D3E802E3541-TDI Injection and Glow Plug System (6-Cyl 3 0 LTR 4-Valve Common Rail)

Service
Workshop Manual
Audi A6 2011 ➤
Audi A7 Sportback 2011 ➤
TDI injection and glow plug system (6-cyl. 3.0 ltr. 4-
valve common rail)
CLAA CLAB CDU
Engine ID
CGQ CKV CDU CKV CPN
C B B D C B
Edition 11.2013
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2014 Audi AG, Ingolstadt D3E802E3541

Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
TDI injection and glow plug system (6-cyl. 3.0 ltr. 4-valve common rail) - Edition 11.2013
Contents
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety precautions and rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when using testers and measuring instruments during a road test . . . . 1
1.2 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 2
1.3 Safety precautions when working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when working on the injection and glow plug system . . . . . . . . . . . . . . 4
1.5 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Overview of fitting locations - injection system (CLAA, CLAB, CDUC, CKVB, CPNB) . . . . 6
2.2 Overview of fitting locations - injection system (CGQB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.4 Filling and bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.5 Connection diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1 Exploded view - air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.4 Removing and installing intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.3 Performing first fuel filling after installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . 50
6 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.1 Exploded view - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.2 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.3 Performing adaption of correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.4 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.5 Measuring return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . 60
6.6 Checking return flow rate of injectors at starter cranking speed . . . . . . . . . . . . . . . . . . . . 63
6.7 Checking restrictor in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.8 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.9 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.10 Installing high-pressure pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7 Senders and sensors
permitted . . . . .by. AUDI
unless authorised . . . AG.
. . .AUDI
. . .AG
. .does
. . .not
. .guarantee
. . . . . or. .accept
. . . any
. . .liability
................... 80
7.1 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.2 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

7.3 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 83
7.4 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.5 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 88
8 Lambda probes and exhaust gas temperature senders (CLAA, CLAB, CDUC, CKVB,
CPNB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.1 Exploded view - Lambda probe, exhaust gas temperature control (CLAA, CLAB, CDUC)
........................................................................ 90
8.2 Exploded view - Lambda probe, exhaust gas temperature control (CKVB, CPNB) . . . . . . 91
8.3 Removing and installing Lambda probe G39 with Lambda probe heater Z19 . . . . . . . . . . 93
8.4 Removing and installing exhaust gas temperature sender 2 G448 (engine code CPNB
only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Contents i
9 Lambda probes and exhaust gas temperature senders (CGQB) . . . . . . . . . . . . . . . . . . . . 95

9.1 Exploded view - Lambda probe, exhaust gas temperature control (CGQB) . . . . . . . . . . . . 95
9.2 Removing and installing Lambda probe G39 with Lambda probe heater Z19 . . . . . . . . . . 96
10 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10.1 Wiring and component check with isolator box VAS 6606 . . . . . . . . . . . . . . . . . . . . . . . . 97
10.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.2 Exploded view - glow plugs, Hall sender, engine speed sender . . . . . . . . . . . . . . . . . . . . 100
1.3 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.4 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.5 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
ii Contents
23 – Mixture preparation - injection

1 Safety precautions and rules for
cleanliness
(ARL003646; Edition 11.2013)
⇒ “1.1 Safety precautions when using testers and measuring in‐
struments during a road test”, page 1
⇒ “1.2 Safety precautions when working on vehicles with start/
stop system”, page 2
⇒ “1.3 Safety precautions when working on the fuel system”, page
2
⇒ “1.4 Safety precautions when working on the injection and glow
plug system”, page 4
⇒ “1.5 Checking vacuum system”, page 4
1.1 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

1.2 Safety precautions when working on ve‐

hicles with start/stop system
When performing repairs on vehicles with start/stop system, note
the following:
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 ensurewiththat thetostart/stop
respect sys‐
the correctness of information in this document. Copyright by AUDI AG.
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).
1.3 Safety precautions when working on the

fuel system
When working on the fuel system note the following warnings:
WARNING
The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the fuel lines and the fuel can reach a
temperature of 100 °C on vehicles with common rail en‐
gine, even after the engine is switched off. Allow the fuel
to cool down before disconnecting the lines - danger of
scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
Risk of injury - fuel system operates under pressure.
♦ 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.
♦ Wrap a clean cloth around the connection before opening
the fuel system. Then release pressure by carefully loos‐
ening the connection.
♦ Wear protective gloves.
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 .
2 Rep. gr.23 - Mixture preparation - injection

To prevent the high-pressure pump from running while it is empty

and to ensure that the engine starts quickly after parts have been
renewed, it is important to observe the following:
Caution
Running when dry causes irreparable damage to high-pres‐

sure pump.
♦ To prevent the high-pressure fuel pump from running
while it is empty and to ensure that the engine starts quick‐
ly after parts have been renewed, it is important to observe
the following:
♦ If components of the fuel system between the fuel tank
and the high-pressure fuel pump are removed or renewed,
the basic setting “Checking fuel system pressurisation
pump” must be performed to bleed the fuel system.
♦ Perform first fuel filling after installing high-pressure pump.
• Clean tools and workbench etc. before working on the injection

system.
• Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
• When removing components, plug all open connections im‐
mediately with suitable clean sealing caps.
• Do not remove sealing caps from components until immedi‐
ately prior to installation. Keep components that are to be re-
used in new, sealable plastic bags.
• Before installing, check the injectors and their surroundings
visually; they must be undamaged and clean. Make sure the
injector bores in the cylinder head are clean. Wipe out if nec‐
essary using a clean cloth, taking care not to cause damage.
Do not use sharp objects of any kind.
• If the high-pressure fuel lines are to be re-used, you must mark
them before removal. High-pressure pipes must always be re-
installed on the same cylinder.
• Take care not to damage the injectors when removing the old
copper seals.
• Check all new O-rings for damage before installing. Lubricate
O-rings with engine oil or assembly oil before installing.
• Position high-pressure pipes so they are free of stress. Tighten
all unions lightly to start with before tightening to final torque.
• Never attempt to bend high-pressure fuel lines to shape.
• When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be with removed
respect to the and
correctness of information in this document. Copyright by AUDI AG.
installed by hand without using tools or other equipment.
• Press the fuel return hoses onto the injectors by hand from
above so that they engage audibly on each injector (do not
press in the release pins when doing this). Then press down
the release pin after connecting the return line. Check that the
fuel return hoses are seated securely and sealed properly by
pulling them by hand from above.
• Do not dismantle individual common rail components. If there
is a fault, the complete components must be renewed.

• When the engine is running, do not perform any repairs to the

common rail system.
• Do not bleed the common rail system by unfastening high-
pressure components after the engine has been started.
• All cable ties which are released or cut open when removing
must be refitted in the same position when installing.
• When the fuel system is open: Do not work with compressed
air if this can be avoided. Do not move the vehicle unless ab‐
solutely necessary.
• Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
1.4 Safety precautions when working on the

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

Special tools and workshop equipment required

♦ Hand vacuum pump - VAS 6213-
Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites
♦ Kinked or crushed lines
♦ 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 remaining 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 Overview of fitting locations - injection system (CLAA,
CLAB, CDUC, CKVB, CPNB)”, page 6
⇒ “2.2 Overview of fitting locations - injection system (CGQB)”,
page 15
⇒ “2.3 Overview - fuel system”, page 26
⇒ “2.4 Filling and bleeding fuel system”, page 27
⇒ “2.5 Connection diagram - vacuum system”, page 28
2.1 Overview of fitting locations - injection system (CLAA, CLAB, CDUC, CKVB,
CPNB)
Engine compartment
1 - Radiator outlet coolant tem‐

perature sender - G83-
❑ Fitting location
⇒ page 13
❑ Removing and installing
⇒ Rep. gr. 19
2 - Right electrohydraulic en‐
gine mounting solenoid valve -
N145-
⇒ Rep. gr. 10
3 - Air mass meter - G70-
⇒ page 80
4 - Pressure differential sender
- G505-
⇒ page 12
❑ Exploded view
⇒ page 90
5 - Exhaust gas temperature
sender 4 - G648- with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Exploded view
⇒ page 90
6 - Engine speed sender -
G28-
❑ Exploded view
⇒ page 100
sender 1 - G235-
⇒ Rep. gr. 26
sender 3 - G495-
❑ Exploded view ⇒ page 90
9 - Brake servo pressure sensor - G294-
10 - Accelerator position sender - G79- and accelerator position sender 2 - G185-
❑ Fitting location ⇒ page 11

11 - Instrument cluster with control unit in dash panel insert - J285-

❑ Removing and installing ⇒ Rep. gr. 90
12 - Brake light switch - F-
13 - Engine control unit - J623-
❑ Removing and installing ⇒ page 98
14 - Lambda probe - G39- with Lambda probe
Protected heater
by copyright. - Z19-
Copying for private or commercial purposes, in part or in whole, is not
❑ Exploded view ⇒ page 90 with respect to the correctness of information in this document. Copyright by AUDI AG.
15 - Left electrohydraulic engine mounting solenoid valve - N144-

16 - Charge pressure sender - G31- / intake air temperature sender - G42-
Engine (top view)
1 - Fuel pressure regulating

valve - N276-
❑ Exploded view
⇒ page 44
2 - Injector, cylinder 1 - N30-
❑ Exploded view
⇒ page 44
3 - Glow plug 1 - Q10-
❑ Exploded view
⇒ page 100
❑ Exploded view
⇒ page 44
5 - Hall sender - G40-
⇒ page 12
❑ Exploded view
⇒ page 100
❑ Exploded view
⇒ page 100
❑ Exploded view
⇒ page 44
❑ Exploded view
⇒ page 100
9 - Fuel temperature sender -
G81-
10 - Control unit for turbo‐
charger 1 - J724-
❑ On turbocharger
2. Injection system 7
11 - Fuel metering valve - N290-

12 - Exhaust gas recirculation control motor - V338-
13 - Fuel pressure sender - G247-
14 - Glow plug 6 - Q15-
16 - Glow plug 5 - Q14-
18 - Glow plug 4 - Q13-
19 - Injector, cylinder
permitted4unless
- N33-authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
20 - Coolant temperature sender - G62-
21 - Exhaust gas recirculation temperature sensor - G98-
22 - Coolant valve for cylinder head - N489-
Engine (front view)

1 - Oil level and oil temperature

sender - G266-
⇒ Rep. gr. 17
2 - Map-controlled engine cool‐
ing system thermostat - F265-
⇒ Rep. gr. 19
3 - Oil temperature sender 2 -
G664-
⇒ page 13
⇒ Rep. gr. 17
4 - Oil pressure switch - F22-
⇒ Rep. gr. 17
5 - Oil pressure switch for re‐
duced oil pressure - F378-
⇒ Rep. gr. 17
6 - Exhaust gas recirculation
cooler change-over valve -
N345-
⇒ Rep. gr. 26
7 - Intake manifold flap motor -
V157-
❑ Exploded view
⇒ page 35
8 - Throttle valve module - J338-
9 - Temperature sender for engine temperature regulation - G694-
10 - Valve for oil pressure control - N428-
A - Fuel pump control unit - J538-
B - Injector for reducing agent - N474-
❑ Only fitted on vehicles with SCR catalytic converter
C - Control unit for NOx senderpermitted
2 - J881-unlessand NOxby sender
authorised 2 - G687-
AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Only fitted on vehicles withwithSCR catalytic converter
respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Fitting location for engine code CKVB ⇒ page 14

