SM - 25 Injection

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 A6 2011 ➤
Audi A7 Sportback 2011 ➤
Direct injection and ignition system (8-cyl. 4.0 ltr. 4-
valve TFSI)
Engine ID
CEU CRD
C B
Edition 12.2012
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
Technicalpermitted
information should
unless authorised always
by AUDI AG. AUDI AGbedoes available
not guaranteeto the any
or accept foremen
liability and mechanics, because their
careful andwith
constant adherence
respect to the to the instructions
correctness of information is essential
in this document. Copyright to ensure vehicle road-worthiness and
by AUDI AG.
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2012 Audi AG, Ingolstadt D3E8048221D

Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Direct injection and ignition system (8-cyl. 4.0 ltr. 4-valve TFSI) - Edition 12.2012
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 working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Safety precautions when working on the injection and ignition system . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 3
1.5 Safety precautions after working in the engine compartment . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Safety precautions when using testers and measuring instruments during a road test . . . . 4
1.7 Rules for cleanliness and instructions for working on fuel system . . . . . . . . . . . . . . . . . . . . 4
1.8 Reducing pressure in high-pressure section of injection system . . . . . . . . . . . . . . . . . . . . 4
1.9 Checking for leaks in the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.10 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1 Exploded view - air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Intake manifold, fuel rail and injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3 Removing and installing intake manifold flap potentiometer . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5 Removing and installing intake air temperature sender G42 . . . . . . . . . . . . . . . . . . . . . . 37
4.6 Removing and installing fuel pressure senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.7 Exploded view - throttle valve module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.8 Removing and installing intake manifold pressure sender G71 . . . . . . . . . . . . . . . . . . . . 42
4.9 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.10 Removing and installing temperature sender for charge air cooler G763 / G764 . . . . . . . . 44
5 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2 Exploded view - fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3 Removing and installing high-pressureProtected pipe by . .copyright.
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. . . . . . .purposes,
. . . . .in. part
. . or
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49is not
5.4 Removing and installing fuel pressure sender for low pressure G410 . . . . . . . . . . . . . . . . 54
5.5 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6 Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.1 Overview - Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.2 Removing and installing Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.1 Wiring and component check with isolator boxes VAS 6606 . . . . . . . . . . . . . . . . . . . . . . 63
7.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1 General notes and safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.2 Safety precautions when working on the injection and ignition system . . . . . . . . . . . . . . . . 68
1.3 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 69
1.4 Safety precautions after working in the engine compartment . . . . . . . . . . . . . . . . . . . . . . 69
1.5 Safety precautions when using testers and measuring instruments during a road test . . . . 70
2 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.1 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Contents i
2.2 Ignition system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2.3 Removing and installing ignition coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.4 Removing and installing knock sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.5 Removing and installing Hall senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.6 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
ii Contents
24 – Mixture preparation - injection

1 Safety precautions and rules for
cleanliness
(ARL003017; Edition 12.2012)
⇒ “1.1 General notes on self-diagnosis”, page 1
⇒ “1.2 Safety precautions when working on the fuel system”, page
2
⇒ “1.3 Safety precautions when working on the injection and ig‐
nition system”, page 2
⇒ “1.4 Safety precautions when working on vehicles with start/
stop system”, page 3
⇒ “1.6 Safety precautions when using testers and measuring in‐
struments during a road test”, page 4
⇒ “1.7 Rules for cleanliness and instructions for working on fuel
system”, page 4
⇒ “1.8 Reducing pressure in high-pressure section of injection
system”, page 4
⇒ “1.9 Checking for leaks in the fuel system”, page 5
⇒ “1.10 Checking vacuum system”, page 6
1.1 General notes on self-diagnosis

♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and fault finding, the event memory must
be interrogated. The vacuum hoses and connections must al‐
so be checked (unmetered air).
♦ A voltage of at least 11.5 V is required for proper operation of
the electrical components.
Additional steps required
– Erase any entries in event memory resulting from testing or
repairs ⇒ Vehicle diagnostic tester, Guided Functions , In-
terrogate event memory , then Generate readiness
code .
1. Safety precautions and rules for cleanliness 1

1.2 Safety precautions when working on the

fuel system
When working on the fuel system note the following warnings:
WARNING
There is a risk of injury: avoid skin contact with fuel.

♦ The fuel pressure in the high-pressure section of the in‐
jection system must be reduced to a residual pressure
prior to opening the system; for the correct procedure see
⇒ page 4 .
♦ The connection must be opened IMMEDIATELY after re‐
ducing the pressure; wrap a cloth around the connection
and allow the residual pressure (approx. 6 bar) to dissi‐
pate.
Escaping fuel can cause a fire risk.
♦ As the fuel pump is activated by the door contact switch
when the driver's door is opened, disconnect the voltage
supply for the fuel pump if the battery has NOT been dis‐
connected.
♦ Remove fuse for fuel pump control unit -J538- ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
♦ Fuel hoses in engine compartment must only be secured with

spring-type
Protected byclips. O-type
copyright. Copyingclips or orscrew-type
for private clips inmust
commercial purposes, part ornot be is not
in whole,
used.permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ 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 probes.

injection and ignition system
To prevent injuries to persons and/or damage to the fuel injection
and ignition system, note the following:
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as the
ignition system and xenon headlights.
♦ Always switch off the ignition before connecting or discon‐
necting electrical wiring for the injection or ignition system or
tester cables.
♦ For safety reasons, the battery must be disconnected before
opening the fuel system to prevent the fuel pump from being
activated by the contact switch on the driver's door.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off ignition before washing engine.
2 Rep. gr.24 - Mixture preparation - injection

Caution
To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .
1.4 Safety precautions when working on ve‐

hicles 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).
1.5 Safety precautions after working in the

engine compartment
After working in the engine compartment, note the following:
WARNING
Danger of fire and damage if the engine cover panel is not fit‐
ted.
♦ The engine cover panel must always be fitted before the
bonnet is closed.
♦ If the engine cover panel is not fitted, it is not permissible
to start or drive the vehicle with the bonnet closed.

1.6 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.
1.7 Rules for cleanliness and instructions

for working on fuel system permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Even small amounts of dirt can cause malfunctions. When work‐

ing on the fuel supply system and injection system, pay careful
attention to the following basic rules:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal off open pipes/lines and connections immediately with
clean plugs, e.g. from engine bung set -VAS 6122- .
♦ Place parts that have been removed on a clean surface and
cover them over. Do not use fluffy cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ 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.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
1.8 Reducing pressure in high-pressure

section of injection system
Special tools and workshop equipment required
♦ Vehicle diagnostic tester

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

cause injury.
♦ The injection system consists of a high-pressure section
(maximum approx. 120 bar) and a low-pressure section
(4 ... 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 pressure in the
high-pressure section must be reduced to a specified lev‐
el. The procedure is described below.
Procedure
– Connect vehicle diagnostic tester , select function “Reducing
fuel pressure in fuel rail” in “Guided Functions” and follow on-
screen instructions.
• Fuel pressure will drop to a specified value.
– Switch off ignition.
The fuel rail is still filled with fuel, however it is no longer under
high pressure.
WARNING
There is a risk of injury: avoid skin contact with fuel.

♦ Wear safety goggles and protective clothing when open‐
ing the fuel system.
♦ Before opening the high-pressure section of the fuel sys‐
tem, place a clean cloth around the connection to catch
escaping fuel.
– 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.
♦ The ignition must not be switched on again from this point on
as this would increase the pressure again.

– Erase any entries in event memory resulting from work per‐
formed ⇒ Vehicle diagnostic tester, Guided Functions ,
Interrogate event memory , then Generate readiness
code .
1.9 Checking for leaks in the fuel system

– Allow engine to run for several minutes at moderate rpm.
– Check complete fuel system for leaks.

– If leaks are found although the connections have been tight‐

ened to the correct torque, the relevant component must be
renewed.
– Road-test vehicle and accelerate with full throttle at least once.
– Then inspect high-pressure section again for leaks.
1.10 Checking vacuum system

♦ 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 an entry is stored in the event memory, check the vacuum
lines leading to the corresponding component and also check
the other vacuum lines leading to other components.
– If it is not possible to build up a vacuum with the hand vacuum
pump -VAS 6213- or if the vacuum pressure drops again im‐
mediately, check the hand vacuum pump and connecting
hoses for leaks.

