Direct Petrol Injection and Ignition System (8-Cyl 4 2 LTR 4-Valve) RS4 RS5

Service
Direct petrol injection and ignition system (8-cyl. 4.2 ltr.

4-valve), RS 4, RS 5
Engine ID
CFS
A
Edition 07.2013
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
24 - Mixture preparation - injection
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
D3E8024D043
Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤
Direct petrol injection and ignition system (8-cyl. 4.2 ltr. 4-valve), RS 4, RS 5 - Edition 07.2013
Contents
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety precautions and rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General notes on self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Safety precautions when working on the injection and ignition system . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 3
1.5 Safety precautions when using testers and measuring instruments during a road test . . . . 3
1.6 Rules for cleanliness and instructions for working on fuel system . . . . . . . . . . . . . . . . . . . . 3
1.7 Reducing pressure in high-pressure section of injection system . . . . . . . . . . . . . . . . . . . . 4
1.8 Checking for leaks in the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.9 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Exploded view - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Exploded view - air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1 Exploded view - intake manifold (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2 Removing and installing throttle valve module J338 / J544 . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3 Removing and installing intake manifold (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4 Exploded view - intake manifold (bottom section), fuel rail and injectors . . . . . . . . . . . . . . 24
4.5 Removing and installing intake manifold (bottom section) with fuel rail . . . . . . . . . . . . . . . . 27
5 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3 Removing and installing high-pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.1 Removing and installing fuel pressure sender G247 / G624 . . . . . . . . . . . . . . . . . . . . . . . . 44
7.2 Checking fuel pressure and residual pressure (up to high-pressure pump) . . . . . . . . . . . . 44
8 Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1 Overview - Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.2 Removing and installing Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.1 Wiring and component check with isolator boxes VAS 6606 . . . . . . . . . . . . . . . . . . . . . . 52
9.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1 General notes and safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.1 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.2 Exploded view - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.3 Removing and installing ignition coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Contents i
2.4 Removing and installing knock sensors G61 / G66 / G198 / G199 . . . . . . . . . . . . . . . . . . 62
2.5 Removing and installing Hall senders G40 / G163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.6 Removing and installing Hall senders G300 / G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.7 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
ii Contents
24 – Mixture preparation - injection

1 Safety precautions and rules for
cleanliness
(ARL003423; Edition 07.2013)
⇒ “1.1 General notes on self-diagnosis”, page 1
⇒ “1.2 Safety precautions when working on the fuel system”, page
2
⇒ “1.3 Safety precautions when working on the injection and ig‐
nition system”, page 2
⇒ “1.4 Safety precautions when working on vehicles with start/
stop system”, page 3
⇒ “1.5 Safety precautions when using testers and measuring in‐
struments during a road test”, page 3
⇒ “1.6 Rules for cleanliness and instructions for working on fuel
system”, page 3
⇒ “1.7 Reducing pressure in high-pressure section of injection
system”, page 4
⇒ “1.8 Checking for leaks in the fuel system”, page 5
⇒ “1.9 Checking vacuum system”, page 5
1.1 General notes on self-diagnosis

♦ The engine control unit has a self-diagnosis capability.
♦ Interrogate the event memory before carrying out any repairs
or Fault Finding.
♦ The vacuum hoses and connections must be checked (to pre‐
vent unmetered air).
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. O-type clips or screw-type clips must not be
used.
♦ A voltage of at least 11.5 V is required for proper operation of
the electrical components.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and will
damage the Lambda probe.
♦ The vehicles are fitted with a crash/fuel shut-off system. This
function is designed to reduce the risk of a vehicle fire after a
crash by deactivating the fuel pump via the engine control unit.
1. Safety precautions and rules for cleanliness 1

