D3E803F744A-TDI Injection and Glow Plug System (6-Cyl 3 0 LTR 4-Valve Common Rail Generation II)

Service
Workshop Manual
Audi A4 2008 ➤
Audi A5 Cabriolet 2009 ➤
Audi A5 Coupé 2008 ➤
Audi A5 Sportback 2010 ➤
TDI injection and glow plug system (6-cyl. 3.0 ltr. 4-
valve common rail, generation II)
Engine ID
CDU CLAB CKV CKV
C B C
Edition 08.2013
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 © 2013 Audi AG, Ingolstadt D3E803F744A

Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
TDI injection and glow plug system (6-cyl. 3.0 ltr. 4-valve common rail, generation II) - Edition 08.2013
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Filling and bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1 Exploded view - air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.4 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4 Removing and installing intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.3 Performing first fuel filling after installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . 39
6 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.1 Exploded view - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.2 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.3unless Performing adaption ofdoes
correction values for
anyinjectors ............................ 45
permitted authorised by AUDI AG. AUDI AG not guarantee or accept liability
with6.4
respect toChecking
the correctnessreturn flowinrate
of information of injectors
this document. with
Copyright engine
by AUDI AG. running . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.5 Checking return flow rate of injectors at starter cranking speed . . . . . . . . . . . . . . . . . . . . 50
6.6 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.7 Checking restrictor in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.8 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.9 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.10 Installing high-pressure pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.1 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.2 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.3 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 68
7.4 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.5 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 73
8 Lambda probes and exhaust gas temperature senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.1 Exploded view - Lambda probe, exhaust gas temperature senders and pressure sender
........................................................................ 74
8.2 Removing and installing Lambda probe G39 with Lambda probe heater Z19 . . . . . . . . . . 75
9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.1 Wiring and component check with isolator box VAS 6606 . . . . . . . . . . . . . . . . . . . . . . . . 77
9.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Contents i
1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

1.1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.2 Exploded view - glow plugs, Hall sender, engine speed sender . . . . . . . . . . . . . . . . . . . . 80
1.3 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.4 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.5 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
ii Contents
23 – Mixture preparation - injection

1 Safety precautions and rules for
cleanliness
(ARL003507; Edition 08.2013)
⇒ “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 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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 ensure that the start/stop sys‐
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 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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 permitted
care not to authorised
unless damage by the
AUDIinjectors
AG. AUDI AGwhen does notremoving the old
guarantee or accept any liability
copperwith
seals.
respect to the correctness of information in this document. Copyright by AUDI AG.
• Check all new O-rings for damage before installing. Lubricate

O-rings with engine oil or assembly oil before installing.
• Position high-pressure pipes so they are free of stress. Tighten
all unions lightly to start with before tightening to final torque.
• Never attempt to bend high-pressure fuel lines to shape.
• When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
• Press the fuel return hoses onto the injectors by hand from
above so that they engage audibly on each injector (do not
press in the release pins when doing this). Then press down
the release pin after connecting the return line. Check that the
fuel return hoses are seated securely 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 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ 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”,
page 6
⇒ “2.2 Overview - fuel system”, page 15
⇒ “2.3 Filling and bleeding fuel system”, page 16
⇒ “2.4 Vacuum system”, page 17
2.1 Overview of fitting locations - injection system

Engine compartment
1 - Air mass meter - G70-

❑ Removing and installing
⇒ page 66
2 - Electrical connector for ex‐
haust gas recirculation tem‐
perature sensor - G98-
⇒ Rep. gr. 26
3 - Electrical connector
❑ For map-controlled en‐
gine cooling system
thermostat - F265- , fuel
metering valve - N290-
and exhaust gas recir‐
culation control motor -
V338-
4 - Restrictor
❑ In fuel return line
5 - Pressure differential sender
- G505-
❑ Fitting location
⇒ page 11
❑ Exploded view
⇒ page 74
❑ Removing and installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 73 with respect to the correctness of information in this document. Copyright by AUDI AG.
6 - Fuel temperature sender -

G81-
7 - Electrical connector for ex‐
haust gas temperature send‐
er 3 - G495-
⇒ page 13 or
⇒ page 13
❑ Exploded view ⇒ page 74
8 - Control unit for turbocharger 1 - J724-
❑ On turbocharger (left-side)
❑ Removing and installing ⇒ Rep. gr. 21
9 - Exhaust gas temperature sender 1 - G235-
❑ Fitting location ⇒ page 13