2 Injection system
⇒ “2.1 Test data”, page 7
⇒ “2.2 Overview of fitting locations - injection system”,
page 8
2.1 Test data

4.0 ltr. TFSI engine
Idling speed Cannot be adjusted; regulated
by idling speed stabilisation
Fuel pressure before high- 4.0 ... 7.0 bar
pressure pump
Fuel pressure after high-pres‐ 25 ... 120 bar
sure pump
2. Injection system 7
2.2 Overview of fitting locations - injection

system
⇒ “2.2.1 Fitting locations in engine compartment”, page 8
⇒ “2.2.2 Fitting locations on engine (from above)”, page 13
⇒ “2.2.3 Fitting locations on engine (from front)”, page 14
⇒ “2.2.4 Fitting locations on engine (from right side)”, page 15
⇒ “2.2.5 Fitting locations on engine (from left side)”, page 16
2.2.1 Fitting locations in engine compartment
1 - Turbocharger air recircula‐

tion valve -N249-
❑ Exploded view ⇒ En‐
gine, mechanics; Rep.
gr. 21
2 - Fuel metering valve -N290-
❑ Protected
Exploded view Copying for private or commercial purposes, in part or in whole, is not
by copyright.
⇒ pageunless
permitted 45 authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
3 - Power unit mounting sender
1 -G748- / power unit mounting
actuator 1 -N513-
4 - Charge pressure sender -
G31-
gr. 21
5 - Brake servo pressure sen‐
sor -G294-
6 - Gearbox oil cooling valve -
N509-
❑ Fitting location
⇒ page 11
gr. 19
7 - Accelerator position sender
-G79- and accelerator position
sender 2 -G185-
⇒ page 10
8 - Brake light switch -F-
⇒ page 10
9 - Engine control unit -J623-
❑ Fitting location ⇒ page 9
❑ Removing and installing ⇒ page 64
10 - Throttle valve module -J338-
❑ Including 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-
❑ Exploded view ⇒ page 23
11 - Fuel pressure sender for low pressure -G410-

12 - Power unit mounting actuator 2 -N514- power unit mounting sender 2 -G749-
13 - Fuel metering valve 2 -N402-
14 - Secondary air pump motor -V101-
❑ Exploded view ⇒ Engine, mechanics; Rep. gr. 26
15 - Continued coolant circulation pump -V51-
16 - Charge air cooling pump -V188-
17 - Radiator outlet coolant temperature sender -G83-
18 - Sender 1 for secondary air pressure -G609-
19 - Turbocharger air recirculation valve, cylinder bank 2 -N427-
20 - Charge pressure sender 2 -G447-
21 - Temperature sender 2 for charge air cooler -G764-
Fitting location of engine control unit -J623-

♦ -Item 1- in plenum chamber (left-side)
Fitting location of accelerator position sender -G79- / accelerator

position sender 2 -G185-
♦ In accelerator pedal module
2 - Electrical connector
Note
The accelerator position sender -G79- and accelerator position

sender 2 -G185- are integrated in the accelerator pedal module
and cannot be renewed individually.
Removing and installing ⇒ fuel supply system; Rep. gr. 20
Fitting location of brake light switch -F- with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ In footwell on brake pedal

Removing and installing ⇒ Brake system; Rep. gr. 45 .
Fitting location of radiator outlet coolant temperature sender -

G83-
♦ In bottom coolant hose (left-side) on radiator.
Removing and installing ⇒ Engine, mechanics; Rep. gr. 19
Fitting location of continued coolant circulation pump -V51-

♦ At front left, beneath headlight

Fitting location of charge air cooling pump -V188-

♦ At front left, beneath headlight
Fitting location of gearbox oil cooling valve -N509-

♦ At rear left of subframe
Fitting with
location ofthetemperature senderin 1
thisfor charge air cooler
by AUDI -AG.
respect to correctness of information document. Copyright
G763- / temperature sender 2 for charge air cooler -G764-
♦ On throttle valve module -J338- (bottom)
Fitting location of fuel pump control unit -J538-

♦ Fuel pump control unit -J538- -arrow- is located between floor
panel and fuel tank level with rear seat bench (right-side).
Note
For illustration purposes, the floor panel is cut open in the illus‐
tration.
Removing and installing ⇒ fuel supply system; Rep. gr. 20
Fitting location of secondary air pump motor -V101-

♦ In engine compartment (front left)
Fitting location of sender 1 for secondary air pressure -G609-

♦ In engine compartment (front left) in secondary air pipe
Fitting location of power
with respect unit mounting
to the correctness control
of information unit -J931-
in this document. Copyright by AUDI AG.
♦ At rear of wheel housing (front right)


2.2.2 Fitting locations on engine (from above)
1 - Intake manifold pressure

sender -G71-
❑ Exploded view
⇒ page 41
2 - Ignition coil 1 with output
stage -N70-
❑ Exploded view
⇒ page 72
stage -N127-
❑ Exploded view
⇒ page 72
stage -N291-
❑ Exploded view
⇒ page 72
5 - Hall sender -G40-
❑ Exploded view
⇒ page 72
stage -N292-
❑ Exploded view
⇒ page 72
7 - Activated charcoal filter sol‐
enoid valve 1 -N80-
8 - Hall sender 3 -G300-
❑ Exploded view
⇒ page 72
9 - Temperature sender for en‐
gine cover panel -G765-
❑ Removing and installing
⇒ Engine, mechanics;
Rep. gr. 21
10 - Piston cooling jet control valve -N522-
11 - Stage 3 oil pressure switch -F447-
12 - Ignition coil 8 with output stage -N326-
13 - Hall sender 4 -G301-
Protected❑ Exploded
by copyright. view
Copying ⇒ page
for private 72 purposes, in part or in whole, is not
or commercial
15respect
with - Hall sender
to the 2 -G163-
correctness of information in this document. Copyright by AUDI AG.

2.2.3 Fitting locations on engine (from front)
1 - Oil temperature sender 2 -

G664-
gr. 17
2 - Coolant temperature send‐
er -G62-
gr. 19
3 - Temperature sender for en‐
gine temperature regulation -
G694-
gr. 19
4 - Coolant valve for cylinder permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
head -N489- with respect to the correctness of information in this document. Copyright by AUDI AG.

gr. 19
5 - Intake manifold flap poten‐
tiometer 2 -G512-
❑ Exploded view
⇒ page 23
6 - Charge pressure control
solenoid valve -N75-
7 - Map-controlled engine cool‐
ing system thermostat -F265-
Exploded view ⇒ Engine, me‐
chanics; Rep. gr. 19

2.2.4 Fitting locations on engine (from right side)
1 - Engine speed sender -G28-

❑ Exploded view
⇒ page 72
2 - Oil pressure switch for re‐
duced oil pressure -F378-
gr. 17
3 - Oil pressure switch -F22-
gr. 17
4 - Knock sensor 2 -G66-
❑ Exploded view
⇒ page 72
5 - Fuel pressure sender
Protected -by copyright. Copying for private or commercial purposes, in part or in whole, is not
G247- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Exploded view
⇒ page 23
6 - Intake manifold flap valve -
N316-
tiometer -G336-
❑ Exploded view
⇒ page 23
8 - Injector, cylinder 4 -N33-
❑ Exploded view
⇒ page 23
❑ Exploded view
⇒ page 23
10 - Camshaft control valve 1 -
N205-
11 - Exhaust camshaft control valve 1 -N318-
12 - Inlet cam actuator 2 for cylinder 3 -F457-
13 - Exhaust cam actuator 2 for cylinder 3 -F459-

23 - Oil level and oil temperature sender -G266-
2.2.5 Fitting locationsProtected

on engine
by copyright. (from
Copying forleft
privateside)
or commercial purposes, in part or in whole, is not
1 - Valve for oil pressure con‐

trol -N428-
gr. 17
2 - Secondary air inlet valve -
N112-
❑ Exploded view
⇒ page 72
4 - Secondary air inlet valve 2
-N320-
❑ Exploded view
⇒ page 23
❑ Exploded view
⇒ page 23
7 - Inlet cam actuator 2 for cyl‐
inder 5 -F465-
gr. 15
8 - Exhaust cam actuator 2 for
cylinder 5 -F467-
cylinder 5 -F466-
10 - Inlet cam actuator 1 for
cylinder 5 -F464-
11 - Inlet cam actuator 1 for
cylinder 8 -F476-
cylinder 8 -F478-
14 - Exhaust camshaft control valve 2 -N319-
15 - Camshaft control valve 2 -N208-