1.2 Safety precautions when working on the

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

♦ The fuel pressure in the high-pressure section of the in‐
jection system must be reduced to a residual pressure
prior to opening the system; for the correct procedure see
⇒ page 4 .
♦ The connection must be opened IMMEDIATELY after re‐
ducing the pressure; wrap a cloth around the connection
and allow the residual pressure (approx. 7 bar) to dissi‐
pate.
Escaping fuel can cause a fire risk.
♦ As the fuel pump is activated by the door contact switch
when the driver's door is opened, disconnect the voltage
supply for the fuel pump if the battery has NOT been dis‐
connected.
♦ Remove fuse for fuel pump control unit - J538- ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
♦ Fuel hoses in engine compartment must only be secured with

spring-type clips. O-type clips or screw-type clips must not be
used.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and will
damage the Lambda probes.
1.3 Safety precautions when working on the

injection and ignition system
To prevent injuries to persons and/or damage to the fuel injection
and ignition system, note the following:
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as the
ignition system and xenon headlights.
♦ Always switch off the ignition before connecting or discon‐
necting electrical wiring for the injection or ignition system or
tester cables.
♦ For safety reasons, the battery must be disconnected before
opening the fuel system to prevent the fuel pump from being
activated by the contact switch on the driver's door.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off ignition before washing engine.
♦ If you want to turn the engine at cranking speed without ac‐
tually starting the engine (e.g. compression test), first unplug
the electrical connectors from the injectors and the ignition
coils ⇒ page 61 .
2 Rep. gr.24 - Mixture preparation - injection

Caution
To prevent irreparable damage to the electronic components

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

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

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

for working on fuel system
Even small amounts of dirt can cause malfunctions. When work‐
ing on the fuel supply system and injection system, pay careful
attention to the following basic rules:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.

♦ Seal off open pipes/lines and connections immediately with

clean plugs, e.g. from engine bung set - VAS 6122- .
♦ Place parts that have been removed on a clean surface and
cover them over. Do not use fluffy cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).
♦ When the system is open: Do not work with compressed air.
Do not move the vehicle unless absolutely necessary.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
1.7 Reducing pressure in high-pressure

section of injection system
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
WARNING
The fuel system operates at extremely high pressure. This can

cause injury.
♦ The injection system consists of a high-pressure section
(maximum approx. 140 bar) and a low-pressure section
(4 ... 7 bar).
♦ Prior to opening the high-pressure section (e.g. when re‐
moving the high-pressure pump, fuel rail, injectors, fuel
pipes or fuel pressure sender - G247- ), the pressure in
the high-pressure section must be reduced to a specified
level. The procedure is described below.
Procedure
– Connect ⇒ Vehicle diagnostic tester, select function “Reducing
fuel pressure in fuel rail” in “Guided Functions” and follow on-
screen instructions.
• Fuel pressure will drop to a specified value.
– Switch off ignition.
The fuel rail is still filled with fuel, however it is no longer under
high pressure.
WARNING
There is a risk of injury: avoid skin contact with fuel.

♦ Wear safety goggles and protective clothing when open‐
ing the fuel system.
♦ Before opening the high-pressure section of the fuel sys‐
tem, place a clean cloth around the connection to catch
escaping fuel.
– The high-pressure system must be opened »immediately« af‐

ter reducing the fuel pressure; wrap a clean cloth around the
connection. Catch the escaping fuel.

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

heat if the high-pressure system is not opened immediately.
♦ The ignition must not be switched on again from this point on
as this would increase the pressure again.
Additional steps required

– Erase event memory and generate readiness code in engine
control unit in “Guided Functions” mode.
1.8 Checking for leaks in the fuel system

– Allow engine to run for several minutes at moderate rpm.
– Switch off ignition.
– Check complete fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.
– Road-test vehicle and accelerate
Protectedwith full throttle
by copyright. Copyingat
forleast
private once.
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
– Then inspect high-pressure section again
with respect for leaks.
to the correctness of information in this document. Copyright by AUDI AG.
1.9 Checking vacuum system

♦ Hand vacuum pump - VAS 6213-
Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites
♦ Kinked or crushed lines
♦ Lines porous or leaking
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
– If a fault is stored in the event memory, check all vacuum lines
leading to the corresponding component, and also check the
remaining vacuum lines leading to other components.
– If it is not possible to build up 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.

Vacuum units
– After renewing vacuum units, check vacuum system for leaks.
– If there are still leaks, remove intake manifold (bottom section)
and trace leaks.
– Also check that intake manifold flaps -arrows- function cor‐
rectly and are not obstructed by guide plates in cylinder head.