❑ Fitting location for engine code CPNB ⇒ page 15
D - Control unit for NOx sender - J583- with NOx sender - G295-
❑ Only fitted on vehicles with SCR catalytic converter (engine code CPNB only)
E - Control unit for reducing agent metering system - J880-
F - Exhaust gas temperature sender 4 - G648-
G - Exhaust gas temperature sender 2 - G448-
H - Particulate sensor - G784-

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
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 ⇒ Rep. gr. 20
Fitting location of brake light switch - F-

♦ In footwell on brake pedal
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

unlessillus‐
permitted authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
tration. with respect to the correctness of information in this document. Copyright by AUDI AG.
Fitting location of pressure differential sender - G505-

♦ -Item 2- at rear right of engine
Fitting location of Hall sender - G40-

♦ -Item 2- on cylinder head cover, cylinder bank 1 (right-side)
Fitting location of fuel metering valve - N290-

♦ -Item 2- in high-pressure pump
Fitting location of charge pressure sender - G31- / intake air tem‐

♦ -Item 2- at air pipe (left-side) in engine compartment

Fitting location of temperature sender for engine temperature

regulation - G694-
♦ -Item 1- at front left of cylinder block
Fitting location of radiator outlet coolant temperature sender -

G83-
Oil temperature sender 2 - G664-
Valve for oil pressure control - N428-
Injector for reducing agent - N474- (engine codes CKVB and

CPNB only)
Components at bottom of tank (engine code CKVB only)

1 - Control unit for reducing agent metering system - J880-
2 - Reservoir
3 - Control unit for NOx sender 2 - J881- and NOx sender 2 -
G687-
4 - Electrical
Protected connector for heater
by copyright. Copying for privatefor reducing
or commercial agentinline
purposes, part or- in
Z104-
whole, is not
5 - Reducing agent
with respect line
to the correctness of information in this document. Copyright by AUDI AG.
The following components are located in the reservoir -item 2-:

♦ Tank sender for reducing agent - G684-
♦ Temperature sender for reducing agent - G685-
♦ Pressure sender for reducing agent metering system - G686-
♦ Pump for reducing agent - V437-
♦ Heater for reducing agent tank - Z102-
Fitting locations of exhaust gas temperature sensors (engine

code CPNB only)
1- Exhaust gas temperature sender 3 - G495-
3- NOx sender - G295-
4- Lambda probe - G39-
5- Electrical connector for exhaust gas temperature sender 2
- G448-
- G495-
7- Electrical connector for Lambda probe - G39-

Control unit for NOx sender - J583- with NOx sender - G295- (en‐
gine code CPNB only)
1- Electrical connector for control unit for NOx sender - J583-
2- NOx sender - G295-
3- Control unit for NOx sender - J583-
Control unit for NOx sender 2 - J881- and NOx sender 2 - G687-
(engine code CPNB only)
1- Electrical connector for control unit for NOx sender 2 - J881-
2- NOx sender 2 - G687-
3- Control unit for NOx sender 2 - J881-
Particulate sensor - G784- (engine code CPNB only)

1- Electrical connector
Protected by for particulate
copyright. Copying sensorpurposes,
for private or commercial - G784- in part or in whole, is not
2- Particulate sensor
with respect - G784-
3- Control unit for particulate sensor - G784-
2.2 Overview of fitting locations - injection system (CGQB)

Engine compartment

⇒ page 80
⇒ page 22
❑ Exploded view
⇒ page 100
3 - Electrical connector for ex‐
haust gas recirculation tem‐
perature sensor - G98-
⇒ page 22
⇒ Rep. gr. 26
4 - Electrical connector
❑ For map-controlled en‐
gine cooling system
thermostat - F265- , fuel
metering valve - N290-
and exhaust gas recir‐
culation control motor -
V338-
⇒ page 22
5 - Restrictor
❑ In fuel return line
⇒ page 22
- G505-
❑ For electrical connector
for exhaust gas temper‐
ature Protected
senderby3copyright.
- G495-Copying for private or commercial purposes, in part or in whole, is not
❑ Fittingpermitted
location ⇒ authorised
unless page 24by AUDI AG. AUDI AG does not guarantee or accept any liability
7 - Fuel temperature sender - G81-
8 - Control unit for structure-borne sound - J869-
9 - Control unit for turbocharger 1 - J724-
❑ Exhaust gas temperature sender 1 - G235-
❑ Charge pressure sender 2 - G447-
11 - Regulating flap potentiometer - G584-
12 - Lambda probe - G39- with Lambda probe heater - Z19-
❑ Tightening torque ⇒ page 55

14 - Electrical connector for Lambda probe - G39-

15 - Engine control unit - J623-
16 - Charge pressure sender - G31- / intake air temperature sender - G42-
18 - Injectors
❑ Cylinder bank 2
19 - Turbine changeover valve - N529-
❑ Checking ⇒ Rep. gr. 21
22 - Intake manifold flap motor - V157-
23 - Exhaust gas recirculation cooler change-over valve - N345-
24 - Map-controlled engine cooling system thermostat - F265-
26 - Charge pressure control solenoid valve - N75-
27 - Oil pressure switch for reduced oil pressure - F378-
❑ Removing and installing ⇒ byRep.
Protected gr.Copying
copyright. 17 for private or commercial purposes, in part or in whole, is not
28 - Fuel pressure regulatingwith
valve - toN276-
respect the correctness of information in this document. Copyright by AUDI AG.
29 - Injectors
❑ Cylinder bank 1
Engine (top view)

valve - N276-
❑ Exploded view
⇒ page 44
❑ Exploded view
⇒ page 44
❑ Exploded view
⇒ page 100
❑ Exploded view
⇒ page 44
⇒ page 22
❑ Exploded view
⇒ page 100
❑ Exploded view
⇒ page 100
❑ Exploded view
⇒ page 44
❑ Exploded view
⇒ page 100
9 - Fuel temperature sender -
G81-
sender 1 - G235-
12 - Charge pressure sender 2 - G447-
13 - Control unit for turbocharger 1 - J724-
❑ On turbocharger
❑ Removing and installingProtected
⇒ Rep. gr. 26 Copying for private or commercial purposes, in part or in whole, is not
by copyright.
15 - Glow plug 6 - Q15- with respect to the correctness of information in this document. Copyright by AUDI AG.

17 - Glow plug 5 - Q14-


22 - Glow plug 4 - Q13-
23 - Coolant temperature sender - G62-
25 - Exhaust gas recirculation cooler change-over valve - N345-
26 - Electrical connector for charge pressure control solenoid
Protected valve
by copyright. - N75-
27 - Electrical connector coolant valve for cylinder head - N489-
28 - Charge pressure control solenoid valve - N75-

30 - Restrictor in fuel return line
❑ Checking ⇒ page 66
Engine (front view)
1 - Oil level and oil temperature

sender - G266-
⇒ Rep. gr. 17
2 - Map-controlled engine cool‐
ing system thermostat - F265-
⇒ Rep. gr. 19
3 - Oil temperature sender 2 -
G664-
⇒ page 23
⇒ Rep. gr. 17
4 - Oil pressure switch - F22-
⇒ Rep. gr. 17
5 - Oil pressure switch for re‐
duced oil pressure - F378-
⇒ Rep. gr. 17
cooler change-over valve - Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
N345- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ Rep. gr. 26
V157-
❑ Exploded view
⇒ page 35
8 - Throttle valve module -
J338-
❑ Exploded view
⇒ page 35
9 - Turbine changeover valve - N529-
❑ Checking ⇒ Rep. gr. 21
11 - Valve for oil pressure control - N428-

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
Note
The accelerator position sender - G79- and accelerator position

sender 2 - G185- are integrated in the accelerator pedal module
and cannot be renewed individually.
Fitting locations (driver's side)

1 - Brake light switch - F- and brake pedal switch -permitted
F47- unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2 - Clutch position sender - G476- with clutch pedal switch for
engine start - F194- and clutch pedal switch - F36- (manual gear‐
box only)
Radiator fan control unit - J293-

1 - Radiator fan control unit - J293-
2 - Electrical connector for radiator fan - V7-
3 - Electrical connector for radiator fan 2 - V177-
Fitting location of Hall sender - G40-

♦ -Item 2- on cylinder head cover, cylinder bank 1 (right-side)
Electrical connectors
1- For exhaust gas recirculation temperature sensor - G98-
2- For map-controlled engine cooling system thermostat -
F265- , fuel metering valve - N290- and exhaust gas recir‐
culation control motor - V338-
3- Restrictor in fuel return line
Fitting location of fuel metering valve - N290-

♦ -Item 2- in high-pressure pump
Fitting location of charge pressure sender - G31- / intake air tem‐

♦ -Item 2- at air pipe (left-side) in engine compartment

Fitting location of temperature sender for engine temperature

regulation - G694-
♦ -Item 1- at front left of cylinder block
Fitting location of radiator outlet coolant temperature sender -

G83-
Regulating flap potentiometer - G584-
Oil temperature sender 2 - G664-
Valve for oil pressure control - N428-
Fuel pressure sender - G247- -arrow-
Lambda probe - G39-

2 - Lambda probe - G39-
Fitting location of pressure differential sender - G505-

1 - Exhaust gas temperature sender 3 - G495-
2 - Pressure differential sender - G505-
3 - Connection from pressure pipe for pressure differential sender
- G505-
♦ -Item 2- at rear right of engine

Fitting locations on turbocharger

1 - Charge pressure sender 2 - G447-
The turbocharger 1 control unit - J724- can be seen on the left.
Exhaust gas temperature sender in turbocharger

2 - Electrical connector for exhaust gas temperature sender 1 -
G235-
Exhaust gas temperature
with respect sender
1 - Electrical connector for bank 2 exhaust gas temperature send‐

er 4 - G649-
2 - Exhaust gas temperature sender 4 for cylinder bank 2 - G649-
Note
♦ The removal of the exhaust gas temperature sender 4 for bank

2 - G649- is shown as an example.
♦ Exhaust gas temperature sender 4 - G648- is fitted on the op‐
posite side.
Engine mounting (left-side)

1 - Left electrohydraulic engine mounting solenoid valve - N144-
2 - Electrical connector for left electrohydraulic engine mounting
solenoid valve - N144-
Engine mounting (right-side)

1 - Electrical connector for right electrohydraulic engine mounting
solenoid valve - N145-
2 - Right electrohydraulic engine mounting solenoid valve - N145-
Engine speed sender - G28-
2.3 Overview - fuel system
Caution
Risk of malfunctions caused by dirt.