10 - Jump start box

❑ Fitting location ⇒ page 13 or ⇒ page 13
12 - Coolant valve for cylinder head - N489-
13 - Lambda probe - G39- with Lambda probe heater - Z19-
❑ Removing and installing ⇒ page 75
14 - Exhaust gas recirculation control motor - V338-
15 - Coolant temperature sender - G62-
16 - Electrical connector for Lambda probe - G39-
17 - Engine control unit - J623-
18 - Charge pressure sender - G31- / intake air temperature sender - G42-
❑ 5 Nm
19 - Throttle valve module - J338-
20 - Injectors
❑ Cylinder bank 2
21 - Fuel pressure sender - G247-
22 - Valve for oil pressure control - N428-
23 - Temperature sender for engine temperature regulation - G694-
24 - Intake manifold flap motor - V157-
25 - Exhaust gas recirculation cooler change-over valve - N345-
26 - Oil pressure switch for reduced oil pressure - F378-
27 - Oil pressure switch - F22-
28 - Fuel pressure regulating valve - N276-
29 - Radiator outlet coolant temperature sender - G83-
30 - Injectors
❑ Cylinder bank 1
2. Injection system 7
Engine (top view)
1 - Fuel pressure regulating

valve - N276-
❑ Exploded view
⇒ page 33
2 - Injector, cylinder 1 - N30-
❑ Exploded view
⇒ page 33
3 - Glow plug 1 - Q10- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Exploded view
⇒ page 80
❑ Exploded view
⇒ page 33
5 - Hall sender - G40-
⇒ page 12
❑ Exploded view
⇒ page 80
6 - Glow plug 2 - Q11-
❑ Exploded view
⇒ page 80
❑ Exploded view
⇒ page 33
8 - Glow plug 3 - Q12-
❑ Exploded view
⇒ page 80
9 - Fuel temperature sender -
G81-
10 - Control unit for turbo‐
charger 1 - J724-
❑ On turbocharger
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-
20 - Coolant temperature sender - G62-
21 - 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-
⇒ 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 24
8 - Throttle valve module -
J338-
❑ Exploded view
⇒ page 24
9 - Temperature sender for engine temperature regulation - G694-
10 - Valve for oil pressure control - N428-
A - Exhaust gas temperature sender 4 - G648-
❑ Only fitted on vehicles with SCR catalytic converter
B - Control unit for NOx sender 2 - J881- with NOx sender 2 - G687-
❑ Only fitted on vehicles with engine codes CKVB and CKVC
C - Particulate sensor - G784-
❑ Only installed on vehicles with engine code CKVC
D - Exhaust gas temperature sender 2 - G448-
❑ Only installed on vehicles with engine code CKVC
Fitting location of engine control unit - J623-

♦ In left electronics box in engine compartment

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 locations on pedal bracket

1 - Brake light switch - F- and brake pedal switch - F47-
2 - Clutch position sender - G476-
Integrated functions: clutch pedal switch for engine start - F194-
and clutch pedal switch - F36- (manual gearbox only)
Removing and installing brake light switch - F- ⇒ Rep. gr. 45
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).
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‐

perature sender - G42-
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-
♦ -Item 2- in coolant hose (front right)
Temperature sender in turbocharger

1- Exhaust gas temperature sender 1 - G235-
Exhaust temperature sender 3 - G495- (version 1)

1- Electrical connector for exhaust gas temperature sender 3
- G495-
Exhaust temperature sender 3 - G495- (version 2)

3 - Electrical connector for exhaust gas temperature sender 3 -
G495-
Fitting locations of exhaust gas temperature sensors (engine

code CKVC only)
3- Lambda probe - G39-
- G448-
- G495-
6- Electrical connector for Lambda probe - G39-
Exhaust gas temperature sender

2 - Electrical connector for exhaust gas temperature sender 4 -
G648-
Control unit for NOx sender 2 - J881- with NOx sender 2 - G687-
(engine codes CKVB and CKVC only)
1- NOx sender 2 - G687-
2- Control unit for NOx sender 2 - J881- on active tank for re‐
ducing agent
Particulate sensor - G784- (engine code CKVC only)

1 - Control unit for particulate sensor - G784-
2 - Electrical connector from control unit
3 - Particulate sensor - G784-

2.2 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.
1 - Fuel metering valve - N290-

❑ Do not unscrew
2 - High-pressure fuel pump
❑ Exploded view
⇒ page 33
3 - Fuel rail
❑ For cylinder bank 1
(right-side)
4 - Fuel pressure regulating
valve - N276-
❑ Cannot be re-installed
⇒ page 68
❑ Tightening torque
⇒ page 44
5 - Fuel pressure sender -
G247-
❑ Tightening torque
⇒ page 44
⇒ page 70
6 - Fuel rail
❑ For cylinder bank 2 (left-
side)
7 - Injector
⇒ page 55
8 - Fuel return hoses
❑ Do not dismantle
❑ Renew together with re‐
strictor
9 - Restrictor Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Maintains a residual pressure in fuel return with
hosesrespect to the correctness of information in this document. Copyright by AUDI AG.
❑ Cannot be renewed separately; if defective, renew fuel return hoses
10 - Fuel system pressurisation pump - G6-

11 - Fuel filter
2.3 Filling and bleeding fuel system
Caution
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.
If the supplementary fuel pump, fuel line (between fuel tank
and high-pressure fuel pump) or fuel filter is removed or re‐
newed, the basic setting “Checking fuel system pressurisation
pump” must be performed before the engine is started for the
first time. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Proceed as follows to fill fuel system with fuel:

– Connect a ⇒ Vehicle diagnostic tester.
– Switch on ignition.
– Select “Engine electronics” in vehicle self-diagnosis.
– Then select “Basic setting”.
– Select “Checking fuel system pressurisation pump” from the
list.
– Press “Start” key: The fuel pump will start running.
– The fuel pump must run for approx. 3 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 event memory.
– 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.

