Direct Petrol Injection and Ignition System (4-Cyl 1 8 LTR 4-Valve Turbo With Timing Chain)

Service
Direct petrol injection and ignition system (4-cyl. 1.8 ltr.

4-valve turbo with timing chain)
Engine ID
CAB CAB CDH CDH CCU CAB
A B A B A D
Edition 10.2011
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
24 - Mixture preparation - injection
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
A005A400320
Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤
Direct petrol injection and ignition system (4-cyl. 1.8 ltr. 4-valve turbo with timing chain) - Edition
10.2011
Contents
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety precautions and rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General notes on self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when using testers and measuring instruments during a road test . . . . 1
1.3 Safety precautions for vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Rules for cleanliness and instructions for working on fuel system . . . . . . . . . . . . . . . . . . . . 3
1.6 Safety precautions when working on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Reducing pressure in high-pressure section of injection system . . . . . . . . . . . . . . . . . . . . 4
1.8 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1 Air cleaner - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4 Removing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 Intake manifold - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2 Fuel rail - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3 Removing and installing intake manifold with fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.4 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1 High-pressure pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.1 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.2 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7 Components of injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.1 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.2 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.3 Checking residual pressure in fuel system (up to high-pressure pump) . . . . . . . . . . . . . . 44
7.4 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.5 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.6 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.7 Checking intake manifold change-over function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.8 Checking dual non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8 Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.1 Lambda probes - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.2 Removing and installing Lambda probe G39 and Lambda probe heater Z19 before catalytic
converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.3 Removing and installing Lambda probe after catalytic converter G130 and Lambda probe 1
heater after catalytic converter Z29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.1 Wiring and component check with test box V.A.G 1598/42 . . . . . . . . . . . . . . . . . . . . . . . . 56
9.2 Renewing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1 General notes and safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Contents i
10.2011
2 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.1 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.2 Ignition system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.3 Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.4 Removing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
ii Contents
10.2011
24 – Mixture preparation - injection

1 Safety precautions and rules for
cleanliness
1.1 General notes on self-diagnosis

♦ The engine control unit has a self-diagnosis capability. Inter‐
rogate the event memory before carrying out repairs. The
vacuum hoses and connections must be checked (to prevent
unmetered air).
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. O-type clips or screw-type clips must not be
used.
♦ A voltage of at least 11.5 V is required for proper operation of
the electrical components.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and will
damage the Lambda probe.
♦ The vehicles are fitted with a crash/fuel shut-off system. This
reduces the risk of a vehicle fire after a crash. The fuel pump
relay deactivates the fuel pump.
♦ At the same time, this system also improves the engine's start‐
ing performance. Each time the driver's door is opened, the
fuel pump is activated for 2 seconds. Initial fuel pressure will
then build up. Observe safety precautions ⇒ page 1 .
♦ Use release tool -T40138- to unplug connectors that cannot
be accessed easily.
1.2 Safety precautions when using testers

and measuring instruments during a
road test
Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
Accidents can be caused if the driver is distracted by test

equipment while road-testing, or if test equipment is not prop‐
erly secured.
Persons sitting in the front passenger's seat could be injured if
the airbag is triggered in an accident.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Test equipment must always be secured on the rear seat
with a strap and operated from the rear seat by a second
person.
1. Safety precautions and rules for cleanliness 1

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1.3 Safety precautions for vehicles with

start/stop system
WARNING
Risk of injury due to automatic engine start on vehicles with

start/stop system.
♦ On vehicles with activated start/stop system (this is indi‐
cated by a message in the instrument cluster display), the
engine may start automatically on demand.
♦ Therefore it is important to ensure that the start/stop sys‐
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).
1.4 Safety precautions when working on the

fuel system
WARNING
The fuel system operates at extremely high pressure. This can

cause injury.
♦ The fuel system is pressurised. The fuel pressure in the
high-pressure section of the injection system must be re‐
duced to a residual pressure prior to opening; for proce‐
dure see ⇒ page 4 .
♦ The connection must be opened immediately after reduc‐
ing the pressure; wrap a cloth around the connection and
allow the residual pressure (approx. 7 bar) to dissipate.
Caution
To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
2 Rep. gr.24 - Mixture preparation - injection

10.2011
1.5 Rules for cleanliness and instructions

for working on fuel system
When working on the fuel system note the following warnings:
WARNING
♦ If the battery is not disconnected, the fuse for the fuel

pump control unit -J538- must be removed as a precau‐
tionary measure before opening the fuel system because
the fuel pump will otherwise be activated by the contact
switch on the driver's door.
♦ The fuel system is pressurised. The fuel pressure in the
high-pressure section of the injection system must be re‐
duced to a residual pressure prior to opening; for proce‐
dure see ⇒ page 4 .
♦ The connection must be opened immediately after reduc‐
ing the pressure; wrap a cloth around the connection and
allow the residual pressure (approx. 7 bar) to dissipate.
Note
Removing the fuse (located in fuse carrier in dash panel on driv‐

er's side) will interrupt the power supply from »terminal 30« for
the fuel pump control unit -J538- . ⇒ Current flow diagrams, Elec‐
trical fault finding and Fitting locations
Even small amounts of dirt can cause malfunctions. For this rea‐
son, please observe the following rules when working on the fuel
supply system and injection system:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Plug open lines and connections with suitable protective caps
immediately.
♦ Place parts that have been removed on a clean surface and
cover them over. Do not use fluffy cloths.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).
♦ When the system is open: Do not work with compressed air.
Do not move the vehicle unless absolutely necessary.

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1.6 Safety precautions when working on the

ignition system
To prevent injuries to persons and/or irreparable damage to the
fuel injection and ignition system, the following must be noted:
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as the
ignition system and gas-discharge headlights.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off the ignition before connecting or discon‐
necting injection or ignition system wiring or tester cables.
♦ If engine is to be operated at cranking speed without it starting
(e.g. compression test), unplug connectors from ignition coils
and remove fuse for electric fuel pump.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. The event memory should therefore be inter‐
rogated and (if necessary) erased after completing the tests
and any repair work that may be required.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ If the event memory has been erased,
permitted you must
unless authorised generate
by AUDI AG. AUDItheAG does not guarantee or accept any liability
readiness code again. with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Always switch off the ignition before cleaning the engine.

♦ If the engine has to be operated at the starting speed without
actually starting (e.g. to test compression pressure), detach
the four connectors from the ignition coils using assembly tool
-T40039- ⇒ page 64 . Also remove fuse for fuel pump control
unit -J538- .
Note
♦ The fuse is located in the fuse holder in the dash panel.

♦ Removing the fuse (located in fuse carrier in dash panel on
driver's side) will interrupt the power supply from »terminal 30«
for the fuel pump control unit -J538- . ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
1.7 Reducing pressure in high-pressure

section of injection system
WARNING
The fuel system operates at extremely high pressure. This can

cause injury.
♦ The injection system consists of a high-pressure section
(maximum approx. 140 bar) and a low-pressure section
(approx. 7 bar).
♦ Prior to opening the high-pressure section (e.g. when re‐
moving the high-pressure pump, fuel rail, injectors, fuel
pipes or fuel pressure sender -G247- ), the fuel pressure
in the high-pressure section must be reduced to a residual
pressure of approx. 7 bar. The procedure is described be‐
low.
Reducing fuel pressure in high-pressure section:

– Connect a ⇒ Vehicle diagnostic tester.

10.2011
– Start engine and run at idling speed.

– Select „Engine electronics“ in vehicle self-diagnosis.
– Then select „Measured values“.
– Select „Fuel pressure“ from the list.
– With the engine idling, the fuel pressure displayed will be be‐
tween 30 and 40 bar.
– Pry off cover -1- on left side/right side of dash panel using re‐
moval wedge -3409- -arrow- or similar.