19 - Intake air temperature sender -G42-
20 - Coolant circulation pump 2 -V178-
21 - Fuel pressure sender 2 -G624-
❑ Exploded view ⇒ page 72 to the correctness of information in this document. Copyright by AUDI AG.
with respect
3 Air cleaner
⇒ “3.1 Exploded view - air cleaner”, page 18
⇒ “3.2 Removing and installing air filter element”, page 18
⇒ “3.3 Removing and installing air cleaner housing”, page 20
3.1 Exploded view - air cleaner
1 - Retainer
❑ For air cleaner housing
2 - Rubber buffer
3 - Air cleaner (bottom section)
❑ Clean out salt deposits,
dirt and leaves, etc.
⇒ “3.3 Removing and in‐
stalling air cleaner hous‐
ing”, page 20
4 - Air filter element
❑ Use genuine air filter el‐
ement ⇒ Electronic
parts catalogue
❑ Change intervals ⇒
Maintenance tables
⇒ page 18
5 - Air cleaner (top section)
⇒ page 18 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - Air ducts with respect to the correctness of information in this document. Copyright by AUDI AG.
7 - Sealing element
8 - Air duct
9 - Bolt
❑ 2.5 Nm
10 - Air duct
3.2 Removing and installing air filter ele‐

ment
♦ Silicone-free lubricant

Removing
– Loosen hose clips -2- and remove air hoses.
– Release catch -3-, turn air cleaner (top section) -1- in anti-
clockwise direction -arrow B- and detach.
– Take out air filter element.
Installing
To ensure that the fuel systems function properly, 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 components and affect the measured values. This
would lead to loss of power, since a smaller injection quantity
is calculated.
♦ Always use genuine part for air filter element.
♦ The air cleaner housing MUST be clean.
♦ Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
♦ Use a silicone-free lubricant when installing the air hoses.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ To prevent malfunctions, cover critical parts of the engine air
intake (such as air pipes, etc.) with a clean cloth when blowing
out the air cleaner housing with compressed air.
♦ Observe environmental requirements for disposal.
– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections) using a vacuum cleaner.
– Blow out water drain -arrow- with compressed air. Copying for private or commercial purposes, in part or in whole, is not
Protected by copyright.
– Check for dirt and leaves in air duct going from
with respect lock
to the carrierof to
correctness information in this document. Copyright by AUDI AG.
air cleaner housing.
– When installing air filter element, check that it is properly cen‐

tred in retainer in air cleaner housing.
– Carefully fit air cleaner (top section) onto air cleaner housing
without using any force.
– Turn air cleaner (top section) -1- in clockwise direction
-arrow A- until catch -3- engages.
– Make sure that air ducts are securely fitted on air cleaner (top
section).
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install air hoses with screw-type clips -2- ⇒ Engine, mechan‐
ics; Rep. gr. 21 .
3. Air cleaner 19
3.3 Removing and installing air cleaner

housing
♦ Silicone-free lubricant
Removing
– Remove lock carrier cover ⇒ General body repairs, exterior;
Rep. gr. 63 .
– Remove bolts -arrows- and detach air duct -1-.

– Release hose clips -2- and detach air hoses.

– Lift off air cleaner housing -1- with air hoses.
Installing
Note
♦ The air cleaner housing MUST be clean.

♦ To prevent malfunctions, cover critical parts of the engine air
intake (such as air pipes, etc.) with a clean cloth when blowing
out the air cleaner housing with compressed air.
♦ Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
♦ Use a silicone-free lubricant when installing the air hoses.
– Check for salt residue, dirt and leaves in air pipe (engine intake
side).
– Check for dirt and leaves in air duct going from lock carrier to
air cleaner housing.
note the following:
– Install air ducts with screw-type clips ⇒ Engine, mechanics;
Rep. gr. 21 .
3. Air cleaner 21

4 Intake manifold, fuel rail and injectors

⇒ “4.1 Exploded view - intake manifold”, page 23
⇒ “4.2 Removing and installing intake manifold”, page 25
⇒ “4.3 Removing and installing intake manifold flap potentiome‐
ter”, page 32
⇒ “4.4 Removing and installing injectors”, page 34
⇒ “4.5 Removing and installing intake air temperature sender G42
”, page 37
⇒ “4.6 Removing and installing fuel pressure senders”,
page 39
⇒ “4.7 Exploded view - throttle valve module”, page 41
⇒ “4.8 Removing and installing intake manifold pressure sender
G71 ”, page 42
⇒ “4.9 Removing and installing throttle
Protected valve
by copyright. module
Copying J338
for private ”, page purposes, in part or in whole, is not
or commercial
43 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ “4.10 Removing and installing temperature sender for charge
air cooler G763 / G764 ”, page 44
4.1 Exploded view - intake manifold
Note
The illustration shows the intake manifold on the left side of the vehicle.
1 - Gasket
❑ Renew
tiometer 2 -G512-
❑ Cylinder bank 1 (right-
side): intake manifold
flap potentiometer -
G336-
⇒ page 32
3 - Bolt
❑ 2.5 Nm
4 - Seal
❑ Renew if damaged
❑ When renewing lever
out with screwdriver
❑ Press in by hand
5 - Coupling
6 - Gaskets
❑ For intake manifold
❑ Renew
7 - Bolt
❑ 3 Nm
8 - Union nut
❑ For high-pressure pipe
❑ To loosen connection
4. Intake manifold, fuel rail and injectors 23

-item 9-, counterhold at fuel rail

❑ Observe all instructions for installing high-pressure pipes ⇒ page 53
❑ 25 Nm
9 - Connection
❑ 40 Nm
10 - Support ring
❑ Make sure it is correctly seated
❑ Via this support ring, the fuel rail exerts the force which holds the injector in the cylinder head
11 - O-ring
❑ Renew
❑ Lubricate lightly with clean engine oil
12 - Spacer ring
❑ Renew if damaged
13 - Combustion chamber ring seal
❑ Renewing ⇒ “4.4 Removing and installing injectors”, page 34
14 - Sealing element
15 - Injector
Removing and installing ⇒ page 34
16 - Fuel rail
17 - Fuel pressure sender 2 -G624-
❑ Cylinder bank
permitted 1 (right-side):
unless authorised by AUDIfuel
AG. pressure
AUDI AG doessender -G247-
not guarantee or accept any liability

❑ Lubricate threads lightly with clean engine oil

❑ 25 Nm
18 - Retaining clip
❑ For fuel rail
19 - Bolt
❑ 3 Nm
20 - Bolt
❑ 2.5 Nm
21 - Intake air temperature sender -G42-
22 - O-rings
❑ Renew
23 - Vacuum unit
❑ For actuating intake manifold flaps
24 - Intake manifold
25 - Bolt
❑ Tighten in stages and in diagonal sequence
❑ 9 Nm

4.2 Removing and installing intake manifold

⇒ “4.2.1 Removing and installing intake manifold (right-side) with
fuel rail, cylinder bank 1”, page 25
⇒ “4.2.2 Removing and installing intake manifold (left-side) with
fuel rail, cylinder bank 2”, page 28
4.2.1 Removing and installing intake manifold

(right-side) with fuel rail, cylinder bank 1
Removing
• Engine/gearbox assembly removed ⇒ Engine, mechanics;
Rep. gr. 10 .
WARNING

cause injury.
prior to opening the system.
– Reduce fuel pressure in high-pressure section of injection sys‐

tem ⇒ page 4 .
– Remove charge air cooler housing ⇒ Engine, mechanics;
Rep. gr. 21 .

– Disconnect vacuum hoses -arrows-.

– Unplug electrical connector at intake manifold flap valve -
N316- -item 1-.
– Take intake manifold flap valve out of bracket and move elec‐
trical wiring clear at intake manifold (right-side) -2-.
– Unplug electrical connector -arrow- for fuel pressure sender -

G247- .
– Remove nuts -1, 2- and bolt -3-, move wiring guide clear and
push to one side.
– Unscrew centre hex stud -arrow- and remove guard plate -1-.

– Remove nut -3-, move retaining clip clear and remove centre
hex stud.
– Remove bolts -2 and 5-.
– Unscrew union nuts -arrows- and push high-pressure pipe to
one side.
Note
Do not attempt to bend high-pressure pipe to a different shape.
– Unplug electrical connector -2- for intake manifold flap poten‐

tiometer -G336- .
– Detach noise insulation panels.

– Remove bolts -arrows- and detach intake manifold with fuel
rail.
Caution
Risk of irreparable damage to engine.

♦ Block off the intake ports with clean cloths to prevent small
objects from dropping into the engine through the intake
ports in the cylinder heads.
Installing
• Tightening torques: refer to exploded view of intake manifold
⇒ page 23 .
Note
♦ Renew seals and/or gaskets.

(same as original equipment) ⇒ Parts catalogue.
Caution
Risk of damage to intake manifold flaps.
♦ To prevent the intake manifold flaps from catching on the
guide plates in the cylinder head, the flaps must be in the
open position when the intake manifold is installed.

– Connect hand vacuum pump -VAS 6213- to vacuum unit for

actuating intake manifold flaps, as shown in illustration.
– Use vacuum pump to generate a vacuum.
• This will cause the intake manifold flaps to open.
– Press intake manifold with fuel rail evenly onto injectors.
– Tighten bolts for intake manifold in diagonal sequence and in
stages.
– Disconnect hand vacuum pump from vacuum unit for actuat‐
ing intake manifold flaps.
note the following:
– Install high-pressure pipe ⇒ page 53 .
– Install charge air cooler housing ⇒ Engine, mechanics; Rep.

gr. 21 .
WARNING
ted.
bonnet is closed.

(left-side) with fuel rail, cylinder bank 2
Removing
Rep. gr. 10 .
WARNING

cause injury.


tem ⇒ page 4 .
Rep. gr. 21 .
– Remove coolant pipe (top left) ⇒ Engine, mechanics; Rep. gr.

19 .
– Disconnect vacuum hose -3- and move clear.