2.4 Vacuum system
1 - Exhaust gas recirculation

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 18
⇒ “3.2 Removing and installing engine cover panel”, page 20
⇒ “3.3 Removing and installing air filter element”, page 20
⇒ “3.4 Removing and installing air cleaner housing”, page 22
3.1 Exploded view - air cleaner
1 - Hose clip
2 - Air hose
❑ To throttle valve module
- J338-
❑ When installing, pay at‐
tention to marking
⇒ page 19
3 - Hose clip
4 - Air mass meter
air mass meter - G70-
with intake air tempera‐
ture sender - G42-
⇒ page 66
❑ 5 Nm
5 - O-ring
❑ Renew if damaged
6 - Air filter element Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Always use genuine permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
part for air filter element with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ For maintenance inter‐
vals refer to ⇒ Mainte‐
nance ; Booklet 811 (for
A5 Coupé); ⇒ Mainte‐
nance ; Booklet 812 (for
A4); or ⇒ Maintenance ;
Booklet 818 (for A5
Cabriolet)
⇒ page 20
❑ Also clean snow screen

(if fitted)
7 - Air duct
❑ Clipped into air cleaner (top section)
❑ Clean dirt and leaves out of air duct
8 - Air duct
❑ Clean dirt and leaves out of air duct
9 - Air duct
❑ To lock carrier
❑ Clean dirt and leaves
permitted unlessout of airbyduct
authorised AUDI AG. AUDI AG does not guarantee or accept any liability
10 - Rubber grommet
11 - Water drain hose
❑ Clean any leaves and dirt out of water drain hose (important)
12 - Guide for water drain hose
13 - Hot air intake (countries with cold climates only)
❑ Slide hot air intake into air cleaner as far as stop; then turn clockwise until it engages noticeably
14 - Air cleaner (bottom section)
❑ Clean any salt residue, leaves and dirt out of air cleaner (bottom section)
❑ Check for dirt in water drain and clean as required (important)
15 - Retainer for air cleaner (bottom section)
16 - Intake hose for secondary air pump
❑ Installed on petrol engines only
17 - Air filter bypass flap valve - N275-
❑ With flap for variable intake manifold change-over
18 - Bolt
❑ For air filter bypass flap valve - N275-
19 - Bolt
20 - Air cleaner (top section)
❑ Clean any salt residue, leaves and dirt out of air cleaner (top section)
21 - Bolt
❑ For securing air filter element
Pay attention to arrows when installing intake hose.
3. Air cleaner 19
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
– Remove air duct -1-.
– Unplug electrical connector -2- at air mass meter - G70- .
– Release hose clip -3- and detach air hose from air mass meter
- G70- .
– Remove bolts -arrows- from air cleaner (top section) and lift
out air cleaner (top section).

– Remove 2 securing bolts -arrows- from air filter element.

– Take out air filter element.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques
To ensure the proper function of the air mass meter - G70- it is
important to observe the following instructions.
Note
♦ If the air filter element is very dirty or wet, dirt or water could
reach the air mass meter - G70- and affect the air mass value.
This would lead to loss of power, since a smaller injection
quantity is calculated.
♦ Always use genuine part for air filter element.
♦ The air cleaner housing MUST be clean. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ 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.
– Check water drain hose -arrow- in air cleaner (bottom section)

for dirt and other obstructions (clean if necessary).
– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections); use a vacuum cleaner if necessary.
– Check for salt residue, dirt and leaves in air mass meter and
air intake hose (engine intake side).
– Check for dirt in air duct leading to air filter element.
– When installing air filter element, check that it is properly cen‐
tred in retainer in air cleaner (top section).
3. Air cleaner 21
– Screw air cleaner (top section) onto new air filter element.
– Lug on air filter element -1- must make contact with lug on air
cleaner housing -2-.
– Fit the top section of the air cleaner carefully on the bottom
section, without using force.
Note
Before tightening bolts, make sure that top section of air cleaner
is inserted into groove on bottom section of air cleaner (to prevent
air leaks).
– Then screw top section of air cleaner back onto bottom sec‐
tion.
– Ensure secure fit of air hose at air mass meter - G70- .
– Re-connect electrical connector at air mass meter - G70- .
– The remaining installation steps are carried out in the reverse
sequence.
3.4 Removing and installing air cleaner

housing
Removing
– Remove cover above radiator grille (4 bolts).
– Remove air duct -1-.
– Unplug electrical connector -2- at air mass meter - G70- .
– Release hose clip -3- and detach air hose from air mass meter
- G70- .