10.2011
– With engine idling, pull out fuse for fuel pump control unit -
J538- in fuse carrier in dash panel (driver's side) ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
Note
Removing the fuse will interrupt the voltage supply »terminal 30«
for the fuel pump control unit -J538- .
– Observe fuel pressure displayed on diagnostic system.

• The fuel pressure will decrease very quickly because the me‐
chanical high-pressure pump is no longer being supplied with
fuel by the fuel system pressurisation pump -G6- .
– Switch off ignition as soon as fuel pressure has dropped to
approx. 8 bar.
Note
Fuel pressure must not fall below 6 bar, otherwise the engine will
stall (this could damage the catalytic converter).
WARNING
There is a risk of injury: avoid skin contact with fuel.

♦ The fuel lines are still filled with fuel, however the fuel is
no longer under high pressure. Wear safety goggles and
protective clothing when opening the fuel system.
♦ Before opening the high-pressure section, wrap a cloth
around the connection.
– The high-pressure system must be opened »immediately« af‐

ter reducing the fuel pressure; wrap a clean cloth around the
connection. Catch the escaping fuel.
Note
The pressure will increase again due to the effect of residual heat
if the high-pressure system is not opened immediately.
Additional steps required

– Refit fuse.
– Erase event memory and generate readiness code in engine
control unit in „Guided Functions“ mode.
1.8 Checking vacuum system

Special tools and workshop equipment required

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♦ 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
♦ Lines porous or leaking
– 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.

10.2011
2 Injection system
2.1 Technical data

Engine data 1.8 ltr. turbo FSI engine
Idling speed is not adjustable (con‐ 640 ... 800 rpm
trolled by idling speed stabilisa‐
tion).
Maximum rpm governed by deac‐ 6500 rpm
tivation of fuel injectors
Fuel pressure Initial fuel pressure up to 3.0 ... 10.5 bar
high-pressure pump (gen‐
erated according to require‐
ments by electric fuel pump
in fuel tank)
Pressure in high-pressure 25 ... 150 bar
fuel circuit (generated by
mechanical single-plunger
pump) at a coolant temper‐
ature of approx. 85°C.
2.2 Overview of fitting locations

Components A to I are not shown in the overview.

10.2011
1 - Lambda probe -G39- and

Lambda probe heater -Z19-
❑ Fitting location
⇒ page 16
❑ Removing and installing
⇒ page 53
2 - Lambda probe after catalyt‐
ic converter -G130- and Lamb‐
da probe heater 1 after catalyt‐
ic converter -Z29-
⇒ page 16
⇒ page 54
3 - Fuel pressure regulating
valve -N276-
⇒ page 14
4 - High-pressure pump
⇒ page 14
5 - Vacuum unit for air flow
control flaps (intake manifold
flaps)
⇒ page 13
6 - Intake manifold flap valve -
N316-
⇒ page 13
7 - Engine speed sender -G28-
⇒ page 14
❑ 4.5 Nm
8 - Activated charcoal filter solenoid valve 1 -N80-
9 - 6-pin connectors
❑ For Lambda probe -G39- and Lambda probe heater -Z19- (black)
❑ Lambda probe after catalytic converter -G130- and Lambda probe 1 heater after catalytic converter -Z29-
(brown connector)
❑ Fitting location ⇒ page 16
10 - Electrical connectors for
❑ Knock sensor 1 -G61-
❑ Intake manifold flap valve -N316-
❑ Fuel pressure sender -G247-
❑ Intake manifold flap potentiometer -G336-
❑ Coolant temperature sender -G62-
❑ Hall sender -G40-
❑ Injectors -N30- ... -N33-
11 - Engine control unit -J623-
❑ Removing and installing ⇒ page 58
2. Injection system 9
10.2011
12 - Charge pressure sender -G31-

❑ Removing and installing ⇒ Rep. gr. 21
13 - Throttle valve module -J338- , throttle valve drive (electric throttle operation) -G186-
❑ Throttle valve drive angle sender 1 -G187- and throttle valve drive angle sender 2 -G188-
❑ Throttle valve module -J338- must always be re-adapted to engine control unit -J623- after removal and
installation or if it has been renewed
14 - Intake air temperature sender -G42-
15 - Knock sensor 1 -G61-
❑ To remove, first remove coolant pump with thermostat
❑ 20 Nm
16 - Coolant temperature sender -G62-
17 - Valve for oil pressure control -N428-
18 - Oil pressure switch for reduced oil pressure -F378-
19 - Fuel pressure sender -G247-
20 - Oil pressure switch -F22-
❑ Removing, installing and testing ⇒ Rep. gr. 17
21 - Intake manifold flap potentiometer -G336-
22 - Hall sender -G40- (camshaft position sensor)
23 - Camshaft control valve 1 -N205-
24 - Ignition coils with output stages
❑ Puller -T40039- is required for removing ignition coils from cylinder head.
25 - Turbocharger air recirculation valve -N249-
❑ Located directly on turbocharger ⇒ page 17
26 - Charge pressure control solenoid valve -N75-
❑ Located directly on turbocharger ⇒ page 17
27 - Air mass meter -G70-

10.2011
A - Diagnostic connector
❑ In driver's knee restraint
B - Fuel pump control unit -J538-
C - Brake light switch - F- and brake pedal switch -F47-
❑ In footwell on brake pedal
D - Clutch position sender -G476-
❑ Only fitted on vehicles with manual gearbox
E - Accelerator position sender -G79- and accelerator position sender 2 -G185-
❑ On accelerator pedal (both senders are accommodated in one housing)
F - Radiator fan control unit -J293-
❑ Incorporated in radiator fan
G - Injectors
❑ In fuel rail
❑ Injector, cylinder 1 -N30-
H - Continued coolant circulation pump -V51-
❑ For hot countries only
I - Left electrohydraulic engine mounting solenoid valve -N144-
❑ Not installed in all vehicles (depends on gearbox type)
Engine control unit -J623-

♦ In left electronics box in engine compartment
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Fuel pump control unit -J538- -1-

Removing and installing ⇒ Rep. gr. 20
Accelerator position sender -G79- and accelerator position send‐

er 2 -G185-
2 - Electrical connector
Clutch position sender -G476- -2-

Integrated functions: clutch pedal switch for engine start -F194-
and clutch pedal switch -F36- (manual gearbox only)
1 - Brake light switch -F- and brake pedal switch -F47-
Continued coolant circulation pump -V51-

1 - Electrical connector for continued coolant circulation pump -
V51-

10.2011
Ignition coils
1 - Ignition coil 1 with output stage -N70-
Fuel pressure sender -G247- -1-

• Make sure that connecting piece is tightened to specified tor‐
que „25 Nm“ before installing fuel pressure sender -G247-
Intake manifold flap valve -N316- -2-

1 - Vacuum unit for intake manifold flaps
Intake manifold flap potentiometer -G336- -1-
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Hall sender -G40- -1-
Electrical connectors
1 - From activated charcoal filter solenoid valve 1 -N80-
2 - From knock sensor 1 -G61-
3 - (14-pin connector) from intake manifold flap valve -N316- , fuel
pressure sender -G247- , intake manifold flap potentiometer -
G336- , coolant temperature sender -G62- and Hall sender -G40-
4 - (8-pin) from injectors -N30-...-N33-
5 - From throttle valve module -J338-
6 - From intake air temperature sender -G42-
High-pressure pump
1 - Fuel pressure regulating valve -N276-
- -Arrows- denote securing bolts
Engine speed sender -G28- -2-

10.2011
Camshaft control valve 1 -N205- -arrow-
Components
2 - Throttle valve module -J338-
Coolant temperature sender -G62- -1-
Charge pressure sender -G31- -1-

– Removing and installing ⇒ Rep. gr. 21
10.2011
Oil pressure switch

2 - Oil pressure switch -F22-
3 - Oil pressure switch for reduced oil pressure -F378-
Valve for oil pressure control -N428- -3-
Component and electrical connectors