– Detach secondary air inlet valves from bracket and move clear
to one side:
1- Secondary air inlet valve 2 -N320-
2- Secondary air inlet valve -N112-
– Unplug electrical connectors -4, 5- and move clear wiring har‐
ness at intake manifold.
– Unplug electrical connector -2- for intake manifold flap poten‐

tiometer 2 -G512- .

– Remove bolt -3- and move bracket with electrical connector

-2- to one side.
– Detach charge pressure control solenoid valve -N75-

-item 2- from bracket -1- and push it clear to one side.
– Remove bolts -arrows- and push bracket towards front of ve‐
hicle. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove bolts -2-.

– Unscrew union nuts -arrows- and push high-pressure pipe to
one side.
Note
♦ Do not attempt to bend high-pressure pipe to a different shape.

♦ Disregard -item 1-.

– Detach noise insulation panels.

– Remove bolts -arrows- and detach intake manifold with fuel
rail.
Caution
Risk of irreparable damage to engine.

♦ Block off the intake ports with clean cloths to prevent small
objects from dropping into the engine through the intake
ports in the cylinder heads.
Installing
• Tightening torques: refer to exploded view of intake manifold
⇒ page 23 .
Note
♦ Renew seals and/or gaskets.

(same as original equipment) ⇒ Parts catalogue.
Caution
Risk of damage to intake manifold flaps.

♦ To prevent the intake manifold flaps from catching on the
guide plates in the cylinder head, the flaps must be in the
open position when the intake manifold is installed.

– Connect hand vacuum pump -VAS 6213- to vacuum unit for

actuating intake manifold flaps, as shown in illustration.
– Use vacuum pump to generate a vacuum.
• This will cause the intake manifold flaps to open.
– Press intake manifold with fuel rail evenly onto injectors.
– Tighten bolts for intake manifold in diagonal sequence and in
stages.
– Disconnect hand vacuum pump from vacuum unit for actuat‐
ing intake manifold flaps.
note the following:
– Install coolant pipe (top left) ⇒ Engine, mechanics; Rep. gr.
19 .
gr. 21 .
WARNING
ted.
bonnet is closed.

flap potentiometer
⇒ “4.3.1 Removing and installing intake manifold flap potentiom‐
eter G336 ”, page 32
⇒ “4.3.2 Removing and installing intake manifold flap potentiom‐
eter 2 G512 ”, page 34

flap potentiometer -G336-
Removing
– Remove catalytic converter, cylinder bank 2 (left-side) ⇒ En‐
gine, mechanics; Rep. gr. 26 .

– Remove cover -1- for drive shaft in wheel housing (right-side).
– Remove bolts -arrows- and detach heat shield (right-side)

-1-.
– Remove bolts -arrows- and detach heat shield for drive shaft
(right-side).
– Detach drive shaft (right-side) from flange shaft of gearbox ⇒

Running gear, front-wheel drive and four-wheel drive; Rep. gr.
40 .

– Unplug electrical connector -2-.

– Remove bolts -1- and detach intake manifold flap potentiom‐
eter -G336- .
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques
– Secure drive shaft (right-side) to flange shaft of gearbox ⇒
40 .
– Install heat shield for drive shaft (right-side) ⇒ Rep. gr. 34 or
⇒ Rep. gr. 37 .
– Install catalytic converter, cylinder bank 2 (left-side)
Protected ⇒ Engine,
by copyright. Copying for private or commercial purposes, in part or in whole, is not
mechanics; Rep. gr. 26 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

flap potentiometer 2 -G512-
Removing
– Remove high-pressure pipe at cylinder bank 2 (left-side)
⇒ page 51 .
– Remove bolts -arrows- and push bracket to one side.
– Remove bolts -1- and detach intake manifold flap potentiom‐
eter 2 -G512- .
Installing
4.4 Removing and installing injectors

♦ Tool set for FSI engines -T10133-
Removing
Rep. gr. 10 .
– Remove intake manifold ⇒ page 25 .

– Unplug relevant electrical connector -2- and remove support

ring -1-.
– Apply puller -T10133/2A- to groove on injector.
– Apply puller -T10133/16A- and pull out injector by turning bolt
-1-.
Dismantling injector
– Pull O-ring -3- and spacer ring -2- off injector -1-.
– Unclip sealing element -5-.
– Carefully remove old combustion chamber ring seal -6-. To do
so, cut open combustion chamber ring seal using knife or prise
open with small screwdriver and then pull off forwards.
Note
Take care not to damage groove on injector. The injector must be

renewed if the groove is damaged.
Installing
Note
♦ Renew sealing element, combustion chamber ring seal and

O-ring.
♦ Renew spacer ring if damaged.
♦ Lubricate O-rings of injectors lightly with clean engine oil.
– Clean bore in cylinder head with nylon cylinder brush -

T10133/4- .

– Fit assembly cone -T10133/5- with new combustion chamber

ring seal -1- from repair kit onto injector -2-.
– Using assembly sleeve -T10133/6- , push combustion cham‐

ber ring seal onto assembly cone -T10133/5- as far as it will
go.
– Turn round assembly sleeve -T10133/6- and slide combustion
chamber ring seal into groove.
Note
The combustion chamber ring seal is widened

Protected whenCopying
by copyright. it is pushed
for private or commercial purposes, in part or in whole, is not
onto the injector. After pushing it on,permitted
it therefore has tobybeAUDI
unless authorised com‐AG. AUDI AG does not guarantee or accept any liability
pressed again. This is done in two stages, as described below.
– Push calibration sleeve -T10133/7- onto injector as far as it will

go and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/7- off again by turning it in the
opposite direction.
– Push calibration sleeve -T10133/8- onto injector as far as it will

go and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/8- off again by turning it in the
opposite direction.

– Fit parts from repair kit onto injector -1-:

2 - Spacer ring
3 - O-ring
4 - Support ring
5 - Sealing element
– To make it easier to install injector in fuel rail, lubricate new O-
ring lightly with clean engine oil before installing it.
Note
The combustion chamber ring seal -6- must not be lubricated.
– Use assembly tool -T10133/9- to insert injector as far as it will

go into hole in cylinder head; note correct installation position.
• Electrical connector of injector must engage in recess in cyl‐
inder
permitted head.
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
It should be possible to insert the injector easily. If necessary wait

until the combustion chamber ring seal has contracted sufficient‐
ly.
Perform further installation in reverse order, paying attention to

the following:
– Install intake manifold ⇒ page 25 .
4.5 Removing and installing intake air tem‐

perature sender -G42-
Removing
– Remove engine cover panel ⇒ Engine, mechanics; Rep. gr.
10 .

– Lift retaining clips -1, 4- and disconnect coolant hoses.

– Move coolant hose clear -arrow-.
– Remove bolt -3-.
– Lift coolant expansion tank out of bracket and push towards
front.

– Pull off intake air temperature sender -G42- and unplug elec‐
trical connector -2-.
Installing
WARNING
ted.
bonnet is closed.
Note
♦ Fit new O-ring.


4.6 Removing and installing fuel pressure

senders
⇒ “4.6.1 Removing and installing fuel pressure sender G247 ”,
page 39
⇒ “4.6.2 Removing and installing fuel pressure sender 2 G624 ”,
page 40
4.6.1 Removing and installing fuel pressure

sender -G247-
Removing
– Remove engine mounting (right-side) ⇒ Engine, mechanics;
Rep. gr. 10 .
– Remove nut -2- and move earth wire clear.

– Remove bolts -arrows- and detach engine support -1- (right-
side).

– Unplug electrical connector -arrow-.

– Unscrew fuel pressure sender -G247- .
Installing
• Tightening torque
– Install engine support and engine mounting (right-side) ⇒ En‐
4.6.2 Removing and installing fuel pressure

sender 2 -G624-
Removing
– Remove electromechanical steering rack ⇒ Running gear,
front-wheel drive and four-wheel drive; Rep. gr. 48 .

– Unscrew fuel pressure sender 2 -G624- .
Installing
– Install electromechanical steering rack ⇒ Running gear, front-
wheel drive and four-wheel drive; Rep. gr. 48 .

4.7 Exploded view - throttle valve module
1 - Charge air cooler housing

❑ With air ducts
⇒ Engine, mechanics;
Rep. gr. 21
2 - O-ring
❑ Renew
3 - Intake manifold pressure
sender -G71-
⇒ page 42
4 - Bolt
❑ 3 Nm
5 - Gasket
❑ For throttle valve mod‐
ule -J338-
❑ Renew
6 - Bolt
❑ 9 Nm
7 - Temperature sender 1 for
charge air cooler -G763-
⇒ page 44
8 - O-rings
❑ Renew
9 - Air duct
❑ With turbocharger air re‐
circulation valve -N249-
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 9 Nm
12 - Gasket
❑ Renew
13 - Bolt
❑ 5 Nm
14 - Air hoses
❑ To turbochargers
15 - Throttle valve module -J338-
❑ Removing and installing ⇒
with respect page
to the 43 of information in this document. Copyright by AUDI AG.
correctness
16 - O-rings
❑ Renew

18 - Bolt
❑ 9 Nm

pressure sender -G71-
Removing
Rep. gr. 21 .
– Unscrew bolts -arrows- and pull intake manifold pressure

sender -G71- -item 1- out of air pipe.
Installing
Note
Fit new O-ring.

gr. 21 .
WARNING
ted.
bonnet is closed.