– Detach vacuum hose -1-.

– Release retainer for bottom section of air cleaner (press in
rubber on left and right side and pull upwards).
– Unplug electrical connector at air filter bypass flap valve -
N275- -2-.
– Carefully take out air cleaner (bottom section).
Installing
To ensure the proper function of the air mass meter - G70- it is
important to observe the following instructions.
Note
reach the air mass meter - G70- and affect the air mass value.
This would lead to loss of power, since a smaller injection
quantity is calculated.
♦ Always use genuine part for air filter element.
♦ Use a silicone-free lubricant when installing the intake hose.
(same as original equipment) ⇒ Parts catalogue
♦ Do not use lubricant when installing retainer.
– If hot air intake is fitted (for countries with cold climates only),
make sure that air intake connection has engaged properly
-arrows- (pay attention to markings).
– Check water drain hose -1- in air cleaner (bottom section) for
dirtunless
permitted andauthorised
other obstructions
by AUDI AG. AUDI (clean
AG does notif necessary).
guarantee or accept any liability
– Check for salt residue, dirt and leaves in air mass meter and
air intake hose (engine intake side).
– Check for dirt in air duct leading to air filter element.
– Plug in electrical connector at air filter bypass flap valve -
N275- again.
– Re-install air cleaner (bottom section).
Note
The water drain hose must be routed straight downwards and

must not be kinked.
– Slide vacuum hose for air filter bypass flap valve - N275- back
on.
3. Air cleaner 23
4 Intake manifold
⇒ “4.1 Exploded view - intake manifold”, page 24
⇒ “4.2 Removing and installing intake manifold”, page 25
⇒ “4.3 Removing and installing throttle valve module J338 ”, page
30
⇒ “4.4 Removing and installing intake manifold flap motor V157
”, page 31
4.1 Exploded view - intake manifold
1 - Bracket
❑ For air pipe Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 9 Nm
3 - Bolt
❑ 9 Nm
4 - Gasket
❑ Renew
5 - Bolt
❑ 9 Nm
6 - Bolt
❑ 9 Nm
7 - Intake manifold flap motor -
V157-
⇒ page 31
8 - Gasket
❑ Renew
9 - Intake manifold
⇒ page 25
10 - Bolt
❑ Tightening torque and
sequence ⇒ page 25
11 - Mounting pin
❑ For engine cover
❑ 5 Nm
12 - Bracket
❑ For electrical connector
13 - Bolt
❑ 4 Nm
14 - Cable guide
15 - Bolt
❑ 4 Nm
16 - Gaskets
❑ Renew

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
25 - Throttle valve module - J338-
26 - Seal
❑ Renew
27 - Pipe
❑ For exhaust gas recirculation
28 - Bolt
❑ 9 Nm
29 - Pipe
❑ For exhaust gas recirculation
30 - Seal
❑ Renew with respect to the correctness of information in this document. Copyright by AUDI AG.
31 - Screw-type clip
❑ Tightening torque ⇒ Rep. gr. 26
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

4. Intake manifold 25
♦ Removal lever - 80 - 200-
♦ Hose clip pliers - VAS 6362-
Removing
Caution with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ 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 20 .

– 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 70 .
– Remove bolts -1 ... 4- and -arrows- and detach intake mani‐

fold.
Installing
⇒ Fig. ““Intake manifold - tightening torque and sequence”“ ,
page 25
Note
♦ Renew seals and/or gaskets.

installing.
– Tighten bolts for intake manifold ⇒ page 25 .

– Install high-pressure pipe ⇒ page 64 .
– 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
Installation is carried
Protected out Copying
by copyright. in the for
reverse
private or order; note
commercial the infollowing:
purposes, part or in whole, is not
• Tightening
with torques
Note
♦ Renew gasket.
installing.

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-. with respect to the correctness of information in this document. Copyright by AUDI AG.
– 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.

– Install dipstick guide tube ⇒ Rep. gr. 17 .

– Install exhaust gas recirculation pipe ⇒ Rep. gr. 26 .

5 High-pressure pump
⇒ “5.1 Exploded view - high-pressure pump”, page 33
⇒ “5.2 Removing and installing high-pressure pump”, page 34
⇒ “5.3 Performing first fuel filling after installing high-pressure
pump”, page 39
5.1 Exploded view - high-pressure pump
1 - Nut
❑ To loosen, counterhold
adapter -item 2- using
counterhold tool -
T40248-
❑ 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
caused by dirt.
Observe
♦
⇒ “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 39 .