2 - Lambda probe after catalytic converter -G130- and Lambda
probe heater 1 after catalytic converter -Z29-
3 - Lambda probe -G39- and Lambda probe heater -Z19-
Lambda probes

10.2011
Components on turbocharger
1 - Turbocharger
2 - Vacuum unit for turbocharger; checking, adjusting, removing
and installing ⇒ Rep. gr. 21
3 - Charge pressure control solenoid valve -N75-
4 - Turbocharger air recirculation valve -N249- (note installation
position, refer to next illustration)
For removing and installing components on turbocharger, refer to
⇒ Rep. gr. 21 .
Pay attention to installation position of turbocharger air recircula‐

tion valve -N249-
10.2011
3 Air cleaner
3.1 Air cleaner - exploded view
1 - Hose clip
2 - Air hose
3 - Hose clip
4 - Air duct
❑ Clipped into air cleaner
housing
❑ Clean dirt and leaves
out of air duct
5 - Air duct
out of air duct
6 - Air duct
❑ Secure to lock carrier
(2 Nm)
out of air duct
7 - Rubber grommet
8 - Water drain hose
❑ Important: Clean any
leaves and dirt out of
water drain hose
9 - Guide for water drain hose
10 - Hot air intake (countries
with cold climates only)
❑ Slide hot air intake into
air cleaner as far as
stop; then turn clock‐
wise until it engages no‐
ticeably
11 - Air cleaner (bottom sec‐
tion)
❑ Clean any salt residue, leaves and dirt out of air cleaner (bottom section)
❑ Important: Check for dirt in water drain and clean as required
12 - Retainer for air cleaner (bottom section)
❑ Must engage positively
❑ Do not use any lubricants
13 - Variable intake manifold change-over valve -N335-
❑ Bypass flap and variable intake manifold change-over valve -N335- are not installed on certain equipment
versions or on vehicles for certain export markets
14 - Bolt
❑ Only if variable intake manifold change-over valve -N335- is fitted
15 - Air filter element
❑ Always use genuine part for air filter element
❑ Maintenance intervals ⇒ Maintenance ; Booklet 812

10.2011
❑ Also clean snow screen (if fitted)

16 - Frame insert for air cleaner (bottom section)
17 - Air cleaner (top section)
❑ Clean any salt residue, leaves and dirt out of air cleaner (top section)
18 - Bolt
19 - O-ring
❑ Renew if damaged
20 - Air mass meter
❑ Removing and installing air mass meter -G70- with intake air temperature sender -G42- ⇒ page 47
3.2 Removing and installing engine cover

panel
Removing
– Pull engine cover panel carefully off retaining pins. 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).
– Press engine cover panel with both hands into the rubber
grommets.
3.3 Removing and installing air filter ele‐

ment
Removing air filter element
– Unplug electrical connector -1- at air mass meter -G70- .
3. Air cleaner 19
10.2011
– Release hose clip -2- securing air hose (going to turbocharger)

and disconnect hose from air mass meter -G70- .
– Remove all bolts -arrows- from air cleaner (top section) and lift
out air cleaner (top section).
– Take out old filter element.
Installing air filter element
To ensure the proper 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 or water could
reach the air mass meter -G70- and affect the air mass value.
♦ This would lead to loss of power, since a smaller injection
quantity is calculated.
♦ Always use genuine part for air filter element.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. Do not use any lubri‐
cants containing 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.
– Blow out water drain -arrow- in air cleaner (bottom section)

with compressed air.
Note
Disregard items 1, 2 and 3.
– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections); use a vacuum cleaner if necessary.
– Check for salt residue, dirt and leaves in air mass meter and
air intake hose (engine intake side).
– Check for dirt and leaves in air duct going from lock carrier to
air cleaner housing.
– If fitted, re-connect vacuum hose at variable intake manifold
change-over valve -N335- .
– When installing the air filter element, check that it is properly
centred in the retainer in the air cleaner (bottom section).
– Fit the top section of the air cleaner carefully on the bottom
section, without using force. Make sure the top section of the
air cleaner is fitted straight on the air filter element (note posi‐
tion of sealing lip on air filter element).
– Ensure secure fit of intake hose at air mass meter -G70- .
The remaining installation steps are carried out in the reverse se‐
quence.

10.2011
3.4 Removing air cleaner housing

Removing
– Release hose clip -2- securing air hose (going to turbocharger)
– Remove air duct -3-.
– Detach vacuum hose -arrow- (if fitted).
3. Air cleaner 21
10.2011
– Release retainer -4- for bottom section of air cleaner (press in

rubber on left and right side and pull upwards).
Note
♦ These components (bypass flap with variable intake manifold

change-over valve -N335- -1-) are not installed on certain
equipment versions or on vehicles for certain export markets.
♦ Do not use lubricant when installing retainer.
– Disconnect electrical connector at variable intake manifold

change-over valve -N335- (if fitted).
– Carefully take out complete air cleaner housing.
Installing
important to observe the following instructions.
Note
This would lead to loss of power, since a smaller injection
♦ Use a silicone-free lubricant when installing the intake hose.
– If warm air intake hose is fitted (for countries with cold climates
only), make sure that air intake connection has engaged prop‐
erly -arrows- (pay attention to markings).
– Check water drain hose -1- in air cleaner (bottom section) for
dirt and other obstructions (clean if necessary).
– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections); use a vacuum cleaner if necessary.
– Check for dirt in air duct leading to air filter element.
– Re-attach electrical connector at variable intake manifold
change-over valve -N335- (if fitted).
– Re-install air cleaner (bottom section).
Note
The water drain hose must be routed straight downwards without

kinks.

10.2011
– Slide vacuum hose -3- (if fitted) back onto connection of vari‐
able intake manifold change-over valve -N335- -1-.
– Fit the top section of the air cleaner carefully on the bottom
section, without using force.
Note
Before tightening bolts, make sure that top section of air cleaner
is inserted into groove on bottom section of air cleaner (to prevent
air leaks).
– Then screw top section of air cleaner back onto bottom sec‐
tion.
– Ensure secure fit of intake hose at air mass meter -G70- .
– Re-connect electrical connector at air mass meter -G70- .
– The remaining installation steps are carried out in the reverse
sequence.
3. Air cleaner 23
10.2011
4 Intake manifold
4.1 Intake manifold - exploded view
1 - Screw for intake air temper‐

ature sender -G42-
❑ 5 Nm
2 - Intake air temperature
sender -G42-
3 - Activated charcoal filter sol‐
enoid valve 1 -N80-
❑ With dual non-return
valve
4 - Intake manifold
⇒ page 26
5 - Vacuum unit for air flow
control flaps (intake manifold
flaps)
6 - Intake manifold flap valve -
N316-
7 - Injectors
❑ Renew O-ring and teflon
ring
❑ Ensure correct installa‐
tion position.
⇒ page 36
8 - Intake manifold support
9 - Bolt
❑ For intake manifold sup‐
port
❑ 23 Nm
10 - Securing nut for intake
manifold support
❑ 10 Nm
11 - Bolts for throttle valve module -J338-
❑ 10 Nm
12 - Throttle valve module -J338- , throttle valve drive for electric throttle -G186-
❑ Throttle valve drive angle sender 1 for electric throttle -G187- and throttle valve drive angle sender 2 for
electric throttle -G188-
❑ Throttle valve module -J338- must be re-adapted to engine control unit -J623- after removal and instal‐
lation or if it has been renewed, see vehicle diagnostic, testing and information system -VAS 5051B-
„Guided Functions“
13 - Seal
❑ Renew