4.9 Removing and installing throttle valve

module -J338-
Removing
10 .
– Release hose clip -1- and detach air hose.
– Unplug electrical connector -2- and move wiring clear.
– Remove bolts -arrows- and move turbocharger air recircula‐
tion valve -N249- and turbocharger air recirculation valve,
cylinder bank 2 -N427- clear to one side.
– Unscrew bolts -arrows- and release hose clips -1-.

– Detach throttle valve module -J338- and unplug electrical con‐
nectors -2-.
Installing
Note
♦ Renew gasket.

Rep. gr. 21 .
– After renewing throttle valve module, perform “Adaption” in
“Guided Functions” mode of vehicle diagnostic tester .

4.10 Removing and installing temperature

sender for charge air cooler -G763- / -
G764-
Removing
– Remove throttle valve module -J338- ⇒ page 43 .
– Unscrew relevant bolt -2- and detach temperature sender:
Installing
Note with respect to the correctness of information in this document. Copyright by AUDI AG.
Fit new O-rings.
– Install throttle valve module -J338- ⇒ page 43 .

5 High-pressure pump
⇒ “5.1 Exploded view - high-pressure pump”, page 45
⇒ “5.2 Exploded view - fuel lines”, page 46
⇒ “5.3 Removing and installing high-pressure pipe”, page 49
⇒ “5.4 Removing and installing fuel pressure sender for low pres‐
sure G410 ”, page 54
⇒ “5.5 Removing and installing high-pressure pump”, page 55
5.1 Exploded view - high-pressure pump
1 - Hose clip
2 - Fuel hose (low-pressure
section)
3 - Union nut
❑ For high-pressure pipe
❑ Counterhold connection
on high-pressure pump
to loosen
❑ Observe all instructions
for installing high-pres‐
sure pipes ⇒ page 53
❑ 25 Nm
4 - High-pressure pump
❑ Do not hold onto or pull Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
on plunger of high-pres‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
sure pump with respect to the correctness of information in this document. Copyright by AUDI AG.

side) with fuel metering
valve -N290-
❑ Cylinder bank 2 (left-
side) with fuel metering
valve 2 -N402-
⇒ page 55
5 - Bolt
❑ Renew
❑ 20 Nm + +45°
6 - Fuel pressure sender for
low pressure -G410-
⇒ page 54
❑ 15 Nm
7 - O-ring
❑ Renew
❑ Lubricate lightly with clean engine oil before installing
8 - Roller tappet
❑ Can only be installed in one position
❑ Lubricate lightly with clean engine oil before installing
5. High-pressure pump 45
5.2 Exploded view - fuel lines

⇒ “5.2.1 Exploded view - fuel lines, cylinder bank 1 (right-side)”,
page 46
⇒ “5.2.2 Exploded view - fuel lines, cylinder bank 2 (left-side)”,
page 47
5.2.1 Exploded view - fuel lines, cylinder bank 1 (right-side)
1 - Centre hex stud

❑ 9 Nm
2 - Bolt
❑ 9 Nm
3 - High-pressure pipe
WARNING
The fuel system oper‐
ates at extremely high
pressure. This can
cause injury.
The
♦ fuel pressure in the
high-pressure section of
the injection system must
be reduced to a residual
pressure prior to opening
the system.
❑ Reducing fuel pressure

in high-pressure section
of injection system
⇒ page 4
⇒ page 58
❑ Counterhold at connec‐
tion on high-pressure
pump/fuel rail when
loosening union nuts
❑ Observe all instructions
for installing high-pres‐
sure pipes ⇒ page 53
❑ Tightening torque for
union nuts
⇒ Item 8 (page 23) ,
⇒ Item 3 (page 45)
4 - Centre hex stud
❑ 9 Nm
5 - Fuel supply hose
6 - Fuel hose (low-pressure section)
8 - Bolts
❑ For retaining clipsProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 9 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.
9 - Bracket
❑ For low-pressure line

10 - Rubber damper
❑ Must make contact with cylinder block
11 - Low-pressure line
❑ Note minimum clearance from bracket for low-pressure line ⇒ page 49
12 - Bolt
❑ For retaining clip
❑ 9 Nm
13 - Bolt
❑ 9 Nm
14 - Bolt
❑ 9 Nm
15 - Rubber damper
❑ Must make contact with cylinder head cover
5.2.2 Exploded view - fuel lines, cylinder bank 2 (left-side)
1 - Bolt
❑ 9 Nm
2 - Bolt
❑ 9 Nm
3 - Bolt
❑ 9 Nm
4 - Bracket
❑ For low-pressure line
5 - Low-pressure line
❑ Note minimum clear‐
ance from bracket for
low-pressure line
⇒ page 49
6 - Bolts
❑ For retaining clips
❑ 9 Nm
7 - Rubber damper
❑ Must make contact with
bracket for adjacent
low-pressure line
9 - Fuel hose (low-pressure permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
section) with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Note installation posi‐

tion ⇒ page 48
10 - Bolt
❑ 9 Nm
11 - High-pressure pipe
WARNING
The fuel system oper‐
ates at extremely high
pressure. This can
cause injury.
The
♦ fuel pressure in the
high-pressure section of
the injection system must
be reduced to a residual
pressure prior to opening
the system.
❑ Reducing fuel pressure in high-pressure section of injection system ⇒ page 4

❑ Counterhold at connection on high-pressure pump/fuel rail when loosening union nuts
❑ Observe all instructions for installing high-pressure pipes ⇒ page 53
❑ Tightening torque for union nuts ⇒ Item 8 (page 23) , ⇒ Item 3 (page 45)
Installation position of fuel hose (low-pressure section)

• Marking -1- on fuel hose (low-pressure section) must be
aligned with marking -2- on high-pressure pump.
Note
Illustration shows the installation position for cylinder bank 2 (left-

side).
Minimum clearance between fuel hose (low-pressure section)

and exhaust cam actuator 2 for cylinder 5 -F467-
• Minimum clearance -a- = 2 mm must be maintained between
fuel hose (low-pressure section) and exhaust cam actuator 2
for cylinder 5 -F467- .

Minimum clearance between low-pressure line and bracket for

low-pressure line
• Minimum clearance -a- = 2 mm must be maintained between
low-pressure line -1- and bracket -2- for low-pressure line.
5.3 Removing and installing high-pressure

pipe
⇒ “5.3.1 Removing high-pressure pipe (cylinder bank 1, right-
side)”, page 49
⇒ “5.3.2 Removing high-pressure pipe (cylinder bank 2, left-
side)”, page
Protected 51
⇒ “5.3.3 Installing
with respect high-pressure
to the correctness pipe”,
of information in this page 53Copyright by AUDI AG.
document.
5.3.1 Removing high-pressure pipe (cylinder

bank 1, right-side)
♦ Tool set, 17 mm -T10395-
Removing
– Remove air cleaner housing ⇒ page 20 .

-1-.
– Remove bolts -arrows- and detach heat shield for drive shaft
(right-side).
– Detach drive shaft (right-side) from flange shaft of gearbox ⇒

40 .
– Remove ignition coil “cylinder 4” ⇒ page 73 .
– Remove nuts -1, 2- and bolt -3-, move wiring guide clear and
push to one side.

– Unscrew centre hex stud -arrow- and remove guard plate -1-.
Caution
Protect fuel system against contamination.

♦ Observe rules for cleanliness and follow instructions for
working on fuel system ⇒ page 4 .
– Disconnect fuel line -2- by pressing release ring.
Note
Disregard -item 1-.
– Disconnect vacuum hose -1-.

– byRemove
Protected nut -3-,
copyright. Copying move
for private retaining
or commercial clip clear
purposes, and
in part or remove
in whole, is not centre
hex authorised
permitted unless stud. by AUDI AG. AUDI AG does not guarantee or accept any liability
– Release hose clip -4- and detach fuel hose.
– Unscrew union nuts -arrows- (counterhold hexagon flats of
each connection with an open-end spanner when loosening).
– Detach high-pressure pipe.
Note
5.3.2 Removing high-pressure pipe (cylinder

bank 2, left-side)
♦ Socket -T40055-
Removing
Rep. gr. 21 .
– Detach charge pressure control solenoid valve -N75-

-item 2- from bracket -1- and push it clear to one side.
– Remove bolts -arrows- and push bracket towards front of ve‐
hicle.

WARNING
Risk of injury caused by fuel.