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 64
5. High-pressure pump 33
❑ 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 and installing high-pressure

pump
♦ Locking pin - 3242-
♦ Adapter - T40058-
♦ Locking pin -T40245-

♦ Use counterhold tool - T40248- or counterhold tool - T40292-

(different types of adapters are fitted depending on version)
♦ Counterhold tool - T40292-
Removing
– Remove intake manifold ⇒ page 25 .
– 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 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Lay a cloth under the connection to catch escaping fuel.
Note
Disregard -item 1-.
– Unscrew bolts -arrows- and detach high-pressure pump.

Installing
⇒ “5.1 Exploded view - high-pressure pump”, page 33
– 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-.
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 64 .
– Install coolant shut-off valve ⇒ Rep. gr. 19 .
– Install engine oil cooler ⇒ Rep. gr. 17 .
– Install turbocharger ⇒ Rep. gr. 21 .
– Install intake manifold ⇒ page 25 .
– 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 39 .
5.3 Performing first fuel filling after installing

high-pressure pump with respect to the correctness of information in this document. Copyright by AUDI AG.
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.

♦ Vehicle diagnostic tester
Procedure
• Check fuel gauge in instrument cluster; fuel gauge needle
must indicate that fuel is above reserve level.
– Connect ⇒ Vehicle diagnostic tester.
– Switch on ignition.
– Select “Engine electronics” in vehicle self-diagnosis.
– Then select “Basic setting”.
– Select “Checking fuel system pressurisation pump” from the
list.
– Press “Start” key: The fuel pump will start running.
– Let fuel pump run for three minutes.
– Start engine after filling fuel system.
– Run engine at moderate speed for several minutes and then

switch off.
– Check fuel system for leaks.
– Erase event memory.
Note

6 Injectors
⇒ “6.1 Exploded view - injectors”, page 41
⇒ “6.2 Checking injectors”, page 45
⇒ “6.3 Performing adaption of correction values for injectors”,
page 45
⇒ “6.4 Checking return flow rate of injectors with engine running”,
page 46
⇒ “6.5 Checking returnProtected
flow rate of injectors
by copyright. atprivate
Copying for starter cranking
or commercial purposes, in part or in whole, is not
speed”, page 50 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ “6.6 Checking for injectors sticking open”, page 52
⇒ “6.7 Checking restrictor in fuel return line”, page 54
⇒ “6.8 Removing and installing injectors”, page 55
⇒ “6.10 Installing high-pressure pipes”, page 64
6.1 Exploded view - injectors
Caution
6. Injectors 41
1 - Support bracket
❑ For clamping piece
❑ Different tightening tor‐
ques:
♦ To camshaft bearing:
2.5 Nm
♦ To cylinder head: 9 Nm
2 - Clamping piece
❑ Mark allocation for re-in‐
stallation; pay attention
to marking when instal‐
ling
❑ Clamping piece and in‐
jector are matched
❑ 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
❑ When an injector is re‐
newed, the correspond‐
ing clamping piece must
also be renewed
3 - Bolt
❑ Renew
❑ Tighten initially to 6 Nm
❑ Then tighten 90° further
❑ From high-pressure pump to fuel rail
❑ 25 Nm
5 - Retaining clamp Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For high-pressure pipe with respect to the correctness of information in this document. Copyright by AUDI AG.
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
❑ 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 44
17 - Bolt
❑ 22 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ From fuel rail to injector
❑ Mark allocation for re-installation; pay attention to marking when installing
❑ 25 Nm
❑ From injectors
❑ 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
❑ Mark allocation for re-installation; pay attention to marking when installing
❑ Injector and clamping piece are matched
❑ 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
6. Injectors 43
❑ After looking for the fault (switching the injectors around), the injector and the clamping piece must be
re-installed on their original cylinder
❑ 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)
❑ When an injector is renewed, the corresponding clamping piece must also be renewed
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. permitted unless
Turnauthorised
back by 90° AG. AUDI AG does not guarantee or accept any liability
by AUDI
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
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.
• Checking adaption of “Injector delivery calibration values” and
“Injector voltage calibration values” ⇒ page 45
• Checking return flow rate of injectors with engine running
⇒ page 46
• Checking return flow rate of injectors at starter cranking speed
⇒ page 50
• Checking for injectors sticking open ⇒ page 52
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 of
a common rail system individually across the entire operating
range.
♦ 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 must be writ‐
ten into the engine control unit. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– 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
6. Injectors 45
these adaption values if the correct values are already stored

in the engine 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 return flow rate of injectors

with engine running
Note
Checking return flow rate if engine does not start ⇒ page 50

♦ Hose clamps for hoses up to 25 mm - 3094-
♦ Return flow meter - VAS 6684-

♦ Fuel-resistant measuring container

Measuring return flow rate of all injectors
– Clamp off fuel return hose -arrow- downstream of restrictor
-1- using hose clamp up to 25 mm - 3094- and disconnect fuel
return hose.
Caution

♦ Observe
tem”, page 2 .

