nuts on the injectors there is a

risk that the nuts will drop into the cylinder head. Proceed very
carefully to prevent unnecessary dismantling or further dam‐
age.
– Unbolt clamping pieces for injectors -arrows-.
10. Injectors 57
– Apply puller - T10055- with adapter - T10055/1- as shown in

illustration and pull injector out upwards by tapping gently.
– After removal, lay injectors on a clean cloth.
Important instructions for installing injectors:
When installing injectors, the following components must be re‐
newed:
♦ Clamping piece
♦ Copper seal
♦ O-ring for injector bore
♦ O-ring for fuel return line connection
Note

following checks:
cracks.
erwise damaged.
If a used injector is being re-installed:

– Spray tip of injector nozzle with rust-releasing spray. Wait ap‐
prox. 5 minutes and wipe off soot particles and oil with a cloth.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
– Clean off deposits under the copper seal using a suitable scra‐
per.
Continued (same procedure for used and new injectors):
Caution
Risk of damage to injector sealing surface.

♦ To remove carbon deposits from the injector sealing sur‐
face, clean the injector bore in the cylinder head with
cleaning kit - VAS 6811- .

– Renew seal for injector using assembly sleeve - T10377- .

– To prevent damage to the new O-ring, lubricate it with oil and
carefully push it onto the fuel return line connection.
– Install injectors.
– Hand-tighten union nuts on high-pressure pipes. Make sure
that connections are not under tension.
– To tighten unions of high-pressure pipes at injectors, use tor‐

que wrench - V.A.G 1331- with ratchet - V.A.G 1331/1- and
socket - T40055- .
10. Injectors 59
– To tighten unions of high-pressure pipes to fuel rail, use torque

wrench - V.A.G 1331- with tool insert, AF 17 - V.A.G 1331/6- .
• Observe tightening torque: Installing high-pressure pipes
⇒ page 61 .
⇒ page 20 .
– Press return line connections carefully over injector seals
(check seal for damage before connecting return line). The
catch should engage audibly. Then press release pin down
carefully.
After renewing an injector, the “injector delivery calibration val‐
ues” and “injector voltage calibration values” for the new injectors
must be written into the engine control unit.
Additionally, check that the “injector delivery calibration values”
and “injector voltage calibration values” are correctly entered for
all the other injectors. Do NOT attempt to re-enter these calibra‐
tion values if the correct values are
Protected by already
copyright. stored
Copying in the
for private enginepurposes, in part or in whole, is not
or commercial
control unit. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Bleeding fuel system and checking for leaks
Note
The fuel system is self-bleeding; do not open the high-pressure

connections.
– Run engine at idling speed for several minutes and then switch
off.
– Switch off ignition.
– Check the complete fuel system including all 4 return line con‐
nections for leaks.
to correct torque.
Note
The return lines can only be renewed together with the pressure
retention valve as one unit.

Note

11 Senders and sensors

Overview
⇒ “11.1 Removing and installing air mass meter G70 ”,
page 61
⇒ “11.2 Installing high-pressure pipes”, page 61
⇒ “11.3 Checking pressure retention valve in fuel return line”,
page 63
⇒ “11.4 Checking fuel pressure regulating valve N276 ”,
page 65
⇒ “11.5 Checking fuel pressure (low pressure) system”,
page 66
⇒ “11.6 Checking delivery rate of fuel pumps”, page 68
⇒ “11.7 Removing and installing fuel pressure regulating valve
N276 ”, page 69
⇒ “11.8 Removing and installing fuel pressure sender G247 ”,
page 72
11.1 Removing and installing air mass meter

- G70-
Removing
– Unplug electrical connector -1- at air mass meter - G70- .
– Unscrew both bolts from air mass meter - G70- and carefully
pull air mass meter - G70- out of guide on air cleaner housing.
Installing
To ensure the correct function of the air mass meter - G70- , it is
important to observe the following notes and instructions.
Note
♦ Always use genuine air filter elements
Protected by (same
copyright.as original
Copying equip‐
for private or commercial purposes, in part or in whole, is not
ment). permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Use a silicone-free lubricant when installing the air hose.
– Check for salt residue, dirt and leaves in air mass meter and
air intake hose (engine intake side).
– Check intake duct as far as air filter element for dirt. If neces‐
sary, clean salt residue, dirt and leaves out of air cleaner
housing (top and bottom sections); wash out or use a vacuum
cleaner as required. Removing and installing air cleaner
⇒ page 29 .
quence.
11.2 Installing high-pressure pipes

11. Senders and sensors 61

♦ Socket - T40055-

Procedure
Note

following checks:
cracks.
erwise damaged.
– Use vacuum cleaner to remove dirt from taper seat at fuel rail.
– Clean fuel pipe and end of pipe using cleaning solution and
dry with compressed air.
– Lubricate threads of union nuts with fuel.
– Hand-tighten union nuts on high-pressure pipes (ensure that
pipes are not under tension).
• Tightening
permitted torque:
unless authorised 25AG.
by AUDI Nm AUDI AG does not guarantee or accept any liability
– To tighten unions of high-pressure pipes at injectors, use tor‐
que wrench - V.A.G 1331- with ratchet - V.A.G 1331/1- and
socket - T40055- .
– To tighten unions of high-pressure pipes to fuel rail, use torque

wrench - V.A.G 1331- with tool insert, AF 17 - V.A.G 1331/6- .
– Check fuel system for leaks
⇒ “6 Checking fuel system for leaks”, page 25 .
11.3 Checking pressure retention valve in

fuel return line
The pressure retention valve maintains a residual pressure of ap‐
prox. 10 bar in the fuel return line.
This residual pressure is required for the control function of the
injectors

♦ Tester for fuel return system - VAS 6330-
WARNING


– Clean return line connection on cylinder 1 (with commercial
cleaning solution or similar) before removing.
– Dry return line connection on cylinder 1.
– Cover return line connection on cylinder 1 with a cloth.
– Pull return line connection off cylinder 1; to do so, press both
-arrow-.
Note
No dirt must be allowed to get into the disconnected return line or

the open connection on the injector.