♦ To allow the fuel pressure to dissipate, wrap a clean cloth
around the connection and carefully loosen the connec‐
tion before opening the fuel system.
Caution
Protect fuel system against

Protected contamination.
♦ Observe rules with
for respect
cleanliness and follow
to the correctness instructions
of information for Copyright by AUDI AG.
in this document.

– Unscrew union nuts -arrows- (counterhold hexagon flats of
each connection with an open-end spanner when loosening).
– Detach high-pressure pipe.
Note
5.3.3 Installing high-pressure pipe

Installing
Tightening torques:
• Exploded view - intake manifold ⇒ page 23 .
• Exploded view - high-pressure pump ⇒ page 45 .
• Exploded view - fuel lines ⇒ page 46 .
Caution
Risk of leaks.
♦ The connections of the high-pressure pipe must not be
damaged.
Note
– Position retaining clips and rubber dampers as shown in illus‐

trations ⇒ page 46 .
– Lubricate threads of union nuts with clean engine oil.
– First tighten union nut by hand until it makes contact, making
sure that high-pressure pipe is not under tension.
– Tighten union nut initially to 5 Nm using torque wrench.
– Tighten bolts for retaining clips.
– Tighten union nut to final tightening torque using torque

wrench; to do so, counterhold hexagon flats of each connec‐
tion with an open-end spanner.
note the following:
Cylinder bank 1 (right-side):
– Install ignition coil “cylinder 4” ⇒ page 73 .
– Secure drive shaft (right-side) to flange shaft of gearbox ⇒
40 .
⇒ Rep. gr. 37 .
– Install rear section of front right wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 .
– Install air cleaner housing ⇒ page 20 .
Cylinder bank 2 (left-side):
gr. 21 .
WARNING
Danger of fire and damage if the engine cover panel Protected

is not fit‐
ted.

bonnet is closed.
5.4 Removing and installing fuel pressure

sender for low pressure -G410-
Removing
Caution
Protect fuel system against contamination.

♦ Observe rules for cleanliness and follow instructions for

10 .


– Unscrew fuel pressure sender for low pressure -G410- .
Installing
• Tightening torque: refer to exploded view of high-pressure
pump ⇒ page 45 .
Rep. gr. 21 .
– Check fuel system for leaks ⇒ page 5 .
WARNING
ted.
♦ The engine cover permitted
panel must alwaysbybeAUDI fitted before thenot guarantee or accept any liability
unless authorised AG. AUDI AG does
bonnet is closed. with respect to the correctness of information in this document. Copyright by AUDI AG.
5.5 Removing and installing high-pressure

pump
Removing
10 .
tem ⇒ page 4 .
WARNING

cause injury.
Cylinder bank 1 (right-side):

– Remove air filter element ⇒ page 18 .
– Remove bolts -arrows- and push wiring guide -1- slightly to
right side.

– Release hose clips -2 and 4- and detach fuel hoses.
– Unscrew union nut -3- and bolts -arrows-.
– Remove bolts -arrows-.
Cylinder bank 2 (left-side):

– Unplug electrical connectors -3-.
– Release hose clip -4- and detach fuel hose.
– Unscrew union nut -2- and bolts -1- and -arrows-.
Continuation for both sides:
– Carefully pull out high-pressure pump. It is possible that the
roller tappet may remain lodged inside.
Note
Installing
• Tightening torques: refer to exploded view of high-pressure
pump ⇒ page 45 .
Note
♦ Fit new O-ring.

♦ The connections of the high-pressure pipe must not be dam‐
aged.
♦ Do not attempt to bend high-pressure pipe to a different shape.
– Check roller tappet -1- for damage and renew if necessary.

– Lightly lubricate roller tappet with oil and insert it so that lug
-arrow A- slides into guide notch -arrow B-.

– Install front noise insulation -1- ⇒ General body repairs, ex‐

terior; Rep. gr. 66 .
– Rotate crankshaft at alternator in direction of normal engine

rotation -arrow- using ring spanner, and at the same time press
roller tappet into cylinder head until it reaches its lowest point.
note the following:
– Install air filter element ⇒ page 18 .
Rep. gr. 21 .
– Check fuel system for leaks ⇒ page 5 .
WARNING
ted.
♦Protected
The engine cover
by copyright. Copyingpanel must
for private alwayspurposes,
or commercial be fitted before
in part theis not
or in whole,
bonnet is closed.

6 Lambda probes
⇒ “6.1 Overview - Lambda probes”, page 58
⇒ “6.2 Removing and installing Lambda probes”, page 58
6.1 Overview - Lambda probes
1 - Lambda probe after catalyt‐

ic converter -G130-
❑ With Lambda probe 1
heater after catalytic
converter -Z29-
⇒ page 58
2 - Lambda probe 2 -G108-
(before catalytic converter)
❑ With Lambda probe
heater 2 -Z28-
⇒ page 58
3 - Lambda probe -G39- (be‐
fore catalytic converter)
❑ With Lambda probe
heater -Z19-
⇒ page 58
4 - Lambda probe 2 after cata‐
lytic converter -G131-
❑ With Lambda probe 2
heater after catalytic
converter -Z30-
⇒ page 58
6.2 Removing and installing Lambda

probes
⇒ “6.2.1 Removing and installing Lambda probes G39 / G131 ”,
page 58
⇒ “6.2.2 Removing and installing Lambda probes G108 / G130 ”,
page 60
6.2.1 Removing and installing Lambda

probes -G39- / -G131-

♦ Lambda probe open ring spanner set -3337-
Removing
Note
All cable ties which are released or cut open when removing must
be fitted in the same position when installing.

-1-.
– Remove bolts -arrows- and detach heat shield for drive

Protected shaftCopying for private or commercial purposes, in part or in whole, is not
by copyright.
(right-side). permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
6. Lambda probes 59
– Detach electrical connectors from bracket in the sequence

shown; release catches -arrows- to unplug connectors and
move electrical wiring clear:
2 - For Lambda probe -G39-
1 - For Lambda probe 2 -G131- (after catalytic converter)
– Unscrew Lambda probes using ring spanner -3337/7- :

1- Lambda probe 2 after catalytic converter -G131-
2- Lambda probe -G39-
Installing
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. High-temperature paste ⇒
Parts catalogue
♦ When installing, the Lambda probe wire must always be reat‐
tached at the same locations to prevent it from coming into
contact with the exhaust pipe.
♦ Fit all cable ties in the original positions when installing.

⇒ Rep. gr. 37 .
6.2.2 Removing and installing Lambda

probes -G108- / -G130-

♦ Lambda probe open ring spanner set -3337-
Removing
10 .
6. Lambda probes 61
– Detach electrical connectors one after the other from bracket,

unplug connectors and move electrical wiring clear:
1 - For Lambda probe after catalytic converter -G130-
4 - For Lambda probe 2 -G108-
Note
All cable ties which are released or cut open when removing must
be fitted in the same position when installing.
– Unscrew Lambda probes:

2 - Lambda probe 2 -G108- using ring spanner -3337/7-
3 - Lambda probe after catalytic converter -G130- using ring
spanner -3337/3-
Installing
WARNING
ted.
bonnet is closed.
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 permitted
used Lambda probe
unless authorised grease
by AUDI onlyAGthe
AG. AUDI doesthread
not guarantee or accept any liability
with high-temperature paste.
with respect to theThe pasteof information
correctness must notin this
getdocument.
into theCopyright by AUDI AG.
slots on the Lambda probe body. High-temperature paste ⇒
Parts catalogue
♦ When installing, the Lambda probe wire must always be reat‐
tached at the same locations to prevent it from coming into
contact with the exhaust pipe.
♦ Fit all cable ties in the original positions when installing.

Rep. gr. 21 .

7 Engine control unit

⇒ “7.1 Wiring and component check with isolator boxes VAS 6606
”, page 63
⇒ “7.2 Removing and installing engine control unit J623 ”,
page 64
7.1 Wiring and component check with isola‐

tor boxes -VAS 6606-
♦ Isolator box, 198-pin -VAS 6606/1-1-

♦ Sheets -VAS 6606/1-1-
♦ Sheets -VAS 6606/2-1-
♦ Sheets -VAS 6606/3-1-
♦ Set of cables -VAS 6606/7-1- and -VAS 6606/7-2-
Note
♦ Always make sure that the cables are properly connected.

♦ Do not use damaged or worn tools and accessories.
♦ Observe operating instructions. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Connect both cable sets -VAS 6606/7-1- and -VAS 6606/7-2-
to the three isolator boxes -VAS 6606- .
– Use the following sheets:
♦ -VAS 6606/1-1- for isolator box, 198-pin -VAS 6606/1-1-
Note
Make sure that all plug-in bridges are inserted completely in all
isolator boxes.
– Connect earth strap to an isolator box and to an earth point on

the vehicle.
– Remove engine control unit ⇒ page 64 .
7. Engine control unit 63

– Connect engine control unit to cable set -VAS 6606/7-1- .