2 Injection system
⇒ “2.1 Technical data”, page 7
⇒ “2.2 Overview of fitting locations - injection system”,
page 7
⇒ “2.3 Exploded view - vacuum system”, page 14
2.1 Technical data

Engine data 4.2 ltr. FSI engine
Idling speed is not adjustable (con‐ 620 ... 720 rpm
trolled by idling speed stabilisation).
Maximum rpm governed by deacti‐ 8500 rpm
vation of fuel injectors
Fuel pressure Initial fuel pressure up to high-pres‐ 5.0 ... 6.5 bar
sure pump (generated by electric
fuel pump in fuel tank)
Pressure in high-pressure fuel cir‐ 25 ... 135 bar (depending on oper‐
cuit (generated by mechanical sin‐ ating conditions)
gle-plunger pump) at a coolant
temperature of approx. 85°C.
2.2 Overview of fitting locations - injection system

Part 1
2. Injection system 7
1 - Secondary air pump motor

- V101-
❑ Fitting location
⇒ page 13
❑ Removing and installing
⇒ Rep. gr. 26
2 - Continued coolant circula‐
tion pump - V51-
⇒ page 13
⇒ Rep. gr. 19
3 - Throttle valve module -
J338-
❑ Including throttle valve
drive for electric throttle
- G186- , throttle valve
drive angle sender 1 for
electric throttle - G187-
and throttle valve drive
angle sender 2 for elec‐
tric throttle - G188-
⇒ page 21
❑ After renewing, perform
Adaption in Guided
Functions ⇒ Vehicle
diagnostic tester
4 - Lambda probe - G39-
❑ (Before catalytic con‐
verter) with Lambda
probe heater - Z19-
❑ Exploded view
⇒ page 49
5 - Lambda probe after catalyt‐
ic converter - G130-
❑ With Lambda probe 1 heater after catalytic converter - Z29-
❑ Exploded view ⇒ page 49
6 - Accelerator pedal module
❑ With accelerator position sender - G79- / accelerator position sender 2 - G185-
❑ Fitting location ⇒ page 13
❑ Removing and installing ⇒ Rep. gr. 20
7 - Engine control unit - J623-
❑ Removing and installing ⇒ page 53
8 - Lambda probe 2 after catalytic converter - G131-
❑ With Lambda probe 2 heater after catalytic converter - Z30-
9 - Lambda probe 2 - G108-
❑ (Before catalytic converter) with Lambda probe heater 2 - Z28-
10 - Throttle valve module 2 - J544-
❑ With throttle valve drive 2 - G296- , angle sender 1 for throttle valve drive 2 - G297- and angle sender 2
for throttle valve drive 2 - G298-


❑ After renewing, perform Adaption in Guided Functions ⇒ Vehicle diagnostic tester
11 - Brake vacuum pump - V192-
12 - Secondary air pump motor 2 - V189-
13 - Intake air temperature sender - G42- / intake manifold pressure sender - G71-
1 - Injector, cylinder 1 - N30-

❑ Exploded view
⇒ page 24
2 - Ignition coil 1 with output
stage - N70-
⇒ page 61
stage - N127-
stage - N291-
stage - N292-
9 - Exhaust camshaft control
valve 1 - N318-
10 - Camshaft control valve 1 -
N205-
11 - Knock sensor 2 - G66-
⇒ page 62
12 - Secondary air inlet valve -
N112-
⇒ page 62
14 - Camshaft control valve 2 - N208-

15 - Exhaust camshaft control valve 2 - N319-
16 - Ignition coil 8 with output stage - N326-
25 - Intake air temperature sender - G42- / intake manifold pressure sender - G71-
27 - Fuel pressure sender - G247-

1 - Coolant temperature send‐

er - G62-
⇒ Rep. gr. 19
2 - Intake manifold flap poten‐
tiometer 2 - G512-
tiometer - G336-
4 - Oil pressure switch - F22-
⇒ Rep. gr. 17
5 - Oil temperature sender -
G8-
⇒ Rep. gr. 17
6 - Activated charcoal filter sol‐
enoid valve 1 - N80-
7 - Fuel metering valve 2 -
N402-
8 - Hall sender 2 - G163-
⇒ page 63
⇒ page 64
10 - Servotronic solenoid valve
- N119-
❑ Only on vehicles with
hydraulic power steer‐
ing
11 - Left electrohydraulic en‐
gine mounting solenoid valve -
N144-
❑ On engine mounting (left-side)
12 - Valve for oil pressure control - N428-
13 - Map-controlled engine cooling system thermostat - F265-
1 - Oil pressure switch for re‐