The high-pressure fuel pump has very close tolerances and
must not be allowed to run without fuel. To prevent this and to
enable the engine to start quickly after parts have been re‐
newed, it is important to observe the following:
Note
The high-pressure pump will be damaged if the first fuel filling operation is not performed.


❑ Do not unscrew
2 - High-pressure pump
❑ Exploded view
⇒ page 44
3 - Fuel rail
❑ For cylinder bank 1
(right-side)
valve - N276-
❑ Cannot be re-installed
⇒ page 83
❑ Tightening torque
⇒ page 54
5 - Fuel pressure sender -
G247-
❑ Tightening torque
⇒ page 55
⇒ page 85
6 - Fuel rail
❑ For cylinder bank 2 (left-
side)
7 - Injector
⇒ page 67
8 - Fuel return hoses
❑ Do not dismantle
❑ Renew together with re‐
strictor
9 - Restrictor
❑ Maintains a residual pressure in fuel return hoses
❑ Cannot be renewed separately; if defective, renew fuel return hoses
10 - Fuel system pressurisation pump - G6-
11 - Fuel filter
2.4 Filling and bleeding fuel system

♦ Vehicle diagnostic tester
Caution
♦ If components of the fuel system between the fuel tank

and the high-pressure pump are removed or renewed, the
fuel system must be bled.
♦ If the high-pressure pump is removed or renewed, the fuel
system must be bled before the engine is started for the
first time. Procedure for first fuel filling
⇒ “5.3 Performing first fuel filling after installing high-pres‐
sure pump”, page 50
Proceed as follows to fill fuel system with fuel:

– Connect a ⇒ Vehicle diagnostic tester.
– Switch on ignition.
– Select “Engine electronics” in vehicle self-diagnosis.
– Select “Guided Functions”.
– Then select “Activate fuel pump”.
– Select “120 seconds”.
– The fuel pump starts running.
– The fuel pump must run for approx. 2 minutes to ensure that
the fuel system is filled sufficiently with fuel.
Note
To repeat basic setting, switch ignition off and on once. Then start
basic setting again.
– Start engine after filling fuel system.

– Run engine at moderate speed for several minutes and then
switch off.
– Check fuel system for leaks.
– Erase entry in event memory using ⇒ Vehicle diagnostic test‐
er.
– After completing the repair, road-test the vehicle. Accelerate
with full throttle at least once. Then check the high-pressure
section of the fuel system again for leaks.
Note
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the engine and erase the event memory. Then
continue the road test.
– Interrogate event memory again.
2.5 Connection diagram - vacuum system



cooler change-over valve -
N345-
2 - Coolant valve for cylinder
head - N489-
3 - Vacuum unit
❑ For exhaust gas recircu‐
lation cooler
4 - Non-return valve
5 - To brake servo
6 - Shut-off valve
❑ For coolant
7 - Vacuum connection
❑ On sump (top section)
❑ To vacuum pump
3 Air cleaner
⇒ “3.1 Exploded view - air cleaner”, page 30
⇒ “3.2 Removing and installing engine cover panel”, page 31
⇒ “3.3 Removing and installing air filter element”, page 31
⇒ “3.4 Removing and installing air cleaner housing”, page 33
3.1 Exploded view - air cleaner
1 - Air duct
❑ Clean out salt deposits,
dirt and leaves, etc.
2 - Sealing element
3 - Rubber grommet
❑ For air cleaner housing
4 - Air cleaner housing
❑ Clean out salt deposits,
dirt and leaves, etc.
⇒ page 33
5 - Air filter element
❑ Use genuine air filter el‐
ement ⇒ Electronic
parts catalogue
❑ Change intervals ⇒
Maintenance tables
⇒ page 31
6 - Cover
❑ For air cleaner housing
❑ Clean out salt deposits
and dirt
⇒ page 31
7 - Housing
❑ For air mass meter -
G70-
8 - Bolt
❑ 3.5 Nm
❑ With seal
10 - Air pipe
❑ Tightening torque for hose clips ⇒ Rep. gr. 21
11 - Air duct
❑ Clean out salt deposits, dirt and leaves, etc.
12 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 1.5 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

3.2 Removing and installing engine cover

panel
Removing
– Carefully pull engine cover panel off retaining pins one after
the other -arrows-. Do not jerk engine 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.
– Observe oil filler neck when positioning engine cover panel.
– Press engine cover panel with both hands first onto retaining
pins at rear and then onto retaining pins at front.
3.3 Removing and installing air filter ele‐

ment
Removing
– Release hose clips -arrows- and remove air pipe -1-.
3. Air cleaner 31
– Release catch -1-, turn cover for air cleaner housing in anti-
clockwise direction -arrow A- and detach.
– Take out air filter element.
Installing
Installation is carried out in the reverse order; note the following:
Tightening torques
♦ ⇒ “3.1 Exploded view - air cleaner”, page 30
To ensure that the air mass meter -G70- functions 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 the air mass meter 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.
♦ The air cleaner housing MUST be clean.
♦ Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
♦ To prevent malfunctions, cover critical parts of the engine air
intake (air mass meter, air pipes, etc.) with a clean cloth when
blowing out the air cleaner housing with compressed air.
♦ 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 secure the air hoses at their connections, spray rust re‐
mover onto the worm thread of the used hose clips before
installing.
♦ Observe environmental requirements for disposal.
– Clean salt residue, dirt and leaves out of air cleaner housing
using a vacuum cleaner.
– Blow out water drain -arrow- on air cleaner housing with com‐
pressed air.
– Check for dirt and leaves in air duct going from lock carrier to
air cleaner housing.

– When installing air filter element, check that it is properly cen‐

tred in retainer in air cleaner housing.
– Carefully fit cover on air cleaner housing without using force.
– Turn cover in clockwise direction -arrow B- until catch -1- en‐
gages.
– Make sure that air hose is securely fitted on air cleaner hous‐
ing.
3.4 Removing and installing air cleaner

housing
Removing
– Remove lock carrier cover ⇒ Rep. gr. 63 .
– Remove bolts -arrows- and detach air duct -2-.
Note
Disregard -item 1-.
3. Air cleaner 33
– Unplug electrical connector -2- at air mass meter - G70- and

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

♦ To prevent malfunctions, cover critical parts of the engine air
intake (air mass meter, air pipes, etc.) with a clean cloth when
blowing out the air cleaner housing with compressed air.
♦ Use a silicone-free lubricant when installing the air hoses.
Tightening torques
– 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.
Remaining installation steps are carried out in reverse sequence;
note the following: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Install lock carrier cover ⇒ Rep. gr. 63 .

4 Intake manifold
⇒ “4.1 Exploded view - intake manifold”, page 35
⇒ “4.2 Removing and installing intake manifold”, page 36
⇒ “4.3 Removing and installing throttle valve module J338 ”, page
41
⇒ “4.4 Removing and installing intake manifold flap motor V157
”, page 42
4.1 Exploded view - intake manifold
1 - Bracket
❑ For air pipe
2 - Bolt
❑ 9 Nm
3 - Bolt
❑ 9 Nm
4 - Gasket
❑ Renew
5 - Bolt
❑ 9 Nm
6 - Bolt
❑ 9 Nm
V157-
⇒ page 42
8 - Gasket
❑ Renew
9 - Intake manifold
⇒ page 36
10 - Bolt
❑ Tightening torque and
sequence ⇒ page 36
11 - Mounting pin
❑ For engine cover
❑ 5 Nm
12 - Bracket
❑ For electrical connector
13 - Bolt
❑ 4 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
14 - Cable guide permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
15 - Bolt
❑ 4 Nm
16 - Gaskets
❑ Renew
4. Intake manifold 35
17 - Bracket
❑ For exhaust gas recirculation cooler change-over valve - N345-
18 - Bolt
❑ 9 Nm
19 - Mounting pin
❑ For engine cover
❑ 5 Nm
20 - Air pipe
21 - Bolt
❑ 9 Nm
22 - Seal
❑ Renew
23 - Screw-type clip
❑ Tightening torque ⇒ Rep. gr. 21
24 - Air hose
26 - Seal
❑ Renew
27 - Pipe
❑ For exhaust gas recirculation
28 - Bolt
❑ 9 Nm
29 - Pipe
❑ For exhaust gas recirculation
30 - Seal
❑ Renew
31 - Screw-type clip Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Tightening torque ⇒permitted
Rep.unless
gr. 26authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Intake manifold - tightening torque and sequence

– Tighten bolts in 3 stages as follows:
Stage Bolts Tightening torque
1. -1 to 4-, Screw in by hand until contact is made
-arrows-
2. -1 to 4- 5 Nm, in sequence indicated
3. -1 to 4- -arrows- 9 Nm, in any sequence
4.2 Removing and installing intake manifold


♦ Removal lever - 80 - 200-
♦ Hose clip pliers - VAS 6362-
Removing
Caution
♦ Use an absorbent cloth to catch escaping fuel.

♦ No fuel must be allowed to spill onto components or seals
in the vicinity of the engine; this can ultimately lead to
damage caused by leaking seals.
♦ Risk of malfunctions caused by dirt.
♦ Observe
⇒ “1.3 Safety precautions when working on the fuel sys‐
tem”, page 2 .
– Pull off engine cover panel ⇒ page 31 .

– Use removal lever - 80 - 200- to move electrical wiring harness
and hoses clear at cable guide -1-.
– Pull coolant hose off to rear -arrow-.
– Unscrew bolts -2 and 3- and remove cable guide -1-.
– Unscrew bolts -1 and 2- and detach retaining clamp -3-.

– Unscrew union nuts -arrows- and detach high-pressure pipe
(top).
– Detach electrical connectors -1 and 2- and remove non-return

valve -3- from bracket.
– If fitted, remove bolt -2- at retaining clamp for high-pressure

pipe.
Note
Disregard -item 1-.
– Remove bolt -1- from bracket (right-side) for intake manifold.
Note
Disregard -item 2-.

– Unplug electrical connector -2- at coolant valve for cylinder

head - N489- -item 1-.
– Unscrew bolts -arrows- and place bracket with coolant valve
for cylinder head - N489- to the side.
– Unplug electrical connector -arrow- at coolant temperature

sender - G62- .
– Unplug electrical connectors -1 and 2- and move wiring har‐

ness clear to left side.
– Remove bolt -3- from bracket (centre) for intake manifold.
– Pull out plug -3-.

– Remove bolt -2- for dipstick guide tube.
Note
Disregard -item 1-.
– Release screw-type clip -2- on exhaust gas recirculation pipe.
Note
Disregard -item 1-.
– Remove bolts -2- from bracket (left-side) for air pipe.
Note
Disregard -item 1-.
– Unplug electrical connector -1- at throttle valve module -

J338- .
– Release screw-type clip -3- and detach air hose.
Note
Disregard -item 2-.
– Unplug electrical connectors on glow plugs.
– Remove fuel pressure sender - G247- -arrow- ⇒ page 85 .