10.2011
4.2 Fuel rail - exploded view
1 - Injector
❑ With combustion cham‐
ber ring seal (teflon ring
seal): always renew
❑ Renew O-rings
❑ Ensure correct installa‐
tion position.
⇒ page 36
2 - Support ring
3 - Fuel rail
⇒ page 30
❑ With fuel pressure regu‐
lating valve -N276-
❑ An electric fuel pump
(fitted in fuel tank) sup‐
plies fuel to the mechan‐
ical high-pressure pump
❑ When installing the
high-pressure fuel
pump, it is essential to
ensure that no dirt en‐
ters the fuel system.
❑ The fuel system must
not be under pressure
when installing the high-
pressure pump; proce‐
dure for reducing fuel
pressure ⇒ page 4
❑ Fuel pipes must be free
of tension when instal‐
led.
⇒ page 33
5 - Roller tappet
6 - Fuel pressure regulating valve -N276-
7 - Bolts for high-pressure pump
❑ Renew
❑ 8 Nm + 90°
8 - Connecting piece for fuel supply line at fuel rail
❑ Renew
❑ 25 Nm
9 - Union nut for fuel supply line
❑ 20 Nm
10 - Air flow control flaps (intake manifold flaps)
11 - Gasket
❑ Renew
12 - Intake manifold
4. Intake manifold 25
10.2011
13 - Vacuum unit for air flow control flaps (intake manifold flaps)
14 - Throttle valve module -J338- , throttle valve drive for electric throttle -G186-
❑ Throttle valve drive angle sender 1 for electric throttle -G187- and throttle valve drive angle sender 2 for
electric throttle -G188-
❑ Throttle valve module -J338- must always be re-adapted to engine control unit -J623- after removal and
installation or if it has been renewed. Use ⇒ Vehicle diagnostic tester in „Guided Functions“ mode.
❑ 7 Nm
15 - Bolts for intake manifold
❑ 9 Nm
16 - Intake manifold flap potentiometer -G336-
❑ After intake manifold flap potentiometer -G336- or intake manifold has been removed and installed or
renewed, intake manifold flap potentiometer -G336- must be adapted to engine control unit -J623- . Use
⇒ Vehicle diagnostic tester in „Guided Functions“ mode.
17 - Fuel pressure sender -G247-
❑ 27 Nm
❑ Lubricate threads lightly with clean engine oil
❑ Always renew connecting piece and tighten to 25 Nm
4.3 Removing and installing intake manifold

with fuel rail
After the fuel rail has been removed or renewed, intake manifold
flap potentiometer -G336- must be adapted to engine control unit
-J623- . Use ⇒ Vehicle diagnostic tester in „Guided Functions“
mode.
♦ Assembly tool -T10118-
♦ Hose clip pliers -V.A.G 1921-

10.2011
♦ Socket Torx T30 -T10347-
Removing
Note
♦ The injectors can only be accessed after the intake manifold

and the fuel rail with the air flow control flaps have been re‐
moved.
♦ The combustion chamber ring seal (teflon) and the O-ring
must be renewed.
♦ Intake manifold - exploded view ⇒ page 24
♦ Fuel rail - exploded view ⇒ page 25
WARNING
The fuel system is pressurised. The fuel pressure in the high-

pressure part of the injection system must be reduced to a
residual pressure prior to opening; for procedure see
⇒ page 4 .
– Disconnect negative terminal from battery.

– Remove engine cover panel ⇒ page 19 .
– Disconnect vacuum line -arrow- leading to activated charcoal
filter.
– Unplug following electrical connectors:
2 - From knock sensor 1 -G61-
3 - From intake manifold flap valve -N316- , fuel pressure sender
-G247- and Hall sender -G40-
4 - From injectors
5 - Throttle valve module -J338-
10.2011
Unplug electrical connector -1- at Hall sender -G40- .
– Open hose clip -arrow- securing air intake hose and discon‐
nect hose downwards from throttle valve module -J338- .
– Disconnect vacuum line -1- at connection -2-.

– Remove crankcase breather hose -3-.
Note
– Release spring-type clip -top arrow- and detach fuel supply

hose from high-pressure pump.
– Unscrew union nut for high-pressure pipe -bottom arrow- at
high-pressure pump.
Note
♦ The fuel system must not be under pressure.

♦ Use a clean cloth to catch escaping fuel.
♦ Seal off open connections with clean caps. Make sure no dirt
gets into the fuel system.

10.2011
– Disconnect vacuum line -arrow- at intake manifold flap valve -

N316- .
– Remove bolt -arrow- for coolant line from intake manifold.
– Unplug electrical connector at fuel pressure sender -G247-

-1-.
– Slightly loosen securing nut -1- and remove bolt -2-.
10.2011
– Loosen oil filter with Hazet strap wrench -2171-1- or with oil
filter tool -3417- and remove oil filter.
– Unscrew bolts from intake manifold using socket Torx T30 -
T10347- .
Note
To remove the bolts that cannot be accessed if you do not have

socket Torx T30 -T10347- , the throttle valve module -J338- must
be removed.
– Carefully pull intake manifold and fuel rail slightly away from
cylinder head.
– Unplug electrical connector -1- from intake manifold flap po‐

tentiometer -G336- and then detach intake manifold.
Note
♦ The injectors can remain in the fuel rail.

♦ Block off intake ports with a clean cloth.
– Disconnect intake manifold from fuel rail ⇒ page 30 .

Installing
Note
Make sure that injectors are installed correctly.
– Fit intake manifold onto studs (left and right) on cylinder head.
sequence.
• Tightening torque: intake manifold - exploded view
⇒ page 24
• Tightening torque: fuel rail - exploded view ⇒ page 25
4.4 Removing and installing fuel rail

After the fuel rail has been removed or renewed, intake manifold
flap potentiometer -G336- must be adapted to engine control unit
-J623- .
Note
Intake manifold must be removed; refer to ⇒ page 26 for removal

procedure.
– Release hose clip -1-.

– Remove hoses from activated charcoal filter.
– Disconnect fuel pipe at fuel rail.

10.2011
– Unscrew two bolts -arrows- on fuel rail.

– Detach fuel rail from intake manifold.
Installing
– Always renew both connecting pieces for fuel supply line.
– Connect fuel pipe.
– Re-connect electrical connectors.
– Install intake manifold ⇒ page 26 .
• Tightening torque: intake manifold - exploded view
⇒ page 24
• Tightening torque: fuel rail - exploded view ⇒ page 25
– Install in reverse order.
10.2011
5 High-pressure pump
5.1 High-pressure pump - exploded view
WARNING
Fuel system operates under high pressure. Always dissipate

fuel pressure prior to opening fuel system. For procedure, refer
to ⇒ page 4
1 - Fuel supply line from tank

2 - Bolt for high-pressure pump
❑ Renew
❑ 8 Nm + 90°
❑ An electric fuel pump
(fitted in fuel tank) sup‐
plies fuel to the mechan‐
ical high-pressure pump
❑ When installing the
high-pressure fuel
pump, it is essential to
ensure that no dirt en‐
ters the fuel system.
❑ The fuel system must
not be under pressure
when installing the high-
pressure pump; proce‐
dure for reducing fuel
pressure ⇒ page 4
❑ Fuel pipes must be free
of tension when instal‐
led.
⇒ page 33
4 - O-ring
❑ Renew
5 - Roller tappet
❑ May remain lodged in‐
side vacuum pump after
removal of high-pres‐
sure pump
6 - Connecting piece
❑ Not available as re‐
placement part, part of high-pressure pump
❑ Do not loosen
7 - Adapter
❑ An adapter may be fitted between connecting piece and fuel supply line on some versions
❑ If fitted, adapter must be renewed; refer to ⇒ Electronic parts catalogue
❑ 25 Nm
8 - High-pressure fuel pipe
❑ Fuel pipe must be free of tension when installed.