– Connect tester for fuel return system - VAS 6330- between

return line connection on injector and return line.
– Start engine.
– Check pressure indicated on tester.
• Specification: approx. 10 bar
If the value does not match the specification, fit a new pressure
retention valve.
Note
The pressure retention valve may only be renewed together with

the fuel return lines.
11.4 Checking fuel pressure regulating valve

- N276-
WARNING


– Detach fuel return line -1-.
– Seal off open return line connection with a plug -1-.

– Attach a suitable hose -3- to return line -2-.

1) Checking while engine is running
– Start the engine and run at idling speed.
• Specification: more than 75 ml in 30 seconds
If specification is not obtained, fuel pressure regulating valve -
N276- is defective.
2) Checking while engine is running
If condition for 1) is met, start engine and increase engine speed
to ≥ 2000 rpm.
• Fuel is still discharged in the first few seconds after the engine
is started
• Specification after a few seconds: return flow rate = 0 ml
• Drip leaks are permissible
If specification is not obtained, fuel pressure regulating valve - N
276- is defective.
3) If engine can no longer be started
Perform check at cranking speed.
• Specification of return flow rate: 0 ml
• Drip leaks are permissible
• If specification is not obtained, fuel pressure regulating valve
- N 276- is defective.
11.5 Checking fuel pressure (low pressure)

system
♦ K-Jetronic pressure tester - V.A.G 1318-
Test conditions:
• Battery voltage at least 12.5 V
• Fuel filter OK.
• Fuel tank at least 1/2 full
• Ignition switched off.
Checking residual pressure

WARNING

♦ To reduce the pressure in the fuel system, wrap a clean
cloth around the connection and carefully loosen the con‐
nection.
– Disconnect fuel supply line -arrow- at high-pressure pump.
– Connect K-Jetronic pressure tester - V.A.G 1318- to fuel sup‐

ply line -1- with suitable adapter -2-. Connect the other adapter
-3- from K-Jetronic pressure tester - V.A.G 1318- to open con‐
nection at high-pressure pump.

Note
In this way the K-Jetronic pressure tester - V.A.G 1318- is con‐

nected into the fuel supply line.

– Let fuel pumps run until maximum fuel pressure has built up.
• Specification: at least 3.5 bar
If specification is not obtained:

Check union between pressure tester and fuel line for leaks.
Check pressure tester for leaks.
Check fuel lines and their connections for leaks.
Fuel filter is blocked.
Check delivery rate of fuel pump ⇒ page 68 .
Note
Check fuel system for leaks.
11.6 Checking delivery rate of fuel pumps

♦ Measuring container (fuel-resistant)
Test conditions:
• Battery voltage at least 12.5 V
• Fuel filter OK.
• Fuel tank at least 1/2 full
• Ignition switched off
Checking fuel delivery rate

WARNING

♦ To reduce the pressure in the fuel system, wrap a clean
cloth around the connection and carefully loosen the con‐
nection.
– Disconnect fuel supply line -arrow- at high-pressure pump.
– Hold fuel supply line -1- into a measuring container -2-.

– Let fuel pumps run for 15 seconds and exit activation function.
• Specification in 15 seconds: at least 500 ml
If minimum delivery rate is not reached, check for the following
causes:
♦ Fuel pump was not running for 15 seconds
♦ Fuel lines have been crushed
♦ Fuel filter is blocked
♦ Fuel pumps defective: Checking ⇒ Rep. gr. 20
Note
Check fuel system for leaks.

11.7 Removing and installing fuel pressure

regulating valve - N276-
♦ Open-end spanner insert, 30 mm - T10553-

♦ Torque wrench

The fuel pressure regulating valve - N276- -2- is located in the

fuel rail. It maintains a constant pressure in the fuel rail and the
injector pipes (high-pressure fuel circuit).
If the pressure in the high-pressure fuel circuit is too high, the
regulating valve opens to allow some of the fuel to flow back from
the fuel rail to the fuel tank via a return line.
If the pressure in the high-pressure fuel circuit is too low, the fuel
pressure regulating valve - N276- closes and seals off the high-
pressure section of the system from the low-pressure section.
Note
Fuel pressure regulating valve - N276- must always be renewed

after it has been removed.
Removing
WARNING
♦ Always observe rules for cleanliness and instructions for


– Remove fuel rail ⇒ page 36 .
– Before removal, clean area around thread for fuel pressure
regulating valve - N276- using commercial cleaning solution
or similar (no dirt must enter opening in fuel rail).
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Clean carefully; cleaning solution must not enter the electrical
connector.
– Dry off fuel pressure regulating valve - N276- .