– Remove bolts -1 ... 4- and -arrows- and detach intake mani‐

fold.
Installing
Note
♦ Renew seals and/or gaskets.

installing.
Tightening torques
♦ ⇒ Fig. ““Intake manifold - tightening torque and sequence”“ ,
page 36
– Tighten bolts for intake manifold ⇒ page 36 .
– Install high-pressure pipe ⇒ page 77 .
– Install dipstick guide tube ⇒ Rep. gr. 17 .
– Install exhaust gas recirculation pipe ⇒ Rep. gr. 26 .
4.3 Removing and installing throttle valve

module - J338-
Removing
– Release hose clip -3- and detach air hose.
– Unplug electrical connector -1-.
– Remove bolts -2- and detach throttle valve module - J338- .
Installing
Note
♦ Renew gasket.
and grease before assembly. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not


installing.
Tightening torques
♦ ⇒ “4.1 Exploded view - intake manifold”, page 35
4.4 Removing and installing intake manifold

flap motor - V157-
Removing
– Remove bolt -3- from bracket (centre) for intake manifold.
Note
Disregard -item 1-.
– Remove bolt -2- for dipstick guide tube.
Note
Disregard -items 1, 3-.
– Release screw-type clip -2- on exhaust gas recirculation pipe.
Note
Disregard -item 1-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Remove bolts -2- from bracket (left-side) for air pipe.
Note
Disregard -item 1-.
– Remove bolts -arrows-.

– Press air pipe -2- to left side and detach intake manifold flap
motor - V157- -item 1-.
Installing
Note
♦ Renew seals and/or gaskets.

Tightening torques
♦ ⇒ “4.1 Exploded view - intake manifold”, page 35
– Install dipstick guide tube ⇒ Rep. gr. 17 .
– Install exhaust gaspermitted
recirculation pipe by
unless authorised ⇒AUDI
Rep.AG. gr.
AUDI 26 . not guarantee or accept any liability
AG does
5 High-pressure pump
⇒ “5.1 Exploded view - high-pressure pump”, page 44
⇒ “5.2 Removing and installing high-pressure pump”, page 45
⇒ “5.3 Performing first fuel filling after installing high-pressure
pump”, page 50
5.1 Exploded view - high-pressure pump
1 - Nut
❑ To loosen, counterhold
adapter -item 2- using
counterhold tool -
T40248- or counterhold
tool - T40292-
❑ 70 Nm
2 - Adapter
❑ For chain sprocket for
high-pressure pump
❑ Different types of adapt‐
ers are fitted depending
on version
❑ To loosen nut -item 1-,
use counterhold tool -
T40248- or counterhold
tool - T40292-
❑ Install on new high-
pressure pump when re‐
newing high-pressure
pump
3 - O-ring
❑ Renew
4 - High-pressure pump
Caution
Risk of malfunctions Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
caused by dirt. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Observe
♦ with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ “1.3 Safety precautions
when working on the fuel
system”, page 2 .
Running when dry cau‐
ses irreparable damage
to high-pressure pump.
After
♦ installing the high-
pressure pump, the
pump must first be filled
with fuel before the en‐
gine is started for the first
time ⇒ page 50 .

5 - High-pressure pipe
❑ Do not alter shape
❑ Check for damage before re-installing
❑ Always renew high-pressure pipe when renewing high-pressure pump

❑ Installing ⇒ page 77
❑ Lubricate threads of union nuts with clean engine oil
❑ 25 Nm
6 - Fuel supply hose
7 - Fuel return hose
8 - O-ring
❑ Renew
9 - Fuel temperature sender - G81-
❑ 2 Nm
❑ Always renew high-pressure pipe when renewing high-pressure pump
❑ 25 Nm
11 - Bolt
❑ 22 Nm
5.2 Removing
permitted and installing
unless authorised by AUDI high-pressure
AG. AUDI AG does not guarantee or accept any liability
pump with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Locking pin - 3242-
♦ Adapter - T40058-
5. High-pressure pump 45
♦ Locking pin -T40245-
♦ Counterhold tool - T40248- or counterhold tool - T40292- (dif‐

ferent types of adapters are fitted depending on version)
♦ Counterhold tool - T40292-
Removing
– Remove intake manifold ⇒ page 36 .
– Remove turbocharger ⇒ Rep. gr. 21 .
– Remove engine oil cooler ⇒ Rep. gr. 17 .
– Remove coolant shut-off valve ⇒ Rep. gr. 19 .
– Unscrew bolts -arrows- and swivel bracket -1- for turbocharger
to side.

– Remove rear noise insulation panel -1- ⇒ Rep. gr. 66 .
– Insert guide pin of adapter -T40058- as follows:

• The larger-diameter section -arrow 1- faces towards the en‐
gine.
• The smaller-diameter section -arrow 2- faces the adapter.
Caution
Irreparable damage can be caused if the camshaft timing chain

slips.
♦ Turn crankshaft only in direction of engine rotation
-arrow-.
– Use adapter - T40058- to turn crankshaft to “TDC” position.
• Mark -arrow- must be perpendicular to centre of crankshaft,

as shown in illustration.
Note
Place a cloth beneath the sump (top section) to catch escaping

oil.
– Unscrew plug -arrow- for “TDC” marking from sump (top sec‐
tion).
– Screw locking pin - 3242- into hole (20 Nm); if necessary, turn
crankshaft -1- backwards and forwards slightly to fully cen‐
tralise locking pin.
– Lock chain sprocket for high-pressure pump in position using

locking pin -T40245- .
Caution

♦ Observe
tem”, page 2 .

(right-side) -1-.


(left-side) -1-.
– Seal off open lines and connections with clean plugs.

– Release hose clips -3 and 4- and detach fuel hoses.
Note
Lay a cloth under the connection to catch escaping fuel.
Note
Disregard -item 1-.
– Unscrew bolts -arrows- and detach high-pressure pump.

Installing
Tightening torques
♦ ⇒ “5.1 Exploded view - high-pressure pump”,
permitted page
unless 44 by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
– When renewing high-pressure pump, install adapter from old

high-pressure pump on new pump.
– Use counterhold tool - T40248- or counterhold tool - T40292-
to loosen and tighten nut -arrow-.
– Detach adapter from high-pressure pump -1-, as shown in il‐

lustration. Use commercially available pullers, e.g. Kukko
15-1/, 17-1/ and 18-1.
Note
♦ Different types of adapters are fitted depending on version.

♦ Always renew high-pressure pipes when renewing high-pres‐
sure pump.
– Insert high-pressure pump into chain sprocket.

• The dual toothing -arrow A- on the chain sprocket must align
with the groove -arrow B- in the adapter on the high-pressure
pump shaft.
– Remove locking pin - 3242- and locking pin -T40245- .
– Tighten plug for “TDC” drilling in sump (top section) ⇒ Rep.
gr. 17 .
– Install high-pressure pipes ⇒ page 77 .
– Install coolant shut-off valve ⇒ Rep.Protected
gr. 19by. copyright. Copying for private or commercial purposes, in part or in whole, is not
– Install engine oil cooler ⇒ Rep. gr. 17with
. respect to the correctness of information in this document. Copyright by AUDI AG.
– Install turbocharger ⇒ Rep. gr. 21 .
– Install intake manifold ⇒ page 36 .
– Install rear noise insulation ⇒ Rep. gr. 66 .
Caution

sure pump.
♦ After installing the high-pressure pump, the pump must
first be filled with fuel before the engine is started for the
first time ⇒ page 50 .
5.3 Performing first fuel filling after installing

high-pressure pump

Caution

sure pump.
♦ After installing the high-pressure pump, the pump must
first be filled with fuel before the engine is started for the
first time.
Note
♦ When installing the high-pressure fuel pump, it is essential to

ensure that no dirt enters the fuel system.
♦ Only remove sealing plugs immediately prior to installation of
fuel lines.
♦ There must be sufficient fuel in the tank.
Procedure
• Check fuel gauge in instrument cluster; fuel gauge needle
must indicate that fuel is above reserve level.
– Connect a ⇒ Vehicle diagnostic tester.
– Switch on ignition.
– Protected
Selectby“Engine electronics”
copyright. Copying incommercial
for private or vehicle purposes,
self-diagnosis.
in part or in whole, is not
– Select “Guided
with respect Functions”.
– Then select “Activate fuel pump”.

– Select “120 seconds”.
– The fuel pump starts running.
– Repeat step.
– The fuel pump must run for approx. 4 minutes to ensure that
the fuel system is filled sufficiently with fuel.
– Start engine after filling fuel system.
– Run engine at moderate speed for several minutes and then
switch off.
– Check fuel system for leaks.
– Erase entry in event memory using ⇒ Vehicle diagnostic test‐
er.
Note
– Interrogate event memory again.
6 Injectors
⇒ “6.1 Exploded view - injectors”, page 52
⇒ “6.2 Checking injectors”, page 55
⇒ “6.3 Performing adaption of correction values for injectors”,
page 56
⇒ “6.4 Checking for injectors sticking open”, page 56
⇒ “6.5 Measuring return flow rate of injectors with engine running”,
page 60
⇒ “6.6 Checking return flow rate of injectors at starter cranking
speed”, page 63
⇒ “6.8 Removing and installing injectors”, page 67
⇒ “6.10 Installing high-pressure pipes”, page 77
6.1 Exploded view - injectors
Caution
1 - Support bracket
❑ For clamping piece
❑ Different tightening tor‐
ques:
♦ To camshaft bearing:
2.5 Nm
♦ To cylinder head: 9 Nm
2 - Clamping piece
❑ Use a coloured pen to
mark injectors and cor‐
responding clamping
piece and cylinder for
re-installation; pay at‐
tention to markings
when installing
❑ If the injector is installed
on another cylinder for
testing purposes, the
clamping piece must al‐
so be moved
❑ After looking for the
fault, the injector and the
clamping piece must be
re-installed on their orig‐
inal cylinder
❑ The clamping pieces
can be re-used when in‐
stalling new injectors
3 - Bolt
❑ Renew
❑ permitted
Tighten initially
unless toby6 AUDI
authorised NmAG. AUDI AG does not guarantee or accept any liability
❑ Then tighten 90° further