– Connect vehicle wiring harness to cable set -VAS 6606/7-2- .
The connection on the engine control unit consists of a large and
a small connector.
The large connector has 105 pins and is assigned to the sheets
for the isolator box marked “A 1 to A 105”.
The small connector has 91 pins and is assigned to the sheets
for the isolator box marked “B 1 to B 91”.
When a push-in bridge is pulled out, the corresponding wiring
connection is disconnected.
Note
♦ The “In” contact -1- (red socket) leads to the engine control
unit.
♦ The “Out” contact -2- (blue socket) leads to the wiring harness.
– Carry out test as described in appropriate repair procedures.

Installing engine control unit
Installation is performed in the reverse sequence.
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 events saved in the memories
must be dealt with so that all event memory entries can be erased.
7.2 Removing and installing 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.
♦ 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 locking plate has to be removed before the con‐
nectors can be unplugged from the engine control unit (e.g. to
connect the test box or renew the engine control unit).

♦ Hot air blower -VAS 1978/14A- -item 1- with shrink element for
hot air blower -VAS 1978/15A- -2- from wiring harness repair
set -VAS 1978B-
♦ Small mole grips -3-

Removing
– When renewing engine control unit, select diagnosis object
“Replace engine control unit” in “Guided Functions” mode of
vehicle diagnostic tester .
– Remove filler neck for washer fluid reservoir ⇒ Electrical sys‐
tem; Rep. gr. 92 .
– Release catch -arrow- and detach engine control unit -J623-

-item 1-.
Note
Disregard -item 2-. with respect to the correctness of information in this document. Copyright by AUDI AG.
Perform the following work steps if a protective housing is fitted:
Caution
Wiring, connectors, insulation and control units can be burnt

and damaged.
♦ Keep exactly to the following procedure. Observe the in‐
structions for operating the hot air blower.

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.
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).

– 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.
Installing
– 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 filler neck for washer fluid reservoir ⇒ Electrical system;
Rep. gr. 92 .
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 Protected
controlbyunit”.
copyright. Copying for private or commercial purposes, in part or in whole, is not

28 – Ignition system
1 General notes and safety precau‐
tions
⇒ “1.1 General notes on ignition system”, page 68
⇒ “1.2 Safety precautions when working on the injection and ig‐
nition system”, page 68
⇒ “1.3 Safety precautions when working on vehicles with start/
stop system”, page 69
⇒ “1.4 Safety precautions after working in the engine compart‐
ment”, page 69
⇒ “1.5 Safety precautions when using testers and measuring in‐
struments during a road test”, page 70
1.1 General notes on ignition system

♦ The engine control unit has a self-diagnosis capability. Before

carrying out repairs and fault finding, the event memory must
be interrogated. The vacuum hoses and connections must al‐
so be checked (unmetered air).
♦ A voltage of at least 11.5 V is required for proper operation of
the electrical components.
♦ Entries will be stored in the event memory of the engine control
unit if electrical connectors have been unplugged and the en‐
gine started.
♦ 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 of the engine control unit must then
be interrogated and, if necessary, the control unit must be
adapted.
– Erase any entries in event memory resulting from testing or
repairs ⇒ Vehicle diagnostic tester, Guided Functions , In-
terrogate event memory , then Generate readiness
code .

injection and ignition system
To prevent injuries to persons and/or damage to the fuel injection
and ignition system, note the following:
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as the
ignition system and xenon headlights.
♦ Always switch off the ignition before connecting or discon‐
necting electrical wiring for the injection or ignition system or
tester cables.
♦ For safety reasons, the battery must be disconnected before
opening the fuel system to prevent the fuel pump from being
activated by the contact switch on the driver's door.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off ignition before washing engine.
68 Rep. gr.28 - Ignition system

Caution
To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .
1.3 Safety precautions when working on ve‐

hicles 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 after working in the

engine compartment
After working in the engine compartment, note the following:
WARNING
ted.
bonnet is closed.
to start or drive the vehicle with thepermitted
bonnetunless
closed.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1. General notes and safety precautions 69

1.5 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.

2 Servicing ignition system

⇒ “2.1 Test data”, page 71
⇒ “2.2 Ignition system - exploded view”, page 72
⇒ “2.3 Removing and installing ignition coils”, page 73
⇒ “2.4 Removing and installing knock sensors”, page 77
⇒ “2.5 Removing and installing Hall senders”, page 83
⇒ “2.6 Removing and installing engine speed sender G28 ”, page
87
2.1 Test data

Test data 4.0 ltr. TFSI engine
Idling speed Cannot be adjusted; regulated by idling speed sta‐
bilisation
Ignition timing Not adjustable (determined by control unit)
Ignition system Multi-coil system with 8 ignition coils (output stages
integrated) connected directly to spark plugs via
spark plug connectors
Spark plugs Designations ⇒ Data sheets for exhaust emissions test
Tightening torque ⇒ Maintenance ; Booklet 411
Firing order 1-5-4-8-6-3-7-2
2. Servicing ignition system 71

2.2 Ignition system - exploded view
1 - Knock sensor
side)
❑ Knock sensor 1 -G61-
(front)
❑ Knock sensor 2 -G66-
(rear)
⇒ page 77
2 - Bolt
❑ 25 Nm
❑ The tightening torque in‐
fluences the function of
the knock sensor
3 - O-ring
❑ Renew
4 - Hall sender
❑ Inlet side: Hall sender -
G40- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Exhaust side: Hall send‐to the correctness of information in this document. Copyright by AUDI AG.
with respect
er 2 -G163-
⇒ page 83
5 - Bolt
❑ 9 Nm
6 - Spark plug
❑ Change interval ⇒
Maintenance tables
❑ Tightening torque
⇒ Maintenance ; Book‐
let 411
7 - Ignition coil
8 - Bolt
❑ 9 Nm
9 - Cable guide
10 - Bolt
❑ 5 Nm
11 - Engine speed sender -G28-
12 - Bolt
❑ 9 Nm
13 - Bolt
❑ 9 Nm
14 - Hall sender
❑ Inlet side: Hall sender 3 -G300-
❑ Exhaust side: Hall sender 4 -G301-

15 - O-ring
❑ Renew
16 - Bolt
❑ 25 Nm
❑ The tightening torque influences the function of the knock sensor
17 - Knock sensor
❑ Cylinder bank 2 (left-side)
❑ Knock sensor 3 -G198- (front)
❑ Knock sensor 4 -G199- (rear)
2.3 Removing and installing ignition coils

⇒ “2.3.1 Removing and installing ignition coils N70 / N127 / N291 /
N292 (cylinder bank 1 right-side)”, page 73
⇒ “2.3.2 Removing and installing ignition coils N323 / N324 /
N325 / N326 (cylinder bank 2 left-side)”, page 74
2.3.1 Removing and installing ignition coils -

N70- / -N127- / -N291- / -N292- (cylinder
bank 1 right-side)
Removing
10 .
– Remove air cleaner housing ⇒ page 20 .
– Unplug electrical connectors and move wiring clear:

1 - For ignition coils -N70- , -N127- Protected
, -N291- , -N292-
2 - For Hall sender -G40- with respect to the correctness of information in this document. Copyright by AUDI AG.
4 - For inlet and exhaust cam actuators -F456- , -F457- , -F458- ,

-F459-
5 - For intake air temperature sender -G42-
-F455-
– Disconnect vacuum hoses -3, 7-.
– Remove bolts -arrows-.
– Move earth wire clear and pivot wiring guide towards rear.

– Remove bolt -arrow- and pull off relevant ignition coil -1-.
Installing
Note
Secure all hose connections with the correct type of hose clips
– Align ignition coils with recesses in cylinder head cover.

– Press ignition coils onto spark plugs by hand (do NOT use
tool).
note the following: with respect to the correctness of information in this document. Copyright by AUDI AG.
– Install air cleaner housing ⇒ page 20 .

Rep. gr. 21 .
WARNING
ted.
bonnet is closed.
2.3.2 Removing and installing ignition coils -

N323- / -N324- / -N325- / -N326- (cylin‐
der bank 2 left-side)
Removing
10 .


front.
– Move coolant hoses -3- and air hose -1- clear at wiring guide
-2-.
– Take electrical connectors -1- out of bracket -2-, unplug them

and move electrical wiring clear.
– Lift out bracket.
– Unplug electrical connectors -arrows- and move clear.

– Unplug electrical connectors and move wiring clear:

-F467-
4 - For fuel metering valve 2 -N402-
5 - For fuel pressure sender for low pressure -G410-
6 - For Hall sender 4 -G301-
-F479-
10 - For Hall sender 2 -G163-
11 - For ignition coils -N323- , -N324- , -N325- , -N326-
– Disconnect vacuum hoses -1, 7-.
– Remove bolts -2, 9- and centre hex stud -arrow-, move earth
wire clear and pivot wiring guide towards rear.
– Remove bolt -arrow- and pull off relevant ignition coil -1-.
Installing
Note
Secure all hose connections with the correct type of hose clips
– Align ignition coils with recesses in with
cylinder head
respect to cover. of information in this document. Copyright by AUDI AG.
the correctness
– Press ignition coils onto spark plugs by hand (do NOT use
tool).
note the following:
Rep. gr. 21 .
WARNING
ted.
bonnet is closed.