– Loosen union nut using open-end spanner insert, 30 mm -
T10553- (at the same time, counterhold at hexagon flats on
housing). Then unscrew and remove by hand.
– Extract dirt from opening in fuel rail (thread and sealing sur‐
face) using a vacuum cleaner. Do not use metal tools, etc.
– Seal off open fuel rail connection with clean plug.

Installing
Note
♦ The fuel pressure regulating valve - N276- has a deformable

sealing lip and no separate seal; it can therefore be used only
once.
♦ Check that sealing surfaces (deformable sealing lip) and
threads on new fuel pressure regulating valve - N276- are not
damaged.
♦ Check sealing surface at opening in fuel rail.
♦ The beginning of the thread, the deformable sealing lip and
the O-ring of the fuel pressure regulating valve - N276- must
be coated with diesel fuel.
– Screw on union nut by hand.

– Align new regulating valve so that connecting wire is free of
tension after connector is attached.
– Hold regulating valve in this position by holding hexagon flats
on housing of regulating valve with open-end spanner or pliers
(water pump pliers or similar).
– Tighten union nut using open-end spanner insert, 30 mm -
T10553- (at the same time, counterhold at hexagon flats on
housing) ⇒ page 20 .
– Install fuel rail ⇒ page 36 .
– After installation, run engine at moderate speed for several
minutes and then switch off.
– Check fuel system for leaks.
– Interrogate event memory.
– Interrogate event memory again.
11.8 Removing and installing fuel pressure

sender - G247-
♦ Bit (27 mm) - T40218- or commercially available socket
(27 mm) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Torque wrench

Note
♦ The fuel pressure sender - G247- -1- continuously measures

the fuel pressure in the high-pressure system. It transmits a
corresponding voltage signal to the engine control unit - J623- .
♦ Should the fuel pressure sender fail, the engine control unit
will control the fuel pressure via a mapped open-loop backup
function. Maximum engine speed in this mode is restricted.
♦ The fuel pressure sender - G247- has a deformable sealing lip
and no separate seal; it can therefore be used only once.
Removing
WARNING


– Before removal, clean area around thread for fuel pressure
sender using commercial cleaning solution etc. (no dirt must
enter opening).
Note
Clean carefully; cleaning solution must not enter the electrical

connector.
– Dry off fuel pressure sender - G247- .

– Unplug electrical connector at fuel pressure sender - G247- .

– Unscrew fuel pressure sender - G247- using socket, 27 mm -
T40218- .
Note
An open-end spanner must not be used for loosening or tighten‐

ing.
– Extract dirt from opening in fuel rail (thread and sealing sur‐
face) using a vacuum cleaner. Do not use metal tools, etc.
– Seal off opening in fuel rail with a plug.
Installing
Note
♦ Fuel pressure sender - G247- must always be renewed after

it has been removed.
♦ Also check sealing surface at opening in fuel rail.
♦ The beginning of the thread and the deformable sealing lip of
the fuel pressure sender - G247- must be coated with diesel
fuel.
– Screw in fuel pressure sender - G247- by hand.

– Then tighten fuel pressure sender - G247- to specified torque.
Tightening torques
• ⇒ “4 Exploded view - fuel system”, page 20
– After installing fuel pressure sender - G247- , leave engine
running at moderate speed for a few minutes when bleeding
fuel system and then switch off again.
Note
The fuel system is “self-bleeding”; do NOT open the high-pres‐

sure connections.
– Interrogate event memory and erase it if necessary.

– Carefully check the entire fuel system for leaks.

to correct torque.
Note

– After road test, interrogate event memory again.

12 Lambda probe and exhaust gas tem‐

perature sensors (CBAA, CBAB,
CBBB)
Overview
⇒ page 76
⇒ page 77
⇒ page 78
12.1 Exploded view - Lambda probe and exhaust gas temperature sensors
1 - Bolt for exhaust gas pres‐

sure sensor 1 - G450-
❑ 4.5 Nm
⇒ page 87
❑ Pressure pipes to partic‐
ulate filter: 45 Nm
this component
2 - Control pipe for exhaust gas
pressure sensor 1 - G450-
3 - Particulate filter
particulate filter
4 - Exhaust gas temperature
sender 3 - G495-
⇒ Rep. gr. by26
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 45 Nmwith respect to the correctness of information in this document. Copyright by AUDI AG.
5 - Lambda probe - G39- with
Lambda probe heater - Z19-
❑ New Lambda probes
are coated with an as‐
sembly paste
❑ In the case of a used
Lambda probe, coat on‐
ly thread with high-tem‐
perature paste; refer to
⇒ Parts catalogue for
high-temperature paste
❑ The assembly paste/
high-temperature paste
must not make contact
with the slots on the Lambda probe body
❑ 50 Nm
❑ 45 Nm
7 - Nut

12.2 Removing and installing Lambda probe

- G39- with Lambda probe heater - Z19-
♦ Lambda probe open ring spanner set - 3337-
Removing
WARNING
When working on all parts of the exhaust system:

♦ Observe safety precautions when working on the exhaust
system
⇒ “1.5 Safety precautions when working on the exhaust
system”, page 4 .
– Unplug electrical connector -4- for Lambda probe - G39- .
12. Lambda probe and exhaust gas temperature sensors (CBAA, CBAB, CBBB) 77
– Unscrew Lambda probe - G39- -3- using tool from Lambda

probe open ring spanner set - 3337- .
Installing
When installing, note the following:
Note
♦ Threads of new Lambda probes are already coated with as‐

sembly paste; the paste must not get into the slots on the probe
body.
♦ In the case of a used Lambda probe grease only the thread
with high-temperature paste. The paste must not get into the
slots on the Lambda probe body. For high-temperature paste
refer to ⇒ Parts catalogue .
♦ When installing, the Lambda probe wiring must always be re‐
attached at the same locations to prevent it from coming into
contact with the exhaust pipe.
• Tightening torque: exploded view - Lambda probe ⇒ page 76
12.3 Removing and installing exhaustpermitted

gas unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

The pressure sensor is connected to the take-off points upstream

and downstream of the particulate filter via two pipes. Exploded
view - Lambda probe ⇒ page 76
Exhaust gas pressure sensor 1 - G450- detects the amount of
deposits in the particulate filter.
Removing

– Unplug electrical connector -2- on exhaust gas pressure sen‐

sor 1 - G450- .
– Remove bolt -3- and detach exhaust gas pressure sensor 1 -
G450- from bracket -arrow-.
– Detach retaining clips from both hoses.
– Before disconnecting, spray hoses coming from exhaust gas
pressure sensor 1 - G450- with suitable release agent.
– Carefully disconnect the hoses from their connections (take
care to keep the hoses straight: the connections on pressure
sensor can break off easily).
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– When installing, note the following: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
• Tightening torques: Exploded view - Lambda probe
⇒ page 76
Note
♦ Before installing, blow out control pipes from exhaust gas

pressure sensor 1 - G450- to particulate filter towards partic‐
ulate filter with compressed air (pipes can become obstructed
or may ice up due to condensation).
♦ Make sure that hoses are securely fitted and seal properly.
♦ If pressure connections are detached from particulate filter,
tighten to 45 Nm.
After renewing exhaust gas pressure sensor 1 - G450- and/or

particulate filter, adaption must be performed in order to reset
learnt values. The adaption procedure is described in the Guided
Fault Finding or Guided Functions; use a vehicle diagnostic test‐
er.
12. Lambda probe and exhaust gas temperature sensors (CBAA, CBAB, CBBB) 79
13 Lambda probe and exhaust gas tem‐

perature sensors (CBEA)
Overview
⇒ “13.1 Exploded view - Lambda probe and exhaust gas temper‐
ature sensors”, page 80
⇒ “13.2 Removing and installing Lambda probe G39 with Lambda
probe heater Z19 ”, page 83
⇒ “13.3 Removing and installing Lambda probe after catalytic
converter G130 with Lambda probe 1 heater after catalytic con‐
verter Z29 ”, page 85
⇒ “13.4 Removing and installing pressure differential sender
G505 ”, page 87
⇒ “13.4 Removing and Protected
installing pressure differential sender
G505 ”, page 87 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ “13.5 Removing and installing exhaust gas pressure sensor 1
G450 ”, page 88
⇒ “13.6 Removing and installing control pipe for pressure sen‐
sors”, page 89
⇒ “13.7 Removing and installing control pipe for exhaust gas
pressure sensor 1 G450 ”, page 92
13.1 Exploded view - Lambda probe and exhaust gas temperature sensors

1 - Bolt
❑ 8 Nm
2 - Bolt
❑ 8 Nm
3 - Pressure differential sender
- G505-
⇒ page 87
❑ Reset learnt values after
renewing ⇒ Vehicle di‐
agnostic tester, 01 -
Engine electronics,
functions , 01 - Re-
set learnt values
4 - Control pipe
❑ Control pipe from ex‐
haust gas recirculation
cooler to exhaust gas
pressure sensor 2 -
G451-
5 - Exhaust gas pressure sen‐
sor 1 - G450-
⇒ page 88
❑ Reset learnt values after
renewing ⇒ Vehicle di‐
agnostic tester, 01 -
Engine electronics,
functions , 01 - Re-
13. Lambda probe and exhaust gas temperature sensors (CBEA) 81

set learnt values
6 - Bolt
❑ 8 Nm
7 - Bolt
❑ 8 Nm
❑ Coat with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts catalogue
❑ 45 Nm
❑ Before removing mark installation position
❑ Note installation position: see exhaust gas temperature control (vehicles with engine code CBEA) ⇒
Rep. gr. 26
❑ 45 Nm
❑ Before removing mark installation position
❑ Note installation position: see exhaust gas temperature control (vehicles with engine code CBEA) ⇒
Rep. gr. 26
❑ 45 Nm
11 - Turbocharger
12 - Lambda probe - G39- with Lambda probe heater - Z19-
❑ New Lambda probes are coated with an assembly paste
❑ In the case of a used Lambda probe, coat only thread with high-temperature paste; refer to ⇒ Parts
catalogue for high-temperature paste
❑ The assembly paste/high-temperature paste must not make contact with the slots on the Lambda probe
body
❑ Reset learnt values after renewing ⇒ Vehicle diagnostic tester, 01 - Engine electronics, func-
tions , 01 - Reset learnt valuesProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 50 Nm
❑ 45 Nm
14 - Particulate filter
❑ Adaption must be performed after renewing particulate filter