❑ From high-pressure pump to fuel rail
❑ 25 Nm
5 - Retaining clamp
❑ For high-pressure pipe
6 - Bolt
❑ 9 Nm
7 - Retaining clamp
❑ For high-pressure pipe
8 - Bolt
❑ 9 Nm
❑ From fuel rail on opposite side
❑ 25 Nm
10 - Fuel rail
❑ To fuel tank
❑ From injectors
❑ Do not by
Protected dismantle
copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Renew together with restrictor
❑ After renewing, engine must be run at idling speed for approx. 2 minutes to bleed fuel system
❑ Then check fuel return hoses for leaks
13 - Ring connection for hose
14 - Banjo bolt
❑ 25 Nm
15 - Seals
❑ Renew
16 - Fuel pressure regulating valve - N276-
❑ With deformable sealing lip
❑ Cannot be re-installed
❑ After renewing high-pressure pump and/or fuel pressure regulating valve - N276- , adaption must be
performed. Use ⇒ Vehicle diagnostic tester
❑ Tightening torque ⇒ page 54
17 - Bolt
❑ 22 Nm
6. Injectors 53
❑ From fuel rail to injector
❑ Mark allocation for re-installation; pay attention to marking when installing
❑ 25 Nm
❑ From injectors
❑ Do not dismantle
❑ Renew together with restrictor
❑ After renewing, engine must be run at idling speed for approx. 2 minutes to bleed fuel system
❑ Then check fuel return hoses for leaks
20 - O-ring
❑ Renew
21 - Injector
❑ Use a coloured pen to mark allocation of injectors to corresponding clamping piece and high-pressure
pipe, and to corresponding cylinder for re-installation; pay attention to markings when installing
❑ If the injector is installed on another cylinder for testing purposes, the clamping piece must also be moved
❑ Always renew copper seal when removing and installing
❑ After looking for the fault (switching the injectors around),
permitted unless theby injector
authorised andAGthe
AUDI AG. AUDI doesclamping piece
not guarantee must
or accept be
any liability
re-installed on their original cylinder with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ To remove carbon deposits from the injector sealing surface, clean the injector bore in the cylinder head
with cleaning kit - VAS 6811- (it is important to do this to avoid leaks)
22 - O-ring
❑ Renew
23 - Copper seal
❑ Always renew copper seal when removing and installing
Fuel pressure regulating valve - N276- - tightening torque

– Position fuel pressure regulating valve - N276- so that electri‐
cal wiring is not under tension when connector -arrow- is
plugged in.
– Tighten union nut on regulating valve in 4 stages as follows
(counterhold hexagon flats on housing):
Stage Tightening torque
1. Screw in by hand until contact is made
2. 60 Nm
3. Turn back by 90°
4. 85 Nm

Fuel pressure sender - G247- - tightening torque

– Tighten fuel pressure sender - G247- in 4 stages as follows:
Note
An open-end spanner must not be used for loosening or tighten‐

ing.

♦ Socket, 27 mm - T40218-
♦ Torque wrench
Stage Tightening torque
1. Screw in by hand until contact is made
2. 60 Nm
3. Turn back by 180°
4. 85 Nm
6.2 Checking injectors

There are four different tests for checking the operation of the
injectors.
• ⇒ “6.3 Performing adaption of correction values for injectors”,
page 56 .
• ⇒ “6.4 Checking for injectors sticking open”, page 56 .
• ⇒ “6.5 Measuring return flow rate of injectors with engine run‐
ning”, page 60 .
• ⇒ “6.6 Checking return flow rate of injectors at starter cranking
speed”, page 63 .
Perform the following tests first if the engine does not start at all:
♦ ⇒ “6.4 Checking for injectors sticking open”, page 56 .
♦ ⇒ “6.6 Checking return flow rate of injectors at starter cranking
speed”, page 63 .
♦ ⇒ “7.2 Checking fuel pressure regulating valve N276 ”,
page 81 .
6. Injectors 55
6.3 Performing adaption of correction val‐

ues for injectors
♦ The “Injector delivery calibration” and “Injector voltage cali‐

bration” serve to correct the injection rates for each cylinder
Protected of Copying for private or commercial purposes, in part or in whole, is not
by copyright.
a common rail system individually across the entire operating
range. with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ The 7-digit adaption value -1- (example) is marked separately

on each injector. It may consist of letters and/or numbers (AS‐
CII code).
♦ Reference table for reading out letters and/or numbers on
each injector

The adaption procedure is described in the “Guided Fault Find‐
ing”. (The procedure is also described under “Guided Functions”.)
Use ⇒ Vehicle diagnostic tester.
– When a new injector is installed, the adaption value for the new
injector must be stored in the engine control unit.
– Additionally, check that the “Injector delivery calibration val‐
ues” with “Injector voltage calibration values” are correctly
entered for all the other injectors. Do NOT attempt to re-enter
these values if the correct values are already stored in the en‐
gine control unit.
– When the engine control unit is renewed, the appropriate “In‐
jector delivery calibration values” with “Injector voltage cali‐
bration” values must be written into the new engine control
unit.
6.4 Checking for injectors sticking open

If one of the injectors is sticking open, this means that the injector
needle is not closing fully and fuel escapes into the cylinder.

♦ Hand vacuum pump - VAS 6213-
♦ Use a return line to make an -adapter-.
Procedure
– Remove engine cover panel ⇒ page 31 .
– Clean all fuel rail connections with engine cleaner or brake
cleaner and dry.
Caution

♦ Observe
tem”, page 2 .
– Open clip -arrow- and detach fuel return hose -1- from banjo
bolt.
6. Injectors 57
– Connect hand vacuum pump - VAS 6213- to fuel return hose

-1-.
Note
Make sure you do not widen the fuel return hose -1- when at‐
taching the adapter of the hand vacuum pump - VAS 6213- .
– Create vacuum of -500 mbar with hand vacuum pump - VAS

6213- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
If the vacuum reading remains the same for 30 with
seconds, thecorrectness
respect to the in‐ of information in this document. Copyright by AUDI AG.
jectors are OK.
In the case of a faulty injector, the vacuum will fall back to 0 bar
within 2 to 3 seconds.
If pressure drops, check injectors on individual cylinder banks.
Check all cylinders in turn.
Starting with cylinder 1

– Disconnect fuel return hoses from injectors you want to check;

to do so, press down both tabs and at the same time pull centre
piece up to release connection -arrow-.
Note
Illustration shows cylinder bank 1.
– Connect adapter to return line connection of injector to be tes‐

ted after adapter has been cleaned and blown out.
– Generate a vacuum of -500 mbar using the hand vacuum
pump - VAS 6213- .
If the vacuum reading remains the same for 30 seconds, the in‐
jector is OK.
In the case of a faulty injector, the vacuum will fall back to 0 bar
within 2 to 3 seconds.
Repeat test if necessary; note drop in vacuum reading on hand
vacuum pump - VAS 6213- .
– Renew faulty injectors ⇒ page 67 .
– Secure fuel return hose to banjo bolt with new clip.
Assembling
– Check O-ring for fuel return line connection for damage and
deformation.
If O-ring is damaged or deformed, renew O-ring.
Note
Lubricate all O-rings with engine oil or assembly oil before instal‐
ling.
– Push return line connections carefully over seals and onto in‐
jectors. The catch should engage audibly. Then press release
pin down carefully.
Bleeding fuel system and checking for leaks
– Run engine at idling speed for several minutes (do not press
accelerator) and then switch off. Fuel systempermitted
will bleed
unless itself
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
automatically. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Check the entire fuel system for leaks.

Renew the affected component if leakage occurs.
– Install engine cover panel ⇒ page 31 .
Note
6. Injectors 59
6.5 Measuring return flow rate of injectors

with engine running
♦ Hose clamps, up to 25 mm - 3094-
♦ Return flow meter - VAS 6684-
♦ Fuel-resistant measuring container
Caution

♦ Observe
tem”, page 2 .
Measuring return flow rate of all injectors

bolt.

– Seal off open connection at banjo bolt with plug -arrow-.

– Hold fuel return hose -1- into a suitable measuring container
(lengthen hose if necessary).
– Start engine and run at idling speed for two minutes:
♦ Return flow rate after 2 minutes: 0 ... 50 ml
– If specification is attained, increase engine speed to
2000 ... 2500 rpm for approx. two minutes:
• Return flow rate after 2 minutes: less than 250 ml
If specification is exceeded, this indicates that one or more injec‐
tors are defective.
Measuring return flow rate of individual injectors
Each injector normally
Protectedhas a relatively
by copyright. Copying low return
for private flow rate.
or commercial If the
purposes, in part or in whole, is not
return flow rate atpermitted
one injector is relatively
unless authorised high
by AUDI AG. AUDIcompared to the or accept any liability
AG does not guarantee
other injectors, thatwith
injector isthe
respect to probably
correctnessdefective.
of information in this document. Copyright by AUDI AG.

– Clean all return line connections with engine cleaner or brake
cleaner and dry.
– Clamp off fuel return line downstream of restrictor using hose

clamp up to 25 mm - 3094- .
– Disconnect fuel return hoses from injectors on cylinder bank 1;

6. Injectors 61

– Connect hoses of return flow meter - VAS 6684- to all return

line connections of the six injectors.
– Start engine and run at idling speed for several minutes:
Caution Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Risk of damage to injectors due to increased engine speed.
♦ Do NOT press the accelerator during this test; the engine

must only run at idling speed.
– When the engine is warm and running at idling speed, the re‐
turn flow rates at each of the 6 injectors must not differ by more
than a small amount.
Evaluating return flow rate:

♦ 1 = injectors OK; return flow rate approx. identical on all injec‐
tors.
♦ 2 = injector for cylinder 3 not OK; return flow rate surpasses
value three times the volume of smallest measured return flow
rate.
Note
There is a mechanical fault at the injector if the return flow rate is

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

the others it must be renewed ⇒ page 67 .

– Remove hose clamp up to 25 mm - 3094- from fuel return line.

Assembling
deformation.
Note
ling.
pin down carefully.
accelerator) and then switch off. Fuel system
Protected bywill bleed
copyright. itselffor private or commercial purposes, in part or in whole, is not
Copying
automatically. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
6.6 Checking return flow rate of injectors at

starter cranking speed
Only perform this test if the engine does not start at all.
6. Injectors 63
♦ Return flow meter - VAS 6684-
Caution

♦ Observe
tem”, page 2 .
Measuring return
permitted unlessflow ratebyofAUDI
authorised individual injectors
AG. AUDI AG does not guarantee or accept any liability
Each injector normally has a relatively low return flow rate. If the
return flow rate at one injector is relatively high compared to the
other injectors, that injector is probably defective.
– Clean all return line connections with engine cleaner or brake
cleaner and dry.
– Clamp off fuel return line downstream of restrictor using hose
clamp up to 25 mm - 3094- .



– Connect hoses of return flow meter - VAS 6684- to all return

line connections of the six injectors.
– Operate starter three times (wait approx. 20 seconds each
time after operating starter to prevent it from overheating).
• Specification of return flow rate: 0 ml
– If fuel comes out of one injector, that injector must be renewed
⇒ page 67 .
6. Injectors 65
– Remove hose clamp up to 25 mm - 3094- from fuel return line.