– Connect test hose -1- to restrictor -2- and hold end of hose in
measuring container.
– Start engine and run at idling speed for two minutes:
♦ Return flow rate after 2 minutes: 30 ... 55 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. You must then check the return flow rate from
each injector individually.
Measuring return flow rate of individual injectors:
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.
Measuring, cylinder bank 1:
– Clean all return line connections with engine cleaner or brake
cleaner and dry.
– Clamp off fuel return hose -arrow A- on cylinder bank 1 (right-

side) using hose clamp up to 25 mm - 3094- .
Note
Disregard -arrow B-.
Caution

♦ Observe
tem”, page 2 .
– Disconnect fuel return hoses from injectors; to do so, press

down both tabs -1 and 2- and at the same time pull centre
piece up to release connection -arrow-.
6. Injectors 47
– Connect hoses of return flow meter - VAS 6684- to return line

connections of all three injectors for cylinder bank 1.
– Start engine and run at idling speed for several minutes:
Caution
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 3 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; this injector must be renewed ⇒ page 55 .
Measuring, cylinder bank 2:
– Clamp off fuel return hose -arrow B- on cylinder bank 2 (left-

side) using hose clamp up to 25 mm - 3094- .
Note
Disregard -arrow A-.
Caution

♦ Observe
tem”, page 2 .


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

connections of all three injectors for cylinder bank 2.
– Start engine and run at idling speed for several minutes:
Caution
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 3 injectors must not differ by more
than a small amount.
6. Injectors 49
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; this injector must be renewed ⇒ page 55 .
Assembling
– Check O-ring for fuel return line connection for damage and
deformation.
If O-ring is damaged or deformed, renew O-ring.
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
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 system will bleed itself
automatically.
– Check the entire fuel system for leaks.
Renew the affected component if leakage occurs.
Note
6.5 Checking return flow rate of injectors at

starter cranking speed
Note
If it is not possible to start the engine, you can check the return
flow rate of the injectors at starter cranking speed.

♦ Return flow meter - VAS 6684-
Procedure
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.
Caution Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Observe
tem”, page 2 .

– To prevent fuel from being injected when starter is operated,

unplug electrical connector at fuel pressure regulating valve -
N276- -arrow-.
6. Injectors 51
– 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 of the injectors, that injector must be
renewed ⇒ page 55 .
Assembling
– Plug in electrical connector at fuel pressure regulating valve -
N276- .
– Check O-ring for fuel return line connection for damage and
deformation.
If O-ring is damaged or deformed, renew O-ring.
Note
ling.
– Push return line connections carefully over seals and onto in‐
jectors. The catch should engage audibly. Then press release
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.
Bleeding fuel system and checking for leaks Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Run engine at idling speed for several minutes (do notwith
press
accelerator) and then switch off. Fuel system will bleed itself
automatically.
– Check the entire fuel system for leaks.
Renew the affected component if leakage occurs.
Note
6.6 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
– Interrogate and erase event memory using ⇒ Vehicle diag‐
nostic tester.
– Clean all connections (with commercial cleaning solution or
similar) before removing.
Note
♦ Make sure all parts are clean; no dirt must be allowed to enter
the fuel system.
♦ Check all cylinders in turn.
Caution

♦ Observe
tem”, page 2 .
Start with cylinder No. 1.
6. Injectors 53

down both tabs and at the same time pull centre piece up to
release connection -arrow-.
– Connect adapter to return line connection of injector to be tes‐
ted after adapter has been cleaned and blown out.
– Generate a vacuum of -500 mbar using the hand vacuum
pump - VAS 6213- .
If the vacuum reading remains the same for 30 seconds, the in‐
jector is OK.
If the injector is faulty, the vacuum reading will fall back to 0 bar
within 2 to 3 seconds.
Repeat test if necessary; note drop in vacuum reading on hand
vacuum pump - VAS 6213- .
– Renew faulty injectors ⇒ page 55 .
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-
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-
♦ Puller - T10055- with adapter - T10055/1- and -T10055/3-
6. Injectors 55
♦ Socket - T40055-
♦ 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.

– Remove air cleaner housing ⇒ page 22 .
Caution

♦ Observe
tem”, page 2 .

– 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.

down both tabs and at the same time pull centre piece up to
release connection -arrow-.
Caution
Used injectors must always be re-installed on the same cylin‐

der.
♦ Mark injectors for to ensure that they are
Protected re-installed
by copyright. atprivate
Copying for the or commercial purposes, in part or in whole, is not
correct cylinders. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Loosen union nuts -2, 3 and 4- using socket - T40055- and

remove high-pressure pipes.
– 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 57
– 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 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.
Installing new injectors
When installing a new injector, the following components must be
renewed:
♦ Clamping piece
♦ Bolt for clamping piece
♦ Copper seal
♦ O-ring for injector bore
♦ O-ring for fuel return line connection
Continued (same procedure for used and new injectors):
– Fit new copper seal.
– Lubricate all O-rings with engine oil or assembly oil before in‐
stalling.