15 - Lambda probe after catalytic converter - G130- with Lambda probe 1 heater after catalytic converter - Z29-
❑ New Lambda probes are coated with an assembly paste
❑ In the case of a used Lambda probe, coat only thread with high-temperature paste; refer to ⇒ Parts
catalogue for high-temperature paste
❑ The assembly paste/high-temperature paste must not make contact with the slots on the Lambda probe
body
tions , 01 - Reset learnt values
❑ 50 Nm
16 - NOx storage catalytic converter
tions , 01 - Reset learnt values
❑Protected
17 - Clamp
18 - Seal
19 - Control pipe
❑ Tighten to 45 Nm at exhaust
❑ Secure to pressure sensor with hose clip
❑ Do not attempt to bend control pipe to a different shape
❑ Install free of stress
20 - Nut
❑ 9 Nm
21 - Bracket
❑ For control pipe
22 - Bracket
❑ For pressure differential sender - G505-
23 - Bolt
❑ 9 Nm
24 - Bracket

- G39- with Lambda probe heater - Z19-

Removing
WARNING

system
system”, page 4 .
– Unplug electrical connector -4- for Lambda probe - G39- .

– Unscrew Lambda probe - G39- -1- using tool from Lambda

probe open ring spanner set - 3337- .
Installing
Note

body.
– Learnt values must be reset on engine control unit after re‐

newing Lambda probe - G39- .
– Switch on ignition and select following menu options on ⇒ Ve‐
hicle diagnostic tester:
♦ 01 - Self-diagnosis compatible systems
♦ 01 - Engine electronics
♦ 01 - Engine electronics, functions
♦ 01 - Reset learnt values
Tightening torques
♦ ⇒ “13.1 Exploded view - Lambda probe and exhaust gas tem‐
perature sensors”, page 80

after catalytic converter - G130- with
Lambda probe 1 heater after catalytic
converter
permitted unless - Z29-
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Removing
WARNING

system
system”, page 4 .
– Unscrew nuts -arrows- and pull underbody cover down slight‐

ly.
– Unplug connector -3- for Lambda probe after catalytic con‐

verter - G130- .

– Move clear wiring connection -arrow-.

– Unscrew Lambda probe after catalytic converter - G130- using
tool from Lambda probe open ring spanner set - 3337- .
Installing
Note

body.

newing Lambda probe after catalytic converter - G130- .
Tightening torques
13.4 Removing and installing pressure differ‐

ential sender - G505-
Special toolsunless
permitted and authorised
workshop equipment
by AUDI AG. AUDI AGrequired
does not guarantee or accept any liability
The pressure differential sender - G505- is connected to the take-
off points upstream and downstream of the particulate filter via
two pipes. Exploded view - Lambda probe ⇒ page 80
The pressure differential sender - G505- detects the amount of
deposits in the particulate filter.
Removing

– Unplug electrical connector -2- at pressure differential sender

- G505- .
– Remove bolt -3- and detach pressure differential sender -
G505- from bracket -arrow-.
– Detach retaining clips from both hoses.
– Before disconnecting, spray the hoses for the pressure differ‐
ential sender - G505- with suitable release agent.
– Carefully disconnect the hoses from their connections (take
care to keep the hoses straight: the connections on pressure
sensor can break off easily).
Installing
– When installing, note the following:
Note
♦ Before installing, blow out control pipes from pressure differ‐

ential sender - G505- to particulate filter towards particulate
filter with compressed air (pipes can become obstructed or
may ice up due to condensation).
tighten to 45 Nm.

newing pressure differential sender - G505- and/or particulate
filter.
Tightening torques
perature sensors”, page 80 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
13.5 Removing and installing exhaust gas

Removing
– Detach heat insulation sleeve from exhaust gas pressure sen‐
sor 1 - G450- -3-.

– Detach electrical connector from exhaust gas pressure sen‐

sor 1 - G450- -3-.
– Unscrew bolt and detach bracket from exhaust gas pressure
sensor 1 - G450- .
– Release retaining clips from both hoses.
– Before disconnecting, spray hoses coming from exhaust gas
pressure sensor 1 - G450- with suitable release agent.
– Carefully pull hoses off connections (take care to keep the ho‐
ses straight; the connections can easily break off exhaust gas
pressure sensor 1 - G450- ).
Installing
– When installing, note the following:
Note
♦ Before installing, blow out control pipes from exhaust gas

pressure sensor 1 - G450- to particulate filter towards partic‐
ulate filter with compressed air (pipes can become obstructed
or may ice up due to condensation).
tighten to 45 Nm.

newing pressure differential sender - G505- and/or particulate
filter.
♦ 01 - Engine electronics,
functions

Tightening torques
13.6 Removing and installing control pipe for

pressure sensors
Removing
WARNING

system
system”, page 4 .

– Remove pressure differential sender - G505- -2- ⇒ page 87 .
– Detach heat insulation sleeve and remove exhaust gas pres‐

sure sensor 1 - G450- -3- ⇒ page 88 .
– Detach clamp -1- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Detach clamp -2-, unscrew bolts -1- and take out filter.

– Disconnect control pipe -2- from exhaust pipe behind particu‐

late filter.
– Remove nuts -2-.
Note
Disregard -item 1-.
– Remove bolt -4- and move particulate filter towards rear.

– Slacken nut -2- only until control pipe is loose.

– Guide out and remove control pipe.