Assembling
deformation.
Note
ling.
pin down carefully.
– Entries are stored in the event memory of the engine control
unit because electrical connectors were unplugged: Interrog‐
ate and erase event memory.
accelerator) and then switch off. Fuel system will bleed itself
automatically.
Note
6.7 Checking restrictor in fuel return line

On vehicles with fuel systems with 6 bar, the restrictor maintains
a constant residual pressure in the fuel return line. This residual
pressure is required for the control function of the injectors.
♦ Tester for fuel return system - VAS 6330- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Caution

♦ Observe
tem”, page 2 .

– Clean return line connection on cylinder 1 (with commercial
cleaning solution or similar) before removing.

– Dry return line connection on cylinder 1.

– Cover return line connection on cylinder 1 with a cloth.
– Detach return line connection from cylinder 1. To do so, press
tabs down and pull centre piece up to release connection.
Note
No dirt must be allowed to get into the disconnected return line or

the open connection on the injector.
– Connect tester for fuel return system - VAS 6330- between

return line connection on injector and return line.
– Start engine.
– Check pressure indicated on tester.
♦ Specification: approx. 4 bar
If specification is not attained, renew fuel return line with restrictor.
6.8 Removing and installing injectors

♦ Cleaning kit - VAS 6811-
6. Injectors 67
♦ Puller - T10055- with adapter - T10055/1- and -T10055/3-
♦ Protected
Socket - T40055-
by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Assembly sleeve - T10377-
Removing
Note
All cable ties which are released or cut open when removing must
be fitted in the same position when installing.


Cylinder bank 1 (right-side):
– Remove air cleaner housing ⇒ page 33 .
Cylinder bank 2 (left-side):
– Unscrew nuts -arrows- and move clear coolant pipe on longi‐
tudinal member.
– Release hose clip -3- and detach air hose.
Note

– Remove bolt -3-.
– Lift retaining clip -2- and disconnect coolant line.
– Place coolant expansion tank to one side.
6. Injectors 69
Continuation for both sides
Caution

♦ Observe
tem”, page 2 .
– Unscrew union nut -1- and bolt -2-.

– Unscrew bolts -2 and 3- and remove cable guide.
– Unplug electrical connectors at injectors -arrows- and at fuel

pressure regulating valve - N276- -item 1-.
– Move clear electrical wiring harness at cylinder head cover
and fuel rail.
– Disconnect fuel return hoses from injectors; to do so, press

down both tabs and at the same time pull centre piece up to
release connection -arrow-.
Caution with respect to the correctness of information in this document. Copyright by AUDI AG.
Used injectors must always be re-installed on the same cylin‐

der.
♦ Mark injectors to ensure that they are re-installed at the
correct cylinders.

– Loosen union nuts for high-pressure pipes -2, 3 and 4- using

socket - T40055- .
– Mark position of clamping piece -1- in relation to injector with

paint for re-installation.
– Unscrew bolt -2- and detach clamping piece.
– Repeat work steps on remaining injectors.
6. Injectors 71
– Apply puller - T10055- with adapter -T10055/1- to injector, as

shown in illustration. Pull off injector by tapping gently.
– Place removed injectors on a clean cloth.
Installing
Installing new injectors
When installing a new injector, the following components must be
renewed:
♦ Bolt for clamping piece
♦ Copper seal
♦ O-ring for injector bore
♦ O-ring for fuel return line connection
Installing used injectors
When re-installing a used injector in the same cylinder, the fol‐
lowing components must be renewed:
♦ Bolt for clamping piece
♦ Copper seal
♦ O-ring for injector bore
♦ O-ring for fuel return line connection
– Spray tip of injector nozzle with rust-solvent spray. Wait ap‐
prox. 5 minutes and wipe off soot particles and oil with a cloth.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
– Clean off deposits under the copper seal using a suitable scra‐
per.
Continued (same procedure for used and new injectors):
Caution
Risk of damage to injector sealing surface.

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

– Lubricate all O-rings
Protected with engine
by copyright. oilprivate
Copying for or assembly
or commercialoil before
purposes, in‐or in whole, is not
in part
stalling. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Renew O-ring for injector bore using assembly sleeve -

T10377- .
– Install injectors.
Remaining installation steps are carried out in reverse sequence;
note the following:
Tightening torques
♦ ⇒ “6.1 Exploded view - injectors”, page 52
Note
ling.
– Push the return line connections carefully over the new seals
and onto the injectors. The catch should engage audibly. Then
press release pin down carefully.
After renewing one or more injectors, the “injector delivery cali‐
bration values” and “injector voltage calibration values” for the
new injectors must be written into the engine control unit
⇒ page 56 .
Additionally, check that the “injector delivery calibration values”
and “injector voltage calibration values” are correctly entered for
all the other injectors. Do NOT attempt to re-enter these calibra‐
tion values if the correct values are already stored in the engine
control unit.
accelerator) and then switch off.
Note
The fuel system is self-bleeding; do not open the high-pressure

connections.
– Switch off ignition.

– Carefully check the complete fuel system including all 6 return
line connections for leaks.
Renew affected component if leakage still occurs
permitted unless authorisedafter tightening
by AUDI AG. AUDI AG does not guarantee or accept any liability
to correct torque. with respect to the correctness of information in this document. Copyright by AUDI AG.

with full throttle at least once. Then inspect high-pressure sec‐
tion of fuel system again for leaks.
Note
– Interrogate the event memory again after road-testing.
6. Injectors 73
6.9 Removing and installing fuel rail

♦ Torque wrench - V.A.G 1331-
♦ Ratchet - V.A.G 1331/1-
♦ Socket - T40055-

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

– Remove bolts -2, 3- and move cable guide to rear.
– Unscrew union nut on fuel rail to be removed.
Note
♦ -Left arrow- for fuel rail on cylinder bank 1

♦ -Right arrow- for fuel rail on cylinder bank 2
Fuel rail on cylinder bank 1
6. Injectors 75
– Detach electrical connectors -1 and 2- and remove non-return

valve -3- from bracket.
– Unplug electrical connector -arrow- at fuel pressure regulating

valve - N276- .
– Remove union nut -1- on fuel rail.

– Remove banjo bolt ⇒ Item 14 (page 53) for fuel return lines
from fuel rail.
– Loosen union nuts of high-pressure pipes -2, 3 and 4-.

– Remove bolts -arrows- from fuel rail and place them down
carefully on a clean surface.
Fuel rail on cylinder bank 2


– Remove bolt -3-.
– Lift retaining clip -2- and disconnect coolant line.
– Place coolant expansion tank to one side.
– Unplug electrical connector at fuel pressure sender - G247-

-arrow-.
– Unclip bracket for electrical connectors -6 and 7-.

– Move clear electrical wiring harness.
– Remove union nut of rear fuel supply line on fuel rail.
– Unscrew union nuts for high-pressure pipes between injectors
and fuel rail.
– Remove bolts from fuel rail and place them down carefully on
a clean surface.
Installing
Tightening torques
♦ Exploded view - injectors
⇒ “6.1 Exploded view - injectors”, page 52
6.10 Installing high-pressure pipes

Special tools and Protected
workshop equipment
by copyright. required
6. Injectors 77
♦ Torque wrench - V.A.G 1331-
♦ Ratchet - V.A.G 1331/1-
♦ Socket - T40055-
♦ Open end spanner insert, AF 17 - V.A.G 1331/6-

Procedure
Note
♦ Before re-installation, check taper seats for deformation,

cracks, damage, scores and corrosion. Renew high-pressure
pipes if they are damaged or corroded.
♦ Check that bore in pipe is not distorted, restricted or damaged
in any other way.
♦ When re-installing "old" high-pressure pipe, observe marking
for installation position.
– Use vacuum cleaner to remove dirt from taper seat at fuel rail.
– Clean fuel pipe and end of pipe with engine cleaner or brake
cleaner and dry.
– Lubricate threads of union nuts with clean engine oil.

– Hand-tighten union nuts on high-pressure pipes until they

make contact (ensure that pipes are not under tension).
Tightening torques
♦ ⇒ “6.1 Exploded view - injectors”, page 52 .
Union nuts (AF 17) on fuel rail:
– To secure high-pressure pipes, use torque wrench - V.A.G
1331- with open end spanner insert, AF 17 - V.A.G 1331/6- .
Union nuts (AF 17) on injectors:

– To tighten unions of injectors, use torque wrench - V.A.G
1331- with ratchet - V.A.G 1331/1- and socket - T40055- .
accelerator) and then switch off.
Note
The fuel system is self-bleeding; do not open the high-pressure

connections.

– Carefully check the complete fuel system including all 6 return
line connections for leaks.
Renew affected component if leakage still occurs after tightening
to correct torque.
with full throttle at least once. Then inspect high-pressure sec‐
tion of fuel system again for leaks.
Note
– Interrogate the event memory again after road-testing.
6. Injectors 79
7 Senders and sensors

⇒ “7.1 Removing and installing air mass meter G70 ”, page 80
⇒ “7.2 Checking fuel pressure regulating valve N276 ”,
page 81
⇒ “7.3 Removing and installing fuel pressure regulating valve
N276 ”, page 83
⇒ “7.4 Removing and installing fuel pressure sender G247 ”, page
85
⇒ “7.5 Removing and installing pressure differential sender G505
”, page 88
7.1 Removing and installing air mass meter

- G70-
Removing

– Release catch -1-, turn cover for air cleaner housing with air
mass meter - G70- in anti-clockwise direction -arrow A- and
detach.

– Release catches and detach air mass meter - G70- from cover.
Installing
Tightening torques
To ensure that the air mass meter - G70- functions 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 the air mass meter and affect the air mass value. This
would lead to loss of power, since a smaller injection quantity
is calculated.
♦ Always renew seal for air mass meter if damaged (air leaks in
intake system).
7.2 Checking fuel pressure regulating valve

- N276-
♦ Fuel-resistant measuring container

♦ Test hose for return line connection
Procedure
WARNING

♦ Observe
tem”, page 2 .
– Pullpermitted
off engine cover panel ⇒ page 31 .
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
7. Senders and sensors 81

bolt.
– Seal off open connection at banjo bolt with plug -arrow-.

– Hold fuel return hose -1- into a suitable container (lengthen
hose if necessary).
Note
♦ Fuel return rate of injectors from fuel return hose -1- can be
disregarded for this test.
♦ Fuel temperature above 10 °C.
– Detach fuel return hose -2-.
Note

– Seal off open return line connection with a test hose -2- and a
hose clamp up to 25 mm - 3094- .
– Hold end of fuel return hose -1- in measuring container.
– Start the engine and run at idling speed.
Specifications:
• Return flow rate (engine start): 0 ml
• Return flow rate after 2 minutes: 0 ... 50 ml
If specified values are not obtained, fuel pressure regulating valve
- N276- is defective.
accelerator) and then switch off. Fuel system will bleed itself
automatically. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Note
7.3 Removing and installing fuel pressure

regulating valve - N276-
Note
♦ The fuel pressure regulating valve - N276- maintains a con‐

stant pressure in the fuel rail and the injector pipes (high-
pressure fuel circuit).
♦ It is not possible to start engine if fuel pressure regulating valve
- N276- is defective.
♦ If the pressure in the high-pressure fuel circuit is too high, the
regulating valve opens to allow some of the fuel to flow back
from the fuel rail to the fuel tank via a return hose.
♦ If the pressure in the high-pressure fuel circuit is too low, the
valve closes and seals off the high-pressure section of the
system from the low-pressure section.
♦ The fuel pressure regulating valve - N276- has a deformable
sealing lip and can only be used once. Do not install it for test
purposes.
Removing

WARNING

♦ Observe ⇒ page 2 .
– Clean thread and area all around fuel pressure regulating

valve with engine cleaner or brake cleaner and dry.
Note
♦ Clean carefully; cleaning solution must not enter the electrical

connector.
♦ Make sure no dirt gets into opening in fuel rail.
– Remove banjo bolt for fuel return hoses.