10.2011
❑ 20 Nm
9 - Bolt for high-pressure pump
❑ Renew
❑ 8 Nm + 90°
10 - Connecting piece for fuel supply line at fuel rail
❑ Renew
❑ 25 Nm
11 - Fuel rail
5.2 Removing and installing high-pressure

pump
WARNING
Fuel system operates under high pressure. Always dissipate

fuel pressure prior to opening fuel system. For procedure, refer
to ⇒ page 4
Note
♦ The high-pressure pump must only be removed when the en‐

gine is cold.
♦ When installing the high-pressure fuel pump, it is essential to
ensure that no dirt enters the fuel system.
♦ Use a cloth to catch escaping fuel.
♦ The O-ring must always be renewed.
♦ Always ensure that the high-pressure fuel pipes are free of
tension when tightening the connections.
Removing
– Remove engine cover panel.
– Detach electrical connector -2- from fuel pressure regulating
valve -N276- .
5. High-pressure pump 33
10.2011
– Disconnect both fuel lines -arrows-.
– Remove 2 bolts -arrows-.

– Carefully pull out high-pressure fuel pump. It is possible that
the roller tappet may remain lodged in the vacuum pump.
Installing
– Renew O-ring for high-pressure pump.
– Fit roller tappet in vacuum pump (check roller tappet for dam‐
age first).
Note
♦ The roller tappet must be positioned at the lowest point when

installing the high-pressure pump.
♦ If the old high-pressure pump is re-installed, or if a used pump
is installed, the connecting piece on the pump for the fuel sup‐
ply line must be renewed. Refer to high-pressure pump -
exploded view (item 11) ⇒ page 32 .
– Turn crankshaft until roller tappet is positioned at lowest point.

– Fit high-pressure pump in vacuum pump and secure in posi‐
tion.
– Tighten bolts hand-tight.
– Renew connecting piece at high-pressure pump.
• Tightening torque: refer to exploded view of high-pressure
pump ⇒ page 32 .
– Now tighten bolts in diagonal sequence to specified torque,
refer to high-pressure pump - exploded view ⇒ page 32 .
– Tighten union nut on fuel supply line hand-tight. Align so that
parts are free of tension.
• Tightening torque for fuel supply line (union nut): Intake mani‐
fold - exploded view ⇒ page 24 .

10.2011
– Re-attach electrical connector -2- for fuel pressure regulating

valve -N276- .
– Put back fuse if it has been removed.
Note
Check fuel system for leaks.
5. High-pressure pump 35
10.2011
6 Injectors
6.1 Removing and installing injectors

♦ Tool kit with puller -T10133-
Note
Puller T10133/2 has been modified and now has the designation
puller T10133/2 A . If you have not yet received the new tool you
can make the modification yourself.
Modifying puller T10133/2 to make it equivalent to puller

T10133/2 A
– File out a semi-circular recess as shown in the illustration. The
recess allows the tool to be pushed further onto the injector so
the contact surface is increased.
– For identification purposes, mark the modified tool with the
letter „A“ after the tool number.

♦ Round file, approx. 6 mm
Removing
– Remove engine cover panel ⇒ page 19 .
– Remove intake manifold and fuel rail ⇒ page 26 .
Removing injectors (from fuel rail)
Carefully pull injectors out of fuel rail.

10.2011
Removing injectors (from cylinder head)

Injector (old version)
1 - Combustion chamber ring seal (teflon ring seal) - renew; when
fitting, do not grease ring or use any other lubricant
2 - Support ring is replaced by intermediate ring; see next illus‐
tration ⇒ page 37
3 - Injector
4 - Spacer ring (renew if damaged)
5 - O-ring (renew; apply thin coating of clean engine oil prior to
installation)
6 - Support ring (via this support ring, the fuel rail exerts the force
which holds the injector in the cylinder head)
Injector (new version)

1 - Intermediate ring (renew)
2 - Retainer
3 - Combustion chamber ring seal (teflon ring seal) - renew; when
fitting, do not grease ring or use any other lubricant
4 - Injector
5 - Spacer ring (renew if damaged)
6 - O-ring (renew; apply thin coating of clean engine oil prior to
installation)
7 - Support ring (via this support ring, fuel rail exerts force which
secures injector in cylinder head)
– Cover open inlet ports with a clean cloth.
– Unplug electrical connector at injector that is to be removed.
– Guide puller -T10133/2A- into groove on injector.

– Then attach removal tool -T10133/16- and pull out injector by
turning bolt -1-.
Note
The combustion chamber ring seal must always be renewed be‐

fore the injector is re-installed ⇒ page 37 .
6.1.1 Renewing combustion chamber ring

seal (teflon ring seal)
Note
The combustion chamber ring seal must always be renewed be‐

fore the injector is re-installed.
– Carefully remove old teflon ring using suitable tools (e.g. cut
open ring using razor blade, or prise open ring with small
screwdriver and then pull off forwards). It is important to en‐
6. Injectors 37
10.2011
sure that the groove and the continuous ridge in the bottom of
the groove are not damaged.
Note
The injector must be renewed if the groove is damaged.
– Before new teflon ring is fitted, any combustion residue must

be removed from ring groove and injector stem using a clean
cloth.
Note
The illustration shows an injector with „offset connector“.
– Fit assembly cone -T10133/5- with new teflon ring -1- onto in‐
jector -2-.
– Use assembly sleeve -T10133/6- to press teflon ring further

onto assembly cone -T10133/5- until it seats in groove. Do not
use any lubricants during this procedure.
Note
♦ The teflon ring is widened as it is pushed onto the injector. The

teflon ring must therefore be compressed again after it has
been fitted.
♦ The procedure is divided into two steps and is described be‐
low.
Step 1 of teflon ring calibration is performed with calibration

sleeve -T10133/7- .
– Slide calibration sleeve -T10133/7- onto injector as far as the

stop by pressing lightly and turning approx. 180°. Pull calibra‐
tion sleeve -T10133/7- off again by turning it in the opposite
direction.
Step 2 of teflon ring calibration is performed with calibration
sleeve -T10133/8- .

10.2011
– Slide calibration sleeve -T10133/8- onto injector as far as the

stop by pressing lightly and turning approx. 180°. Pull calibra‐
tion sleeve -T10133/8- off again by turning it in the opposite
direction.
– Fit new O-ring on injector. Lubricate O-ring lightly with clean
engine oil before installing.
– The teflon ring must not be lubricated.
– Use supplied nylon brush -T10133/4- to thoroughly clean

holes for injectors in cylinder head prior to installing injectors.
Note
♦ The teflon seal on the injector must not be oiled or greased.

♦ Make sure that there is no cleaning fluid or oil in the holes in
the cylinder head when installing the injectors.
– Push injector by hand as far as it will go into aperture in cylin‐

der head (do not use oil or grease). Ensure that the injector is
properly seated in the cylinder head.
Note
♦ It should be possible to insert injector easily. If necessary wait

until the combustion chamber ring seal has contracted suffi‐
ciently.
♦ Note correct installation position and ensure that injectors are
properly seated in cylinder head.
♦ If the injector cannot be pushed in by hand, use puller -
T10133/2A- -2- with striker -T10133/3- to insert the injector.

sequence.
It is important to observe the following points:
• Coat O-rings of high-pressure injectors with clean engine oil
to facilitate insertion into fuel rail.
• Renew all seals.
• Fuel rail must be positioned on injectors and pressed in evenly.
• Install intake manifold with fuel rail ⇒ page 26 .
6.2 Cleaning injectors

♦ Ultrasonic cleaning unit -VAS 6418-
♦ Mounting plate for injection modules -VAS 6418/1-
♦ For cleaning fluid refer to electronic parts catalogue.
Cleaning
– Remove injectors ⇒ page 36 .
6. Injectors 39
10.2011
Note
Observe safety precautions and operating instructions for ultra‐

sonic unit.
– Ultrasonic unit must be filled with cleaning fluid.
Note
Ultrasonic unit must be filled with cleaning fluid up to top edge of

apertures (see detail in illustration).
– Insert injectors -1- all the way into mounting plate for injection
modules -VAS 6418/1- -2-.
– Immerse injectors together with mounting plate for injection

modules -VAS 6418/1- into cleaning fluid.
– Set rotary knob -4- to a temperature of 50°C.
– Select a cleaning time of 30 minutes with rotary knob -5-.
– Switch on ultrasonic unit with button -3-.
Note
The time set starts to elapse as soon as a cleaning temperature

of 50°C has been reached.
– After cleaning, always renew combustion chamber ring seal

(teflon ring seal) for each injector ⇒ page 37 .
– Then re-install injectors ⇒ page 36 .