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

T10377- .
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- .
– Install injectors.
Remaining installation steps are carried out in reverse sequence;
note the following:
Tightening torques
♦ Exploded view - injectors
– Install high-pressure pipes
⇒ “6.10 Installing high-pressure pipes”, page 64 .
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 45 .
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. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
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.
6. Injectors 59
Note
– Interrogate the event memory again after road-testing.

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-

– Use removal lever - 80 - 200- to move electrical wiring harness
and hoses clear at cable guide -1-.
– Pull coolant hose off to rear -arrow-.
– 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 61
– Detach electrical connectors -1 and 2- and remove non-return

valve -3- from bracket.
– Release hose clips -arrows- and remove air pipe -1-.
– Unplug electrical connector -arrow- at fuel pressure regulating

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

– Remove banjo bolt ⇒ Item 14 (page 43) 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
– Unbolt coolant expansion tank and place 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
– Install high-pressure pipes ⇒ page 64 .
Tightening torques
♦ Exploded view - injectors
6. Injectors 63
6.10 Installing high-pressure pipes

♦ Ratchet - V.A.G 1331/1-
♦ Socket - T40055-
Procedure
• Tightening torques ⇒ page 41
Note with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ 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).

Union nuts (AF 17):

– 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- .
Bleeding fuel system and checking for leaks:
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.
to correct torque.
with full throttle at least once. Then inspect high-pressure sec‐
tion of fuel system again for leaks.
Note
continue the road test. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Interrogate the event memory again after road-testing.
6. Injectors 65
7 Senders and sensors

⇒ “7.1 Removing and installing air mass meter G70 ”, page 66
⇒ “7.2 Checking fuel pressure regulating valve N276 ”,
page 67
⇒ “7.3 Removing and installing fuel pressure regulating valve
N276 ”, page 68
⇒ “7.4 Removing and installing fuel pressure sender G247 ”, page
70
⇒ “7.5 Removing and installing pressure differential sender G505
”, page 73
7.1 Removing and installing air mass meter

- G70-
Removing
– Release hose clips -arrows- and remove air pipe -1-.

– 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
To ensure that the air mass meter - G70- functions properly, it is
important to observe the following notes and instructions.
Note
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-
♦ Hose clamps for hoses up to 25 mm - 3094-
♦ Fuel-resistant measuring container

♦ Test hose for return line connection
Procedure
WARNING

♦ Observe
tem”, page 2 .
7. Senders and sensors 67

– Detach fuel return hose -2-.
Note
Disregard -items 1, 3-.
– 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.
• Return flow rate (engine start): 0 ml
• Return flow rate after 2 minutes: 30 ... 55 ml
If specified values are not obtained, fuel pressure regulating valve
- N276- is defective.
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
♦ 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 and the deformable sealing lip 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 44 .
– 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 event memory and erase it if necessary.

– 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-
♦ Bit (27 mm) - T40218- or commercially available socket
(27 mm)

♦ 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

♦ 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 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
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- must be coated with diesel
fuel.
– Screw in fuel pressure sender - G247- by hand.

– Then tighten fuel pressure sender - G247- to specified torque.
• Note tightening sequence and tightening torque ⇒ page 44 .
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.

– 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
– 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.
Note
The short measuring line can be pulled off with the pressure dif‐
ferential sender - G505- removed.
Installing
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
⇒ “8.1 Exploded view - Lambda probe, exhaust gas temperature
senders and pressure sender”, page 74
⇒ “8.2 Removing and installing Lambda probe G39 with Lambda
probe heater Z19 ”, page 75
8.1 Exploded view - Lambda probe, exhaust gas temperature senders and
pressure sender
1 - Pressure pipe
❑ For pressure differential
sender - G505-
❑ Tightening torque ⇒
Rep. gr. 26
2 - Lambda probe - G39- with
Lambda probe heater - Z19-
❑ Removing andProtected
installing
⇒ page 75
by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ New Lambda probes with respect to the correctness of information in this document. Copyright by AUDI AG.
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
3 - Pressure differential sender
- G505-
⇒ page 73
4 - Exhaust gas temperature
sender 4 - G648-
⇒ Rep. gr. 26
5 - Exhaust gas temperature
sender 1 - G235-

Control unit for NOx sender 2 - J881- with NOx sender 2 - G687-
(engine codes CKVB and CKVC only)
1- NOx sender 2 - G687-
2- Control unit for NOx sender 2 - J881- on active tank for re‐
ducing agent
Fitting locations of exhaust gas temperature sensors (engine

code CKVC only)
permitted1unless
- Exhaust
authorised bygas
AUDItemperature
AG. AUDI AG doessender 3 - orG495-
not guarantee accept any liability
3- Lambda probe - G39-
- G448-
- G495-
6- Electrical connector for Lambda probe - G39-
Particulate sensor - G784- (engine code CKVC only)