Installing
– Installation is carried out in reverse sequence.
• Tightening torque: Exploded view - Lambda probe
⇒ page 80
Note
♦ Before installing, blow out control pipes to particulate filter to‐

wards particulate filter with compressed air (pipes can become
obstructed or may ice up due to condensation).
13.7 Removing and installing control pipe for

exhaust gas pressure sensor 1 - G450-
Removing
WARNING

system
system”, page 4 .
– Detach heat insulation sleeve and remove exhaust gas pres‐

sure sensor 1 - G450- -3- ⇒ page 88 .
– Remove nut -3-.
Note
Nut -3- is accessible from above.


– Detach clamp -2-, unscrew bolts -1- and take out filter.
– Unscrew exhaust gas temperature sender 1 - G235- -2- from

exhaust manifold using a crow foot wrench.
– Clamp off coolant hoses with hose clamps up to 25 mm - 3094-

as shown in illustration.

– Disconnect coolant hoses.
– Remove nut -3- and union nut -1- and take out control pipe.
Installing
– Perform installation in reverse order of removal.
• Tightening torque: Exploded view - Lambda probe
⇒ page 80 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
♦ Before installing, blow out control pipes to particulate filter to‐

wards particulate filter with compressed air (pipes can become
obstructed or may ice up due to condensation).

14 Engine control unit

Overview
⇒ “14.1 Wiring and component check with test box V.A.G 1598/42
”, page 95
⇒ “14.2 Renewing engine control unit J623 ”, page 97
14.1 Wiring and component check with test

box - V.A.G 1598/42-
♦ Adapter cable - V.A.G 1598/39-1-
♦ Adapter cable - V.A.G 1598/39-2-
♦ Test box - V.A.G 1598/42-
14. Engine control unit 95

Note
♦ The test box has 105 sockets. The connecting cable can be
disconnected from the test box. This means that only the cable
(and not the test box) has to be purchased for future engine
control units with different types of connectors.
♦ The smaller of the two connectors on the engine control unit
has the contacts 1 to 60. The larger of the two connectors has
the contacts 1 to 94.
♦ To carry out tests on the 60-pin wiring harness connector, the
adapter cable -V.A.G 1598/39-1- is connected to connector
“A” on the test box. For components connected to 60-pin wiring
harness connector ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
♦ To carry out tests on the 94-pin wiring harness connector, the
adapter cable -V.A.G 1598/39-2- must be connected to con‐
nectors “A” and “B” on the test box. For components connec‐
ted to 94-pin wiring harness connector ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
♦ The test box - V.A.G 1598/42- is designed so it can be con‐
nected both to the wiring harness for the engine control unit
and to the engine control unit itself at the same time.
♦ The advantage of this is that the electronic engine control sys‐
tem remains fully functional when the test box is connected
(for example, for measuring signals when the engine is run‐
ning).
♦ The relevant test procedure will state whether it is necessary
to also connect the engine control unit to the test box.
WARNING
To prevent irreparable damage to the electronic

Protectedcomponents,
select appropriate measuring range before connecting
permitted the by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
measuring cables and observe the test requirements.
– Remove engine control unit ⇒ page 97 .

– Connect the test box - V.A.G 1598/42- to wiring harness with
adapter cable - V.A.G 1598/39-1- or adapter cable - V.A.G
1598/39-2- . Connect earth clip of test box to negative terminal
of battery. The instructions for performing the individual tests
indicate whether or not the engine control unit itself also needs
to be connected to the test box.
– Carry out test as described in appropriate repair procedures.
Installing engine control unit
Installation is performed in the reverse sequence.
– After installation, the locking plate must be re-fitted on the
control unit.
– Clean threaded holes for shear bolts to remove any residue
from locking fluid. This can be done using a thread tap.
– Always use new shear bolts.
– Interrogate event memory and erase if necessary.

14.2 Renewing engine control unit - J623-

♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle attach‐
ment -2- from wiring harness repair set - VAS 1978 B-
♦ Small, commercially available mole grips -3-
Removing
– Before removing the engine control unit - J623- , the adaption
values of the injectors and the ash deposit mass must be read
out. Use ⇒ Vehicle diagnostic tester.
– Store adaption values as electronic file.
– Switch off ignition and remove ignition key after storing elec‐
tronic file containing adaption values.
Note
♦ Not every engine control unit is bolted to a protective housing.

Whether a protective housing is fitted depends on the engine/
gearbox combination.
♦ If the adaption values of the injectors cannot be read out of the
old (defective) engine control unit, the adaption values must
be entered into the new engine control unit manually and the
adaption procedure must be performed accordingly.
♦ The engine control unit -1- is bolted to the protective housing
-5-. To make it more difficult to unscrew the shear bolts -4- for
locking plate -2-, their threads have been coated with locking
fluid.
♦ The protective housing has to be removed before the connec‐
tors can be unplugged from the engine control unit (e.g. to
connect the test box or renew the engine control unit).
– Switch off ignition and remove ignition key.

– Lever off caps on windscreen wiper arms with a screwdriver.

– Loosen hexagon nuts -arrows- several turns.

– Loosen wiper arms from wiper shafts by tilting slightly.
– Completely remove hexagon nuts and detach wiper arms from
wiper shafts.
Note
If necessary, use puller - T10369- or a commercially available

puller to remove wiper arms.
– Pull off rubber seal -1- and remove plenum chamber cover
-2-.
– Release clip -arrow- and remove engine control unit - J623- .
Note
Cover painted surfaces with a cloth to prevent scratching.