10.2011
7 Components of injection system
7.1 Removing and installing fuel pressure

sender -G247-
If the fuel pressure sender -G247- fails, the fuel pressure regu‐
lating valve -N276- is switched off, the electric fuel pump is fully
activated and the engine is operated with the fuel pressure which
remains. This will reduce engine torque considerably.
♦ Bit (27 mm) -T40218- or commercially available socket

(27 mm)
Removing
– Carefully pull off engine cover panel.
WARNING

⇒ page 4 .
7. Components of injection system 41

10.2011
– Remove bolt -arrow- for coolant line from intake manifold.
– Release connector on fuel pressure sender -G247- -1- using

assembly tool -T10118- .
– Unscrew fuel pressure sender -G247- -1- using bit, 27mm -
T40218- .
Installing
– Make sure that connecting piece is tightened to specified tor‐
que before installing fuel pressure sender -G247- .
• Tightening torque for connecting piece: Fuel rail - exploded
view ⇒ page 25
• Tightening torque for fuel pressure sender -G247- : Fuel rail -
exploded view ⇒ page 25
7.2 Checking fuel pressure sender -G247-

♦ Pressure sensor tester -VAS 6394-
♦ Adapter -VAS 6394/2-
♦ Test instrument adapter -VAS 5570-
♦ Torque wrench -V.A.G 1331-
♦ Vehicle diagnostic tester
Procedure:
WARNING

⇒ page 4 .
– Remove fuel pressure sender -G247- ⇒ page 41 .

10.2011
– Screw in adapter -VAS 6394/2- in place of fuel pressure send‐

er -G247- and tighten adapter with the same torque as that
specified for fuel pressure sender -G247- .
♦ Tightening torque: fuel rail - exploded view ⇒ page 25
– Unscrew plug -2- on pressure gauge -VAS 6394/1- and screw

removed fuel pressure sender -G247- into opening. Tighten to
torque specified for fuel pressure sender.
– Use test instrument adapter -VAS 5570- to make electrical

connection between vehicle and fuel pressure sender -G247- .
– Connect a ⇒ Vehicle diagnostic tester.
– Switch on ignition.
– Then select „Measured values“.
– Select „Fuel pressure“ from the list.
Display zone 3 shows the actual pressure value being transmitted
to the engine control unit by the fuel pressure sender -G247- .
– Switch on pressure gauge -VAS 6394/1- by pressing button

-A- once briefly.
Note
You can press and hold button -A- for 2 seconds to switch on the
illumination for 20 seconds.
Pressure gauge -VAS 6394/1- should indicate 0 bar. If this is not

the case, press button -C- once briefly to zero the tester.

10.2011
– Connect pressure line of pressure gauge -VAS 6394/1- to

adapter -VAS 6394/2- .
– Start engine.
– Compare the pressure indicated by pressure gauge -VAS
6394/1- with the actual pressure value on the vehicle diagno‐
sis, testing and information system -VAS 5051B- .
• The pressure readings must not deviate by more than 5 bar.
– If the deviation is more than 5 bar, test a new fuel pressure
sender -G247- .
WARNING

⇒ page 4 .
– Screw a new fuel pressure sender -G247- into pressure gauge

-VAS 6394/1- .
– Repeat the test with the new fuel pressure sender -G247- and
compare the two pressure values.
If the two values still do not agree:
– Check the electrical connection between the fuel pressure
sender -G247- and the engine control unit; refer to ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
If the values agree:
– Install the new fuel pressure sender -G247- ⇒ page 41 .
7.3 Checking residual pressure in fuel sys‐

tem (up to high-pressure pump)
♦ K-Jetronic pressure tester -V.A.G 1318-
♦ Fuel-resistant measuring container

♦ Protective gloves
Test conditions:
• Battery voltage at least 12.5 V.
• Fuel filter OK.
• Fuel tank at least 1/4 full.
• Fuel pump control unit -J538- OK.

10.2011
• Ignition off.
Checking fuel pressure
– Remove rear seat bench ⇒ Rep. gr. 72 .
– Disconnect fuel line -2- by pulling release ring -1-.
– Screw connector -V.A.G 1318/23- and adapter -V.A.G

1318/17-1- onto K-Jetronic pressure tester -V.A.G 1318- .
– Fit adapter -V.A.G 1318/17-1- onto disconnected fuel supply
line.
– Screw adapter -V.A.G 1318/11- onto K-Jetronic pressure test‐
er -V.A.G 1318- .
– Fit auxiliary hose -arrow- onto pressure tester and hold it in a
container.

10.2011
– Close cut-off valve on pressure tester.

• Lever is at right angle to direction of flow -arrow-.
– Connect a vehicle diagnostic tester.
– Then select „Final control diagnosis“.
– Select „Fuel pump electronics“ from list and press „start“.
Note
This function activates the fuel pump.
– Read off fuel pressure on K-Jetronic pressure tester -V.A.G

1318- .
• Specification: 5 to 8 bar
– End this function when fuel pressure stops rising on K-Jetronic
pressure tester -V.A.G 1318- .
If specification is not obtained:
– Check fuel delivery rate of individual fuel pumps ⇒ Rep. gr.
20 .
Checking residual pressure
– Check system for leaks and check residual pressure by watch‐
ing the drop in pressure on the K-Jetronic pressure tester -
V.A.G 1318- .
• After 10 minutes pressure should still be at least 3 bar.
If the residual pressure drops below 3 bar:
♦ Check union between pressure tester and fuel line for leaks.
♦ Check pressure tester for leaks.
♦ Check fuel lines and their connections for leaks.
♦ Check delivery rate of fuel pump ⇒ Rep. gr. 20 .
♦ Renew fuel filter with integrated fuel pressure regulator ⇒ Rep.
gr. 20 .
♦ Non-return valve of fuel pump is defective ⇒ Rep. gr. 20 .
Assembly is carried out in the reverse order; note the following:
– Switch off ignition.
Note
Before removing pressure tester, release fuel pressure by open‐

ing cut-off valve. Hold a container under the connection.

10.2011
– Reconnect fuel supply line -arrow- (make sure that all parts
are clean).
Note
Check fuel system for leaks.
7.4 Removing and installing air mass meter

-G70-
Removing
– Release hose clip securing air hose -2- (going to turbocharger)
– Unscrew both bolts from air mass meter -G70- .
– Then carefully pull air mass meter -G70- out of guide on air
cleaner housing.
Installing
important to observe the following notes and instructions.
Note
This would lead to loss of power, since a smaller injection
♦ Use a silicone-free lubricant when installing the air hose.
– Check for dirt in air duct leading to air filter element. 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 19 .
The remaining installation steps are carried out in the reverse se‐
quence.
7.5 Removing and installing throttle valve

module -J338-
Removing

10.2011
– Open hose clip -arrow- securing air intake hose and discon‐
nect hose downwards from throttle valve module -J338- .
– Unplug electrical connector -1- from throttle valve module -
J338- .
– Remove the four bolts -arrows- from throttle valve module -

J338- and detach throttle valve module -J338- .
Installing
– Clean sealing surface for seal.
– Renew seal.
• Tightening torques: intake manifold - exploded view
⇒ page 24 .
– After throttle valve module -J338- has been renewed, it must
be re-adapted to engine control unit -J623- , see ⇒ Vehicle
diagnostic tester „Guided Functions“.
7.6 Cleaning throttle valve module -J338-
Note
♦ The throttle valve module must be adapted if a new engine

control unit -J623- is installed.
♦ Take care not to scratch the throttle valve housing when clean‐
ing it.
– Remove throttle valve module -J338- ⇒ page 47 .