– Unplug electrical connector -arrow- at fuel pressure regulating
valve - N276- .
– Loosen union nut at regulating valve (counterhold at fuel rail).
Then remove by hand.
– Remove dirt from thread and sealing surface of fuel rail using
a vacuum cleaner. Do not use metal tools, etc.
Note
Seal off opening in fuel rail immediately with a suitable plug to

prevent dirt from entering.
Installing
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ The fuel pressure regulating valve - N276- has a deformable

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

– Position fuel pressure regulating valve - N276- so that electri‐

cal wiring is not under tension when connector -arrow- is
plugged in.
– Tighten union nut on regulating valve in 4 stages (counterhold
hexagon flats on housing):
• Tightening torque ⇒ page 54
– Tighten banjo bolt for fuel return lines with new seals to 25 Nm.
– After installation, run engine at moderate speed for several
minutes and then switch off.
Note
The fuel system is “self-bleeding”; do NOT open the high-pres‐

sure connections.
– Interrogate eventtomemory
with respect and
the correctness erase itinifthis
of information necessary.
document. Copyright by AUDI AG.

– Carefully check the entire fuel system for leaks.
to correct torque.
After renewing high-pressure pump and/or fuel pressure regulat‐
ing valve - N276- , adaption must be performed. Use ⇒ Vehicle
diagnostic tester.
Note
– After road test, interrogate event memory again.
7.4 Removing and installing fuel pressure

sender - G247-
♦ Socket, 27 mm - T40218-

♦ Torque wrench
Note
♦ The fuel pressure sender - G247- continuously measures the

fuel pressure in the high-pressure system. It transmits a cor‐
responding voltage signal to the engine control unit - J623- .
♦ Should the fuel pressure sender fail, the engine control unit
will control the fuel pressure via a mapped open-loop backup
function. Maximum engine speed in this mode is restricted.
♦ The fuel pressure sender - G247- has a deformable sealing
lip.
Removing
Caution
Risk of malfunctions with

caused
respect by dirt.
♦ Observe ⇒ page 2 .

– Clean thread and area all around fuel pressure sender with
engine cleaner or brake cleaner and dry.
Note
Clean carefully; cleaning solution must not enter the electrical

connector.

– Unplug electrical connector at fuel pressure sender - G247-

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

ing.
– Remove dirt from opening in fuel rail using a vacuum cleaner.

Do not use metal tools, etc.
Seal off opening in fuel rail immediately with a suitable plug to
prevent dirt from entering.
Installing
Note
♦ If the deformable sealing lip and the thread of the fuel pressure
sender - G247- are not damaged, the sender can be re-used
once.
♦ Check that the deformable sealing lip and the thread on the
new fuel pressure sender - G247- are not damaged.
♦ Check sealing surface at opening in fuel rail.
♦ The beginning of the thread and the deformable sealing lip of
the fuel pressure sender - G247- mustProtected
be coated withCopying
by copyright. dieselfor private or commercial purposes, in part or in whole, is not
fuel. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Screw in fuel pressure sender - G247- by hand.

– Then tighten fuel pressure sender - G247- to specified torque.
Note tightening sequence and tightening torque
♦ ⇒ Fig. ““ Fuel pressure sender -G247- - tightening torque”“ ,
page 55 .
After installing fuel pressure sender - G247- , leave engine run‐
ning at moderate speed for a few minutes when bleeding fuel
system and then switch off again.
Note
The fuel system is “self-bleeding”; do NOT open the high-pres‐

sure connections.
– Interrogate event memory.

– Carefully check the entire fuel system for leaks.
to correct torque.

Note
– After road test, interrogate event memory again.
7.5 Removing and installing pressure differ‐

ential sender - G505-
Note
The pressure differential sender - G505- detects the amount of

deposits in the particulate filter.

Removing
Procedure for vehicles with one turbocharger
– Unclip pressure differential sender - G505- -2- from bracket
and detach.
– If hose is to be disconnected from pressure sender, release
hose clips (if fitted) and spray hose with silicone-free lubricant.
– To prevent hose connection from breaking off, carefully dis‐
connect hose and keep it straight when pulling it off.

Procedure for vehicles with two turbochargers

– Unclip pressure differential sender - G505- from bracket and
detach.
– If hose is to be disconnected from pressure sender, release
hose clips (if fitted) and spray hose with silicone-free lubricant.
– To prevent hose connection from breaking off, carefully dis‐
connect hose and keep it straight when pulling it off.
Note
The short measuring line can be pulled off with the pressure dif‐
ferential sender - G505- removed.
Installing
Tightening torque
♦ ⇒ “8.1 Exploded view - Lambda probe, exhaust gas tempera‐
ture control (CLAA, CLAB, CDUC)”, page 90 .
Note
♦ Blow through hose (towards particulate filter) with compressed

air to remove dirt or ice (frozen condensation).
♦ Make sure that hoses are securely fitted and that there are no
leaks.
♦ If pressure pipes have been detached from particulate filter,

tighten connections to specified torque.
Adaption must be performed after renewing pressure differential

sender - G505- and/or particulate filter. Use ⇒ Vehicle diagnostic
tester.

8 Lambda probes and exhaust gas

temperature senders (CLAA, CLAB,
CDUC, CKVB, CPNB)
⇒ “8.1 Exploded view - Lambda probe, exhaust gas temperature
control (CLAA, CLAB, CDUC)”, page 90
control (CKVB, CPNB)”, page 91
⇒ “8.3 Removing and installing Lambda probe G39 with Lambda
probe heater Z19 ”, page 93
8.1 Exploded view - Lambda probe, exhaust

gas temperature control (CLAA, CLAB,
CDUC)
Vehicles withoutProtected
SCR by catalytic converter
copyright. Copying for private or commercial purposes, in part or in whole, is not
1 - Pressure pipe
❑ For pressure differential
sender - G505-
❑ Tightening torque ⇒
Rep. gr. 26
2 - Lambda probe - G39- with
Lambda probe heater - Z19-
⇒ page 93
❑ New Lambda probes
are coated with an as‐
sembly paste
❑ If you are re-using
Lambda probe, coat on‐
ly thread with high-tem‐
perature paste; refer to
⇒ Electronic parts cata‐
logue for high-tempera‐
ture paste
❑ The assembly paste/
high-temperature paste
must not get into the
slots on the Lambda
probe body
❑ 55 Nm
- G505-
❑ 4.5 Nm
⇒ page 88
sender 4 - G648-
⇒ Rep. gr. 26

8.2 Exploded view - Lambda probe, exhaust

gas temperature control (CKVB, CPNB)
Vehicles with SCR catalytic converter
1 - Nut
❑ 2 Nm
2 - Control unit for NOx send‐
er 2 - J881- with NOx sender 2
- G687-
❑ Tightening torque for
NOx sender 2 - G687- :
50 Nm
⇒ Rep. gr. 26
3 - Front exhaust pipe
4 - Particulate filter
sender 3 - G495-
⇒ page 92
⇒ Rep. gr. 26
❑ 45 Nm
⇒ page 92
⇒ page 93
❑ New Lambda probes
are coated with an as‐
sembly paste
❑ If you are re-using
Lambda probe, coat on‐unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
ly thread with high-tem‐
perature paste; refer to
⇒ Electronic parts cata‐
logue for high-tempera‐
ture paste
❑ The assembly paste/high-temperature paste must not get into the slots on the Lambda probe body
❑ 50 Nm
7 - Control unit for NOx sender - J583- with NOx sender - G295-
❑ Only installed on vehicles with engine code CPNB
❑ Tightening torque for NOx sender - G295- : 50 Nm
8 - Nut
❑ 2 Nm
8. Lambda probes and exhaust gas temperature senders (CLAA, CLAB, CDUC, CKVB, CPNB) 91
❑ 45 Nm
10 - Pressure line for exhaust gas pressure sensor 1 - G450-
❑ Fit into particulate filter, clip into bracket and tighten.
❑ 45 Nm
11 - Bolt
❑ 4 Nm
❑ 45 Nm
14 - Turbocharger
❑ 45 Nm
16 - SCR catalytic converter
17 - Particulate sensor - G784-
18 - Nut
❑ 2 Nm
Note
Injector for reducing agent - N474-

Removing and installing injector for reducing agent - N474- ⇒
Rep. gr. 26 Reducing agent metering system - vehicles with SCR
catalytic converter
Fitting locations of exhaust gas temperature sensors

2- Exhaust gas temperature sender 2 - G448- (engine code
CPNB only)
3- NOx sender permitted
- G295- unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4- Lambda probe - G39-
- G448- (engine code CPNB only)
- G495-
7- Electrical connector for Lambda probe - G39-

8.3 Removing and installing Lambda probe

- G39- with Lambda probe heater - Z19-
♦ Tool set - T10395 A-
Removing
– Remove engine cover panel.
– Unplug electrical connector -2- for Lambda probe - G39- .
– Unscrew Lambda probe - G39- -item 1- using a tool from
permitted tool
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
set - T10395 A- . with respect to the correctness of information in this document. Copyright by AUDI AG.
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. For high-temperature paste
refer to ⇒ Parts catalogue .
♦ When installing, the Lambda probe wiring must always be re‐
attached at the same locations to prevent it from coming into
contact with the exhaust pipe.
Tightening torque
ture control (CLAA, CLAB, CDUC)”, page 90
8.4 Removing and installing exhaust gas

temperature sender 2 - G448- (engine
code CPNB only)
8. Lambda probes and exhaust gas temperature senders (CLAA, CLAB, CDUC, CKVB, CPNB) 93
♦ Tool set - T10395 A-
Removing
– Remove engine cover panel.
– Unplug electrical connector -5- from exhaust gas temperature
sender 2 - G448- .
– Move clear electrical wiring.
– Unscrew exhaust gas temperature
permitted unless authorised bysender
AUDI AG.2AUDI- G448-
AG does-item 2- or accept any liability
not guarantee
using a tool from tool set - T10395 A- .
Installing
Note
Fit all cable ties in the original positions when installing.
Tightening torque
ture control (CKVB, CPNB)”, page 91