The threads of the two shear bolts -4- which are not screwed into
the engine control unit are secured with locking fluid. To unscrew
these two bolts, the threads must therefore be heated with the hot
air blower.
The threads of the two shear bolts -3- which are screwed into the
engine control unit are not secured with locking fluid. Do not apply
heat to the threads in the control unit housing; this is not neces‐
sary and would cause overheating of the control unit.
Select settings on hot air blower as shown in illustration, i.e. set

temperature potentiometer -2- to maximum heat output and two-
stage air flow switch -3- to position 3.
WARNING
Heating the thread of the locking plate also heats up the shear
bolts and parts of the metal housing. Take care to avoid burns.
It is also important to ensure that only the thread is heated and
none of the surrounding components if at all possible. These
should be covered if necessary.
Apply heat to the threads of the shear bolts on the connector side
as shown in the illustration.
Switch on the hot air blower and heat the bolt for approximately
20 ... 30 seconds.

– Unscrew shear bolts using suitable vice-grip pliers (see arrow

in illustration).
– The two shear bolts screwed into the engine control unit do
not need to be heated. They should be removed without being
heated.
– Detach protective housing from connectors.
– Release connectors on engine control unit - J623- and unplug
connectors.
Installing
Installation is performed in the reverse sequence.
– After installation, the protective housing must be re-fitted on
the engine control unit - J623- .
– Clean threaded holes for shear bolts to remove any residue
from locking fluid. This can be done using a thread tap.
– Always use new shear bolts.
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 .
The procedure required after connecting the new engine control
unit is described in the Guided Fault Finding or Guided Functions.
Use ⇒ Vehicle diagnostic tester.
– The injector delivery calibration and the injector voltage cali‐
bration must additionally be re-adapted in the engine control
unit - J623- after the control unit has been renewed (these
functions influence engine power and exhaust emissions).
– On vehicles with particulate filter the current mileage (km)
reading must be stored in the engine control unit via an adap‐
tion procedure.

28 – Glow plug system

1 Checking glow plug system
Automatic glow period control unit - J179- is located in relay and
fuse holder in electronics box in plenum chamber.
1 - Automatic glow period control unit - J179-
The glow plug system is activated via the automatic glow period
control unit - J179- . The automatic glow period control unit - J179-
is capable of self-diagnosis.
A fault is stored in the engine control unit if a fault occurs in the
glow plug system.
The procedure for checking the glow plug system is described in
the “Guided Fault Finding”.
For faster starting, the vehicle is equipped with electronically con‐
trolled glow plugs and a separate glow period control unit.
Each glow plug is activated and diagnosed separately.
1. 101
1.1 Removing and installing glow plugs

Special tools and work‐
shop equipment re‐
quired
♦ U/J extension and
socket, 10 mm -
3220- for engine co‐
des CBAA, CBAB,
CBBB
♦ Socket insert AF 12
for glow plugs 4-
cyl.TDI CR diesel -
VAS 6454- for engine
code CBEA
♦ Pliers - 3314-
Glow plug versions

1 - Glow plug with com‐
bustion chamber pres‐
sure sender (only instal‐
led on vehicles with
engine code CBEA)
2 - Glow plug without
combustion chamber
pressure sender
102 Rep. gr.28 - Glow plug system

Note
♦ On vehicles with en‐

gine code CBEA, a
combustion chamber
pressure sender is in‐
tegrated in each glow
plug.
♦ Designation: glow
plug 1 - Q10- with in‐
ternal cylinder pres‐
sure sender for cylin‐
der 1 - G620-
der 2 - G621-
der 3 - G622-
sure sender for cylin‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
der 4 - G623- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Removing
– Remove engine cov‐
er panel ⇒ page 27 .
Caution
Make sure that no

wire connection is
damaged when un‐
plugging the glow
plug connectors; oth‐
erwise the entire wir‐
ing harness must be
renewed.
When unplugging the
glow plug connectors,
do not compress the
pliers - 3314- with too
much force so that the
support sleeve is not
damaged.
1. 103
– Release retaining clips and move clear wiring harness -2-.
– Apply groove -arrow A- of pliers - 3314- to collar of support

sleeve -arrow B- and pull glow plug connectors off glow plugs.
– Clean glow plug openings in cylinder head; make sure no dirt
gets into cylinder.
Note
♦ Cleaning procedure:
♦ Use a vacuum cleaner to remove coarse dirt.
♦ Spray brake cleaner or suitable cleaning agent into glow plug
openings, let it work in briefly, and blow out with compressed
air.
♦ Then clean the glow plug openings using a cloth moistened
with oil.
– To slacken the glow plugs use special tool U/J extension and
socket, 10 mm - 3220- .
Note
For vehicles with engine code CBEA, use socket insert AF 12 for
glow plugs 4-cyl.TDI CR diesel - VAS 6454- to slacken the glow
plugs.
Installing
– Use a suitable torque wrench to tighten glow plugs.
– Then tighten glow plugs to specified torque. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
• Tightening torque for vehicles with engine codes CBAA,
CBAB, CBBB: 17 Nm
• Tightening torque for vehicles with engine code CBEA: 12 Nm

– Fit glow plug connectors back onto glow plugs.
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Illustration shows glow plug connector of vehicle with engine
code CBEA.
♦ Check that glow plug connectors are securely seated.
1.2 Removing and installing automatic glow

period control unit - J179-
Removing
– Switch off ignition and remove ignition key.
– Remove cover -1- over battery; to do so, press release tab
-arrow-.
– Remove battery ⇒ Electrical system; Rep. gr. 27 .
1. 105
– Remove battery tray -arrows-.