– Open throttle valve by hand and block it in the open position
with a suitable object (e.g. plastic or wooden wedge) -arrow-.
WARNING
Acetone is highly flammable. Please observe all accident pre‐

vention regulations and safety precautions when handling
flammable liquids. Do not use compressed air when cleaning
the throttle valve. Wear safety goggles and protective clothing
to avoid possible injury and skin contact.

10.2011
– Clean throttle valve housing thoroughly, especially around the

points -arrows- where the throttle valve closes, using com‐
mercially available acetone and a small brush.
– Wipe out throttle valve housing with a lint-free cloth.
– Allow acetone to evaporate completely and re-install throttle
valve module after cleaning.
– Erase learnt values and adapt engine control unit -J623- to
throttle valve module using a vehicle diagnostic tester.
7.7 Checking intake manifold change-over

function
Only perform this test if there is a loss of engine torque (poor
flexibility or lack of pulling power).
Test condition
♦ Intake manifold flap valve -N316- has been checked with a
vehicle diagnostic tester.
Perform the following steps if the intake manifold flap valve -
N316- is OK.
– Start engine and run at idling speed.
– Have a second mechanic rev up engine quickly (short burst of
throttle) and observe vacuum unit for intake manifold change-
over.
• The vacuum unit should pick up -arrow-.
If the change-over does not operate as described:
– Check vacuum system for leaks.
– Check that change-over mechanism moves freely by moving
linkage manually.
– Check proper connection of vacuum lines.
– Check vacuum hoses for porosity.

10.2011
– Detach vacuum hose -1- from intake manifold flap valve -

N316- -2-.
– Move adjuster ring -1- on hand vacuum pump -VAS 6213- to

position -A- to select "vacuum".
– Connect hand vacuum pump -VAS 6213- to vacuum unit for

intake manifold flap valve -N316- .
– Operate the hand vacuum pump -VAS 6213- several times.
Linkage should move in both directions (arrows).
– If vacuum unit does not move, renew vacuum unit.
7.8 Checking dual non-return valve


10.2011
♦ Auxiliary measuring set -V.A.G 1594C-

Test condition
• Activated charcoal filter solenoid valve 1 -N80- has been
checked with a vehicle diagnostic tester and is OK.
– Unplug connector -1- and detach breather hose -arrow- from
activated charcoal filter solenoid valve 1 -N80- .
– Move adjuster ring -1- on hand vacuum pump -VAS 6213- to

position -A- to select "vacuum".

10.2011
– Connect hand vacuum pump -VAS 6213- to activated charcoal

filter solenoid valve 1 -N80- .
– Connect contacts of activated charcoal filter solenoid valve 1
-N80- -1- to battery using test leads. This will open activated
charcoal filter solenoid valve 1 -N80- .
Then immediately operate hand vacuum pump -VAS 6213- sev‐
eral times.
• Vacuum is built up.
– Again disconnect battery to cut off current supply.
If vacuum does not build up:
– Renew dual non-return valve -1-.
Dual non-return valve, activated charcoal filter solenoid valve 1 -
N80- and plastic hoses are combined as one unit and can only be
renewed together.

10.2011
8 Lambda probes
8.1 Lambda probes - overview
Electrical connectors for Lambda probes
Lambda probes
• Tightening torque: 55 Nm
Note
♦ New Lambda probes are coated with an assembly paste. The

paste must not get into the slots on the Lambda 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. High-temperature paste ⇒
Parts catalogue
♦ When installing, it is important to re-attach the Lambda probe
wiring at the same locations to prevent it from coming into
contact with the exhaust pipe.
Removing and installing Lambda probe -G39- and Lambda probe

heater -Z19- ⇒ „8.1 Lambda probes - overview“, page 53 .
Removing and installing Lambda probe after catalytic converter -
G130- and Lambda probe 1 heater after catalytic converter -Z29-
⇒ „8.3 Removing and installing Lambda probe after catalytic
converter G130 and Lambda probe 1 heater after catalytic con‐
verter Z29 “, page 54
8.2 Removing and installing Lambda probe

-G39- and Lambda probe heater -Z19-
before catalytic converter
8. Lambda probes 53
10.2011
♦ Lambda probe open ring spanner set -3337-
Removing
– Unplug electrical connector -3- for Lambda probe -G39- and
Lambda probe heater -Z19- .
– Unscrew Lambda probe -G39- -2- using tool from Lambda

probe open ring spanner set -3337- .
Installing
When installing, note the following:
Note

Parts catalogue
• Tightening torque: refer to overview of Lambda probes

⇒ page 53 .
8.3 Removing and installing Lambda probe

after catalytic converter -G130- and
Lambda probe 1 heater after catalytic
converter -Z29-

10.2011
♦ Lambda probe open ring spanner set -3337-
Removing
– Unplug electrical connector -2- for Lambda probe after cata‐
lytic converter -G130- and Lambda probe 1 heater after cata‐
lytic converter -Z29- .
– Unscrew Lambda probe after catalytic converter -G130- -1-

using tool from Lambda probe open ring spanner set -3337- .
Installing
When installing, note the following:
Note

Parts catalogue
• Tightening torque: refer to overview of Lambda probes

⇒ page 53 .
8. Lambda probes 55
10.2011
9 Engine control unit
9.1 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-

10.2011
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 components,

select appropriate measuring range before connecting the
measuring cables and observe the test requirements.
– The engine control unit has to be removed before multi-pin

connectors can be unplugged from engine control unit
⇒ page 58 .
– Connect 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.
9. Engine control unit 57

10.2011
The procedure required after connecting the new engine control

unit is described in the Guided Fault Finding or Guided Functions.
Note
After completion of the Guided Fault Finding routine, the tester

will attempt to erase the event memories of all control units. If this
is not successful, the remaining faults registered in the memories
must be rectified until all faults can be erased.
9.2 Renewing engine control unit -J623-
Note
Not every engine control unit is bolted to a protective housing.

Whether a protective housing is fitted depends on the engine/
gearbox combination.

♦ Hot air blower -VAS 1978/14A- -item 1- with nozzle attachment
-2- from wiring harness repair set -VAS 1978 B-
♦ Small, commercially available mole grips -3-
Note
♦ The engine control unit -1- is bolted to a protective casing

-2 and 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 metal housing has to be removed before the connectors
can be unplugged from the engine control unit (e.g. to connect
the test box or renew the engine control unit).
Removing
– When renewing engine control unit, select diagnosis object
„Replace engine control unit“ in „Guided Functions“.
– Switch off ignition and remove ignition key.

10.2011
– Slightly pull off rubber seal in front of nut -1- on plenum cham‐
ber cover.
– Unhook wiring harness -2- from retainers -A-.
– Remove nut -1-.
– Pull filler neck -3- with filler pipe out of washer fluid reservoir
and through opening in body.
– Unscrew bolts -arrows- and take off cover for electronics box.
– Release retainers -arrows A- and pull out engine control unit

-J623- -arrow B-.
Perform the following work steps if a protective housing is fitted:
To help prevent unauthorised access to the connectors on the

engine control unit, the engine control unit -1- is bolted to a pro‐
tective housing -5- by means of shear bolts -3 and 4- and a locking
plate -2-.
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.

10.2011
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
The shear bolts and protective housing also become very hot
when heating the threads of the locking mechanism. 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 for approx. 25 to 30 seconds.
– Unscrew shear bolts using mole grips (see arrow in illustra‐
tion).