1 - Control unit for particulate sensor - G784-
2 - Electrical connector from control unit
3 - Particulate sensor - G784-
8.2 Removing and installing Lambda probe

- G39- with Lambda probe heater - Z19-
8. Lambda probes and exhaust gas temperature senders 75

♦ Lambda probe open ring spanner set - 3337-
Removing
– Unplug electrical connector -2- for Lambda probe - G39- .
Note
Fit all cable ties in the original positions when installing.
– Unscrew Lambda probe - G39- -1- 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
⇒ “8.1 Exploded view - Lambda probe, exhaust gas tempera‐
ture senders and pressure sender”, page 74

9 Engine control unit

⇒ “9.1 Wiring and component check with isolator box VAS 6606
”, page 77
⇒ “9.2 Removing and installing engine control unit J623 ”,
page 78
9.1 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 -VAS 6606- .
– Use the following sheets:
♦ -VAS 6606/1-1- for isolator box, 198-pin - VAS 6606/1-1-
Note
Make sure that all plug-in bridges are inserted completely in all
isolator boxes.
– Connect earth strap to an isolator box and to an earth point on

the vehicle.
– Remove engine control unit ⇒ page 78 .
9. Engine control unit 77

– 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.
Use ⇒ Vehicle diagnostic tester.
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.
9.2 Removing and installing engine control

unit - J623-
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Before removing the engine control unit - J623- , the adaption
values of the injectors and the ash deposit mass must be read
out. Use ⇒ Vehicle diagnostic tester.
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.
Use ⇒ Vehicle diagnostic tester.
9. Engine control unit 79

28 – Glow plug system

1 Glow plug system
⇒ “1.1 Checking glow plug system”, page 80
⇒ “1.2 Exploded view - glow plugs, Hall sender, engine speed
sender”, page 80
⇒ “1.3 Removing and installing glow plugs”, page 81
⇒ “1.4 Removing and installing engine speed sender G28 ”, page
83
⇒ “1.5 Removing and installing Hall sender G40 ”, page 83
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
80 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 81
❑ 12 Nm
3 - Electrical connector
4 - Bolt
❑ 9 Nm
5 - Hall sender - G40- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 83
6 - O-ring
❑ Renew
7 - Engine speed sender -
G28-
⇒ page 83
8 - Bolt
❑ 9 Nm
1.3 Removing and installing glow plugs

♦ U/J extension and socket, 10 mm - 3220-
Removing
1. Glow plug system 81

– 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.
sender”, page 80
– 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.
82 Rep. gr.28 - Glow plug system

1.4 Removing and installing engine speed

sender - G28-
Removing
– Remove rear noise insulation panel -2- ⇒ Rep. gr. 66 .

– Unscrew bolt -1- and detach engine speed sender - G28-
downwards.
Installing
Install in reverse order.
sender”, page 80
– Install noise insulation ⇒ Rep. gr. 66 .
1.5 Removing and installing Hall sender -

G40-
Removing
– Unscrew
permitted boltby-1-
unless authorised AUDIandAG. remove
AUDI AG does Hall
not sender - accept
guarantee or G40-any-item
liability2-.
Installing
Note
Fit new O-ring.
sender”, page 80
1. Glow plug system 83

D3E803F744A-TDI Injection and Glow Plug System (6-Cyl 3 0 LTR 4-Valve Common Rail Generation II)

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Copyright © 2013 Audi AG, Ingolstadt D3E803F744A

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

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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

– 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

• Check all new O-rings for damage before installing. Lubricate

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

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

2.1 Overview of fitting locations - injection system

1 - Air mass meter - G70-

6 - Fuel temperature sender -

6 Rep. gr.23 - Mixture preparation - injection

10 - Jump start box

❑ Removing and installing ⇒ page 55

Engine (top view)

1 - Fuel pressure regulating

8 Rep. gr.23 - Mixture preparation - injection

17 - Injector, cylinder 5 - N83-

Engine (front view)

1 - Oil level and oil temperature

Fitting location of engine control unit - J623-

10 Rep. gr.23 - Mixture preparation - injection

Fitting location of accelerator position sender - G79- / accelerator

The accelerator position sender - G79- and accelerator position

Removing and installing ⇒ Rep. gr. 20

Fitting locations on pedal bracket

Fitting location of fuel pump control unit - J538-

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‐

Fitting location of temperature sender for engine temperature

12 Rep. gr.23 - Mixture preparation - injection

Fitting location of radiator outlet coolant temperature sender -

Temperature sender in turbocharger

Exhaust temperature sender 3 - G495- (version 1)

Exhaust temperature sender 3 - G495- (version 2)

Fitting locations of exhaust gas temperature sensors (engine