– Detach battery tray from front of air duct.
– Pull out the relay carrier from under the electronics box in en‐
gine compartment -arrow-.
– Pull automatic glow period control unit - J179- -item 1- out of
relay carrier below electronics box in engine compartment.
Installing
Installation is carried out in reverse sequence.
– Install battery ⇒ Electrical system; Rep. gr. 27 .
1.3 Removing and installing Hall sender -

G40-
– Remove poly V-belt ⇒ Rep. gr. 13 .
– Remove vibration damper ⇒ Rep. gr. 13 .
– Remove toothed belt ⇒ Rep. gr. 15 .
– Remove exhaust gas recirculation valve - N18- ⇒ Rep. gr.
26 .
Note
On vehicles with engine code CBEA, the exhaust gas recircula‐

tion valve - N18- is called exhaust gas recirculation control motor
- V338- .

– Unplug electrical connector -arrow- from Hall sender - G40-

and detach connector from retainer.
– Unbolt Hall sender - G40- -arrow-.
– Using a screwdriver, remove projections and take out cover

for repair opening -arrows-.
– Take Hall sender - G40- off cylinder head and guide itsbycon‐
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
nector through repair opening in toothed belt cover.
Installing
Installation is carried out in reverse sequence. Note the following:
♦ Seal repair opening in toothed belt cover with rubber plug; for
rubber plug refer to ⇒ ETKA (Electronic parts catalogue) .
– Fit toothed belt and adjust valve timing ⇒ Rep. gr. 15 .
– Install vibration damper ⇒ Rep. gr. 13 .
– Install poly V-belt ⇒ Rep. gr. 13 .
1.4 Removing and installing engine speed

sender - G28-
♦ Socket (4 mm) - T10370-
1. 107
Removing
– Remove oil filter bracket ⇒ Rep. gr. 17 .

– Unplug electrical connector -arrow- at engine speed sender -
G28- using assembly tool - T10118- .
Note
To release electrical connector without assembly tool - Protected

T10118- ,
press connector on engine speed sender in with a screwdriver
and at the same time lift release tab with a thin wire hook.
– Unscrew securing bolt -2- for engine speed sender - G28-

-item 1- using socket (4 mm) - T10370- .
Installing
– Install oil filter bracket ⇒ Rep. gr. 17 .
• Tightening torque
⇒ “2 Overview of fitting locations - injection system”, page 6

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What safety precautions should be observed when working on vehicles?

What safety precautions should be observed when working on vehicles?

What are the main components of the fuel injection system?

What are the main components of the fuel injection system?

Service

Service Department. Technical Information

All rights reserved.

Copyright © 2018 Audi AG, Ingolstadt A0050478920

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13.4 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 87

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

23 – Mixture preparation - injection

1.1 Safety precautions when using testers

1.2 Safety precautions for vehicles with

1. Safety precautions and rules for cleanliness 1

1.3 Safety precautions when working on the

Risk of injury - fuel system operates under high pressure

• Clean tools and workbench etc. before working on the injection

2 Rep. gr.23 - Mixture preparation - injection

• If the high-pressure fuel lines are to be re-used, you must mark

• Do not dismantle individual common rail components. If there

1.4 Safety precautions when working on the

1. Safety precautions and rules for cleanliness 3

1.5 Safety precautions when working on the

Danger from toxic exhaust gases

Risk of damage to flexible joint

1.6 Checking vacuum system

4 Rep. gr.23 - Mixture preparation - injection

♦ Porous or leaking lines

1. Safety precautions and rules for cleanliness 5

2 Overview of fitting locations - injec‐

6 Rep. gr.23 - Mixture preparation - injection

14 - Component on side of intake manifold

2. Overview of fitting locations - injection system 7

17 - Component on front of intake manifold

8 Rep. gr.23 - Mixture preparation - injection

B - Brake light switch - F- and brake pedal switch - F47-

2. Overview of fitting locations - injection system 9

❑ Removing and installing ⇒ Rep. gr. 26

Fitting location of engine control unit - J623-

Accelerator position sender - G79- and accelerator position send‐

The accelerator position sender - G79- and accelerator position

Brake light switch - F- and brake pedal switch - F47- -1-

10 Rep. gr.23 - Mixture preparation - injection

Clutch position sender - G476-

Fuel system pressurisation pump - G6-

Charge pressure sender - G31- with intake air temperature send‐

2. Overview of fitting locations - injection system 11

Components at front of engine

1 - (Engine code CBEA) pressure differential sender - G505-

12 Rep. gr.23 - Mixture preparation - injection

Fitting locations and connectors (engine codes CBAA, CBAB,

Fitting locations and connectors (engine code CBEA)

2. Overview of fitting locations - injection system 13

Pump for exhaust gas recirculation cooler - V400-

Hall sender - G40-

Exhaust gas pressure sensor 1 - G450- -3- (engine code CBEA)

14 Rep. gr.23 - Mixture preparation - injection

Radiator outlet coolant temperature sender - G83- (engine codes