10.2011
– 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 control unit connectors.
– Release connectors on engine control unit and unplug con‐
nectors.
– Take out old engine control unit -J623- and install new engine
control unit -J623- .
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.
• Tightening torque for bolts securing cover of electronics box:
3.5 Nm.
After installing a new engine control unit, the following operation
must be performed:
– Activate engine control unit via a vehicle diagnostic tester in
„Guided Functions“ mode, „Replace engine control unit“.

10.2011
28 – Ignition system
1 General notes and safety precau‐
tions
1.1 General notes on ignition system

♦ The engine control unit has a self-diagnosis capability.
♦ A voltage of at least 11.5 V is required for proper operation of
the electrical components.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. The event memory should therefore be inter‐
rogated and (if necessary) erased after completing the tests
and any repair work that may be required.
♦ If the engine starts, runs for a short period and then cuts out
after completing fault finding, repairs or component tests, this
may be due to the immobilizer disabling the engine control
unit. The event memory must then be interrogated and, if nec‐
essary, the control unit must be adapted.
1.2 Safety precautions

Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
Accidents can be caused if the driver is distracted by test

equipment while road-testing, or if test equipment is not prop‐
erly secured.
Persons sitting in the front passenger's seat could be injured if
the airbag is triggered in an accident.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Test equipment must always be secured on the rear seat
with a strap and operated from the rear seat by a second
person.
To prevent injuries to persons and/or irreparable damage to the

fuel injection and ignition system, the following must be noted:
♦ Do not touch or disconnect ignition wiring when the engine is
running or being turned at starter speed.
♦ The ignition must be switched off before disconnecting or con‐
necting ignition system wiring, high-voltage wires and test
leads.
♦ If you want to crank the engine at starting speed without ac‐
tually starting it (e.g. compression test), first unplug the con‐
nectors from the ignition coils and the injectors. After
completing the work, interrogate and erase the event memory.
♦ Always switch off the ignition before cleaning the engine.
62 Rep. gr.28 - Ignition system

10.2011
2 Servicing ignition system
2.1 Test data

Engine data 1.8 ltr. turbo FSI engine
Idling speed 640...800 rpm
is not adjustable; controlled by the idling speed
stabilisation
Engine speed limiter (deactivates injectors/closes approx. 6,500 rpm
throttle valve)
Ignition timing is determined by the control unit.
Ignition timing cannot be adjusted.
Ignition system Multi-coil ignition system with 4 ignition coils (integrated
output stages) connected directly to spark plugs via
spark plug connectors; ignition coils can be pulled out of
cylinder head using puller - T40039 -
Firing order 1-3-4-2
2.2 Ignition system - exploded view
1 - Knock sensor 1 -G61-

❑ Contacts gold-plated
⇒ page 65
2 - Ignition coil with output
stage
❑ Ignition coil 1 with output
stage -N70-
stage -N127-
stage -N291-
stage -N292-
⇒ page 64
❑ Use puller -T40039- for
removal
3 - Spark plug
❑ 30 Nm
❑ Removing and instal‐
ling; A4 ⇒ Maintenance ;
Booklet 812 , A5
⇒ Maintenance ; Book‐
let 811 , A5 Cabriolet
⇒ Maintenance ; Book‐
let 818
4 - Bolt
❑ Renew
❑ 20 Nm
❑ Tightening torque influ‐
ences functions of
knock sensor
2. Servicing ignition system 63

10.2011
5 - Bolt
❑ Renew
❑ 10 Nm
6 - Hall sender -G40-
❑ Contacts gold-plated
7 - O-ring
❑ Renew O-Ring if damaged
2.3 Removing and installing ignition coils

with output stages
♦ Puller -T40039-
Removing:
– Remove engine cover.
– Unscrew two bolts on connector rail.
– Pull all ignition coils approx. 30 mm out of spark plug holes
using puller -T40039- .
– Release connectors and unplug all connectors from the igni‐
tion coils at the same time.
Installing
– Fit all ignition coils loosely into spark plug holes.
– Align the ignition coils with the connectors and attach all con‐
nectors onto ignition coils simultaneously.
– Press ignition coils onto spark plugs by hand with uniform

pressure (do not use any tools).

10.2011
2.4 Removing knock sensor 1 -G61-

Removing
– Unplug electrical connector -2- at knock sensor 1 -G61- .
– Remove coolant pump with thermostat ⇒ Engine, mechanics;
Rep. gr. 19 .
Note
Knock sensor 1 -G61- is located below the intake manifold and

behind the coolant pump.
– Unscrew knock sensor 1 -G61- .

Installing
• Tightening torque: refer to exploded view of ignition system
⇒ page 63 .
2.5 Removing and installing engine speed

sender -G28-
♦ Socket (4 mm) -T10370-
Removing
– Unplug electrical connector at engine speed sender -G28-
-2- using assembly tool -T10118- .
2. Servicing ignition system 65

10.2011
Note
To release electrical connector without assembly tool -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 -1- using assembly tool -T10118- .

Installing
Installation is carried out in the reverse order; note the following:
• Tightening torque: refer to overview of fitting locations
⇒ page 8 .

Direct Petrol Injection and Ignition System (4-Cyl 1 8 LTR 4-Valve Turbo With Timing Chain)

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Service

Direct petrol injection and ignition system (4-cyl. 1.8 ltr.

Service Department. Technical Information

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

24 – Mixture preparation - injection

1.1 General notes on self-diagnosis

1.2 Safety precautions when using testers

Accidents can be caused if the driver is distracted by test

1. Safety precautions and rules for cleanliness 1

1.3 Safety precautions for vehicles with

Risk of injury due to automatic engine start on vehicles with

1.4 Safety precautions when working on the

The fuel system operates at extremely high pressure. This can

To prevent irreparable damage to the electronic components

2 Rep. gr.24 - Mixture preparation - injection

1.5 Rules for cleanliness and instructions

♦ If the battery is not disconnected, the fuse for the fuel

Removing the fuse (located in fuse carrier in dash panel on driv‐

1. Safety precautions and rules for cleanliness 3

1.6 Safety precautions when working on the

♦ Always switch off the ignition before cleaning the engine.

♦ The fuse is located in the fuse holder in the dash panel.

1.7 Reducing pressure in high-pressure

The fuel system operates at extremely high pressure. This can

Reducing fuel pressure in high-pressure section:

4 Rep. gr.24 - Mixture preparation - injection

– Start engine and run at idling speed.

1. Safety precautions and rules for cleanliness 5

– Observe fuel pressure displayed on diagnostic system.

There is a risk of injury: avoid skin contact with fuel.

– The high-pressure system must be opened »immediately« af‐

Additional steps required

1.8 Checking vacuum system

6 Rep. gr.24 - Mixture preparation - injection

♦ Hand vacuum pump -VAS 6213-

1. Safety precautions and rules for cleanliness 7

2.1 Technical data

2.2 Overview of fitting locations

8 Rep. gr.24 - Mixture preparation - injection

1 - Lambda probe -G39- and

12 - Charge pressure sender -G31-

10 Rep. gr.24 - Mixture preparation - injection

Engine control unit -J623-

Fuel pump control unit -J538- -1-

Accelerator position sender -G79- and accelerator position send‐

Clutch position sender -G476- -2-

Continued coolant circulation pump -V51-

12 Rep. gr.24 - Mixture preparation - injection

Fuel pressure sender -G247- -1-

Intake manifold flap valve -N316- -2-

Intake manifold flap potentiometer -G336- -1-

Hall sender -G40- -1-

Engine speed sender -G28- -2-

14 Rep. gr.24 - Mixture preparation - injection

Camshaft control valve 1 -N205- -arrow-

Coolant temperature sender -G62- -1-

Charge pressure sender -G31- -1-

Oil pressure switch