2.4 Removing and installing knock sensors

⇒ “2.4.2 Removing and installing knock sensor G61 (cylinder
bank 1, right-side) - A7 only”, page 79
⇒ “2.4.3 Removing and installing knock sensor 2 G66 (cylinder
bank 1, right-side)”, page 79
bank 2, left-side)”, page 81
bank 2, left-side)”, page 82
2.4.1 Removing and installing knock sensor -

G61- (cylinder bank 1, right-side) - A6
only
Fitting location
– Disconnect earth wire at battery with ignition switched off.
– Release catches -arrows A- and detach air duct -1- on left and
right -arrow B-.

– Release retaining pins for radiator on both sides and pull out
upwards -arrows-.
– Push radiator towards the front.
– Remove tensioner for poly V-belt ⇒ Rep. gr. 13 .
– Remove nut -1- and detach B+ wire -2-.
– Unscrew bolts -arrows- for alternator approx. 6 turns.

– Tap carefully on bolt heads with a hammer to release sliding
bushes of alternator mountings.
– Remove bolts completely.
– If fitted, remove silencer for auxiliary heater ⇒ Rep. gr. 82 .
– Move alternator as far as possible to the right.
– Loosen bolts and detach coolant hoses -2 and 4- with con‐

nections.


– Unscrew bolt -2- and remove knock sensor 1 -G61- .
Installing
Note
The tightening torque influences the function of the knock sensor.
– Install alternator ⇒ Electrical system; Rep. gr. 27 .
2.4.2 Removing and installing knock sensor -

G61- (cylinder bank 1, right-side) - A7
only
Fitting location
Removing
– Disconnect earth wire at battery with ignition switched off.
– Remove alternator ⇒ Electrical system; Rep. gr. 27 .

Installing
Note
– Install alternator ⇒ Electrical system; Rep. gr. 27 .
2.4.3 Removing and installing knock sensor 2

-G66- (cylinder bank 1, right-side)
Fitting locations
⇒ “2.2 Overview of fitting locations - injection system”, page 8

Removing
– Remove front wheel (right-side) ⇒ Wheels and tyres; Rep. gr.
44 .
– Remove engine mounting (right-side) ⇒ Engine, mechanics;

Rep. gr. 10 .
– Remove nut -2- and move earth wire clear.

– Remove bolts -arrows- and detach engine support -1- (right-
side).
– Unplug electrical connector -4- from starter (push retainer to

rear and press down release catch).
– Unfasten nut -3- and detach battery positive wire from solenoid
switch.


Installing
Note
– Install engine support and engine mounting (right-side) ⇒ En‐


-G198- (cylinder bank 2, left-side)
Fitting location
Removing
– Remove air conditioner compressor ⇒ Air conditioning sys‐
tem; Rep. gr. 87 .
– Detach electrical connector -2- from bracket and unplug.

Note
Disregard -item 3-.
Installing
Note
– Install air conditioner compressor ⇒ Air conditioning system;

Rep. gr. 87 .


-G199- (cylinder bank 2, left-side)
Fitting location
Removing
– Remove electromechanical steering rack ⇒ Running gear,
front-wheel drive and four-wheel drive; Rep. gr. 48 .

– Detach knock sensor 4 -G199- and unplug electrical connector
-1-.
Installing
Note
– Install electromechanical steering rack ⇒ Running gear, front-

wheel drive and four-wheel drive; Rep. gr. 48 .

2.5 Removing and installing Hall senders

⇒ “2.5.1 Removing and installing Hall sender G40 (cylinder bank
1, right-side)”, page 83
⇒ “2.5.2 Removing and installing Hall sender 2 G163 (cylinder
bank 1, right-side)”, page 83
⇒ “2.5.3 Removing and installing Hall sender G300 / G301 (cyl‐
inder bank 2, left-side)”, page 85
2.5.1 Removing and installing Hall sender -

G40- (cylinder bank 1, right-side)
Fitting locations
Removing
10 .
– Remove air filter element ⇒ page 18 .
– Unplug electrical connectors:

1- For Ignition coil 4 with output stage -N292-
2- For Hall sender -G40-
– Unscrew bolt -arrow- and remove Hall sender.
Installing
WARNING
ted.
bonnet is closed.
2.5.2 Removing and installing Hall sender 2 -

G163- (cylinder bank 1, right-side)
Fitting locations


Removing
10 .
– Remove air cleaner (top section) -1-.
– Release hose clip -1- and disconnect hose from activated

charcoal filter.
Note
Disregard -item 2-.
– Unplug electrical connector -1- at activated charcoal filter sys‐

tem solenoid valve 1 -N80- .
– Remove bolt -arrow-.

– Unplug electrical connectors -1, 2-.

– Remove bolts -arrows- and move bracket -3- with electrical
wiring harness to one side.
– Disconnect vacuum hose -1-.

– Remove bolts -arrows- and place vacuum unit for turbocharg‐
er to one side.
Note
Disregard -item 2-.
– Unscrew bolt -arrow- and remove Hall sender -1-.

Installing
WARNING
ted.
bonnet is closed.
2.5.3 Removing and installing Hall sender -
G300- / -G301- (cylinder bank 2, left-
side)
Removing
Fitting locations

Hall sender 3 -G300- :

10 .

front.
Hall sender 4 -G301- :

10 .

Continuation for both Hall senders:

– Unplug relevant electrical connector -1-.
– Unscrew bolt -2- and detach relevant Hall sender.
Installing
If Hall sender 3 -G300- was removed, coolant level must be
checked ⇒ Rep. gr. 19 .
WARNING
ted.
bonnet is closed.
2.6 Removing and installing engine speed

sender -G28-
Removing
– Remove rear noise
Protected by insulation panel
copyright. Copying -2- ⇒
for private Rep. gr.
or commercial 66 . in part or in whole, is not
purposes,
– Remove bolt -arrow- for coolant pipe on gearbox (right-side).

– Remove bolts -arrows- and push ATF cooler slightly to one

side.
Note
Disregard -item 1-.

– Unscrew bolt -1- and pull out engine speed sender -G28- .
Installing
– Install ATF cooler ⇒ Rep. gr. 34 .
– Install coolant pipe (right-side) on gearbox ⇒ Rep. gr. 19 .
– Install rear noise insulation ⇒ Rep. gr. 66 .

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Service

Service Department. Technical Information

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Copyright © 2012 Audi AG, Ingolstadt D3E8048221D

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

2.2 Ignition system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

24 – Mixture preparation - injection

1.1 General notes on self-diagnosis

1. Safety precautions and rules for cleanliness 1

1.2 Safety precautions when working on the

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

♦ Fuel hoses in engine compartment must only be secured with

1.3 Safety precautions when working on the

2 Rep. gr.24 - Mixture preparation - injection

To prevent irreparable damage to the electronic components

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .

1.4 Safety precautions when working on ve‐

Risk of injury due to automatic engine start on vehicles with

1.5 Safety precautions after working in the

1. Safety precautions and rules for cleanliness 3

1.6 Safety precautions when using testers

Accidents can be caused if the driver is distracted by test

1.7 Rules for cleanliness and instructions

Even small amounts of dirt can cause malfunctions. When work‐

1.8 Reducing pressure in high-pressure

4 Rep. gr.24 - Mixture preparation - injection

The fuel system operates at extremely high pressure. This can

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

♦ The pressure will increase again due to the effect of residual

Additional steps required

1.9 Checking for leaks in the fuel system

1. Safety precautions and rules for cleanliness 5

– If leaks are found although the connections have been tight‐

1.10 Checking vacuum system

6 Rep. gr.24 - Mixture preparation - injection

2.1 Test data

2.2 Overview of fitting locations - injection

2.2.1 Fitting locations in engine compartment

1 - Turbocharger air recircula‐

8 Rep. gr.24 - Mixture preparation - injection

Fitting location of engine control unit -J623-

Fitting location of accelerator position sender -G79- / accelerator

The accelerator position sender -G79- and accelerator position

Removing and installing ⇒ fuel supply system; Rep. gr. 20

♦ In footwell on brake pedal

Fitting location of radiator outlet coolant temperature sender -

Fitting location of continued coolant circulation pump -V51-

10 Rep. gr.24 - Mixture preparation - injection

Fitting location of charge air cooling pump -V188-

Fitting location of gearbox oil cooling valve -N509-

Fitting location of fuel pump control unit -J538-

Removing and installing ⇒ fuel supply system; Rep. gr. 20

Fitting location of secondary air pump motor -V101-

Fitting location of sender 1 for secondary air pressure -G609-

♦ At rear of wheel housing (front right)

12 Rep. gr.24 - Mixture preparation - injection

2.2.2 Fitting locations on engine (from above)

1 - Intake manifold pressure

17 - Ignition coil 5 with output stage -N323-