9 Lambda probes and exhaust gas

temperature senders (CGQB)
control (CGQB)”, page 95
⇒ “9.2 Removing and installing Lambda probe G39 with Lambda
probe heater Z19 ”, page 96
9.1 Exploded view - Lambda probe, exhaust gas temperature control (CGQB)

sender 4 for cylinder bank 2 -
G649-
⇒ Rep. gr. 26
❑ Coat thread with high-
temperature paste; for
refer to ⇒ Electronic
parts catalogue
❑ 45 Nm
2 - Pressure pipe
❑ For pressure differential
sender - G505-
❑ 45 Nm
sender 3 - G495-
⇒ Rep. gr. 26
parts catalogue
4 - Exhaust gas temperature permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
sender 1 - G235- with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ Rep. gr. 26
parts catalogue
❑ Not fitted on all versions
❑ Coat thread with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts catalogue
9. Lambda probes and exhaust gas temperature senders (CGQB) 95

❑ Coat thread with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts catalogue
9.2 Removing and installing Lambda probe

- G39- with Lambda probe heater - Z19-
♦ Lambda probe open ring spanner set - 3337-
Removing
– Unplug electrical connector -1- for Lambda probe - G39- .
– Unscrew Lambda probe - G39- -2- using tool from Lambda
probe open ring spanner set - 3337- .
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. For high-temperature paste
refer to ⇒ Parts catalogue .
♦ When installing, the Lambda probe wiring must always be re‐
attached at the same locations to prevent it from coming into
contact with the exhaust pipe.
Tightening torque
ture control (CGQB)”, page 95

10 Engine control unit

⇒ “10.1 Wiring and component check with isolator box VAS 6606
”, page 97
⇒ “10.2 Removing and installing engine control unit J623 ”, page
98
10.1 Wiring and component check with isola‐

tor box -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.
– Connect both cable sets -VAS 6606/7-1- and -VAS 6606/7-2-

to the three isolator boxes
Protected by -VAS
copyright. 6606-
Copying . or commercial purposes, in part or in whole, is not
for private
– Use the following
with sheets:
respect to the correctness of information in this document. Copyright by AUDI AG.
♦ -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 98 .
10. Engine control unit 97

– 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.
10.2 Removing and installing engine control

unit - J623-
Removing
– Before removing the engine
permitted control
unless authorised by unit - J623-
AUDI AG. , the
AUDI AG doesadaption
not guarantee or accept any liability
values of the injectors andtothe
with respect ash deposit
the correctness massinmust
of information be read
this document. Copyright by AUDI AG.
out. Use ⇒ Vehicle diagnostic tester.
The adaption values for the injectors in the old (defective) engine
control unit can be read out via the Guided Fault Finding or Gui‐
ded Functions mode and can be stored as an electronic file in the
⇒ Vehicle diagnostic tester.
– Switch off ignition and remove ignition key after storing elec‐
tronic file containing adaption values.
Note
If the adaption values of the injectors cannot be read out of the

old (defective) engine control unit, they must be entered into the
new engine control unit manually and the adaption procedure
must be performed accordingly.
– Remove plenum chamber cover ⇒ Rep. gr. 50 .

– Unscrew bolts -arrows- and pull filler neck out of washer fluid
reservoir and through opening in body to right side.
– Release catch -arrow- and detach engine control unit - J623-

-item 1-.
Note
Disregard -item 2-.
Installing
– After the engine control unit - J623- has been renewed, the
“Injector delivery calibration” and the “Injector voltage calibra‐
tion” must also be re-adapted in the engine control unit (these
functions influence engine power and exhaust emissions).
– On vehicles with particulate filter the current mileage (km)
reading must be stored in the engine control unit - J623- via
an adaption procedure.
The procedure required after connecting the new engine control
unit is described in the Guided Fault Finding or Guided Functions.
10. Engine control unit 99

28 – Glow plug system

1 Glow plug system
⇒ “1.1 Checking glow plug system”, page 100
⇒ “1.2 Exploded view - glow plugs, Hall sender, engine speed
sender”, page 100
⇒ “1.3 Removing and installing glow plugs”, page 101
⇒ “1.4 Removing and installing engine speed sender G28 ”, page
103
⇒ “1.5 Removing and installing Hall sender G40 ”, page 104
1.1 Checking glow plug system

♦ The glow plug system is activated via the automatic glow pe‐
riod control unit - J179- . The control unit is self-diagnosis
compatible.
♦ A fault is stored in the event memory of the engine control unit
- J623- if a fault occurs in the glow plug system.
♦ The procedure for checking the glow plug system is described
in the “Guided Fault Finding”.
♦ For faster starting, the vehicle is equipped with electronically
controlled glow plugs and a separate glow period control unit.
♦ Each glow plug is activated and diagnosed separately.
Note
♦ Wait for 60 seconds each time after performing final control

diagnosis of the glow period control unit. The ignition must re‐
main switched on.
♦ If you do not wait for 60 seconds (if ignition is switched off and
immediately switched on again), the glow plugs can be dam‐
aged (due to repeated pre-heating).
♦ The activation of the glow plugs is controlled according to
coolant temperature.
1.2 Exploded view - glow plugs, Hall sender, engine speed sender
100 Rep. gr.28 - Glow plug system

1 - Sender wheel
❑ For engine speed send‐
er - G28-
⇒ Rep. gr. 13
2 - Glow plug
Cylinder bank 1 (right-side):
❑ Glow plug 1 - Q10- ,
glow plug 2 - Q11- , glow
plug 3 - Q12-
Cylinder bank 2 (left-side):
❑ Glow plug 4 - Q13- ,
glow plug 5 - Q14- , glow
plug 6 - Q15-
⇒ page 101
❑ 12 Nm
3 - Electrical connector
4 - Bolt
❑ 9 Nm
⇒ page 104
6 - O-ring
❑ Renew
7 - Engine speed sender -
G28-
⇒ page 103 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
8 - Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 9 Nm
1.3 Removing and installing glow plugs

♦ U/J extension and socket, 10 mm - 3220-
Removing
1. Glow plug system 101

– Detach glow plug connectors from glow plugs.

– Clean glow plug opening to make sure no dirt gets into cylin‐
ders.
– Clean glow plug openings in cylinder head; make sure no dirt
gets into cylinder.
Note
♦ Cleaning procedure:
♦ Use a vacuum cleaner to remove coarse dirt.
♦ Spray brake cleaner or suitable cleaning agent into glow plug
apertures, let it work in briefly, and blow out with compressed
air.
♦ Then clean the glow plug openings using a cloth moistened
with oil.
WARNING
Risk of eye injury.


– Loosen glow plugs using U/J extension and socket, 10 mm -

3220- .
– Then unscrew glow plugs carefully by hand or using a suitable
hose. Keep the glow plugs straight while unscrewing.
Installing
– Fit glow plugs carefully by hand or using a suitable hose. Keep
the glow plugs straight while screwing them back in.
– To tighten the glow plugs use special tool U/J extension and
socket, 10 mm - 3220- with a suitable torque wrench.
Tightening torque
♦ ⇒ “1.2 Exploded view - glow plugs, Hall sender, engine speed
sender”, page 100 .
– Attach glow plug connectors correctly and make sure connec‐
tors are securely fitted.
The remaining installation steps are carried out in the reverse se‐
quence.

1.4 Removing and installing engine speed

sender - G28-
Removing
– Remove rear noise insulation panel -2- ⇒ Rep. gr. 66 .
Vehicles withwith
multitronic
respect to thegearbox 0AW:
correctness of information in this document. Copyright by AUDI AG.

– Unscrew bolt -2- and detach engine speed sender - G28- .
Vehicles with dual clutch gearbox 0B5:

– Remove bolts -arrows- and push ATF cooler slightly to one
side.
1. Glow plug system 103


– Unscrew bolt -1- and detach engine speed sender - G28- .
Biturbo vehicles:
– Unscrew bolt from engine speed sender - G28- -1- and remove
engine speed sender.
Installing
Tightening torque
Vehicles with dual clutch gearbox 0B5:
– Install ATF cooler ⇒ Rep. gr. 34 or ⇒ Rep. gr. 37 .
All vehicles:
– Install noise insulation ⇒ Rep. gr. 66 .
1.5 Removing and installing Hall sender -

G40-
Removing
– Unscrew bolt -1- and remove Hall sender - G40- -item 2-.
Installing
Note
Fit new O-ring. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Tightening torque

D3E802E3541-TDI Injection and Glow Plug System (6-Cyl 3 0 LTR 4-Valve Common Rail)

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Service

Service Department. Technical Information

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Copyright © 2014 Audi AG, Ingolstadt D3E802E3541

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

7.2 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

9 Lambda probes and exhaust gas temperature senders (CGQB) . . . . . . . . . . . . . . . . . . . . 95

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

23 – Mixture preparation - injection

1.1 Safety precautions when using testers

Accidents can be caused if the driver is distracted by test

1. Safety precautions and rules for cleanliness 1

1.2 Safety precautions when working on ve‐

Risk of injury due to automatic engine start on vehicles with

1.3 Safety precautions when working on the

To prevent irreparable damage to the electronic components

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

2 Rep. gr.23 - Mixture preparation - injection

To prevent the high-pressure pump from running while it is empty

Running when dry causes irreparable damage to high-pres‐

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

1. Safety precautions and rules for cleanliness 3

• When the engine is running, do not perform any repairs to the

1.4 Safety precautions when working on the

1.5 Checking vacuum system

Special tools and workshop equipment required

♦ Hand vacuum pump - VAS 6213-

4 Rep. gr.23 - Mixture preparation - injection

– Check vacuum line to solenoid valve and from solenoid valve

1. Safety precautions and rules for cleanliness 5

1 - Radiator outlet coolant tem‐

6 Rep. gr.23 - Mixture preparation - injection

11 - Instrument cluster with control unit in dash panel insert - J285-

15 - Left electrohydraulic engine mounting solenoid valve - N144-

Engine (top view)

1 - Fuel pressure regulating

11 - Fuel metering valve - N290-

Engine (front view)

8 Rep. gr.23 - Mixture preparation - injection

1 - Oil level and oil temperature

❑ Fitting location for engine code CKVB ⇒ page 14

10 Rep. gr.23 - 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 ⇒ Rep. gr. 20

Fitting location of brake light switch - F-

Fitting location of fuel pump control unit - J538-

For illustration purposes, the floor panel is cut open in the

Removing and installing ⇒ Rep. gr. 20

Fitting location of pressure differential sender - G505-

Fitting location of Hall sender - G40-

Fitting location of fuel metering valve - N290-

Fitting location of charge pressure sender - G31- / intake air tem‐

12 Rep. gr.23 - Mixture preparation - injection

Fitting location of temperature sender for engine temperature

Fitting location of radiator outlet coolant temperature sender -

Oil temperature sender 2 - G664-

Valve for oil pressure control - N428-