duced oil pressure - F378-
⇒ Rep. gr. 17
2 - Fuel pressure sender for
low pressure - G410-
3 - Sender 2 for secondary air
pressure - G610-
⇒ Rep. gr. 26
4 - Fuel metering valve - N290-
❑ at high-pressure pump
(right-side)
5 - Hall sender - G40-
⇒ page 63
⇒ page 64
7 - Right electrohydraulic en‐
gine mounting solenoid valve -
N145-
❑ On engine mounting
(right-side)
8 - Sender 1 for secondary air
pressure - G609-
⇒ Rep. gr. 26
9 - Engine speed sender -
G28-
⇒ page 65
Fitting location of engine control unit - J623-

♦ In electronics box in engine compartment (left-side)
Removing and installing ⇒ page 53

Fitting location of fuel pump control unit - J538-

♦ Beneath rear seat bench
Removing and installing ⇒ Rep. gr. 20
Fitting location of accelerator pedal module with accelerator po‐

sition sender - G79- / accelerator position sender 2 - G185-
♦ On pedal bracket
Fitting location of secondary air pump motor -V101- / -V189-

♦ Behind wheel housing liner (front)
♦ Illustration shows secondary air pump motor 2 - V189- (left-
side).
♦ Fitting location on right side: symmetrically reversed
Fitting location of continued coolant circulation pump - V51-

♦ Behind wheel housing liner (front right)
Fitting location of valve for oil pressure control - N428-

♦ On left of sump (top section)
Intake air temperature sender - G42- / intake manifold pressure

sender - G71- -2-
Intake manifold flap valve - N316- -1-
2.3 Exploded view - vacuum system
Note
Checking vacuum system ⇒ page 5

1 - Vacuum reservoir
❑ Beneath intake manifold
2 - Secondary air inlet valve -
N112-
3 - Combination valve for sec‐
ondary air system (right-side)
4 - Vacuum reservoir
❑ In plenum chamber
5 - Grommet
❑ As leadthrough for vac‐
uum line
6 - Combination valve for sec‐
ondary air system (left-side)
7 - Vacuum unit
❑ For intake manifold
flaps (left-side)
8 - Vacuum line
❑ With non-return valves
❑ To vacuum reservoir in
plenum chamber
9 - Vacuum line
❑ With non-return valves
❑ To vacuum reservoir
10 - Intake manifold flap valve
- N316-
⇒ page 14
11 - Vacuum unit
❑ For intake manifold
flaps (right-side)
3 Air cleaner
⇒ “3.1 Exploded view - air cleaner housing”, page 16
⇒ “3.2 Removing and installing engine cover panel”, page 17
⇒ “3.3 Removing and installing air filter element”, page 18
⇒ “3.4 Removing and installing air cleaner housing”, page 19
3.1 Exploded view - air cleaner housing
1 - Air duct
2 - Threaded pin
❑ 9 Nm
3 - Nut
❑ 9 Nm
4 - Rubber grommets
❑ Inserted in bracket for
air cleaner
5 - Bracket
❑ For air cleaner
6 - Bolt
❑ 2.5 Nm
7 - Heat shield
8 - Speed nut
9 - Bolt
❑ 3.5 Nm
10 - Air cleaner (top section)
❑ Clean out salt deposits,
dirt and leaves, etc.
11 - Air hose
❑ Clean out salt deposits,
dirt and leaves, etc.
12 - Hose clip
❑ Spray rust remover onto
worm thread before in‐
stalling
❑ 3.5 Nm
13 - Air filter element
❑ Use genuine air filter element ⇒ Electronic parts catalogue
❑ Maintenance intervals ⇒ Maintenance tables
14 - Bolt
❑ 9 Nm
15 - Spacer sleeve
16 - Rubber grommet
17 - Air cleaner (bottom section)
❑ Clean out salt deposits, dirt and leaves, etc.
❑ Removing and installing ⇒ “3.4 Removing and installing air cleaner housing”, page 19

18 - Grommet
❑ For water drain
19 - Water drain
❑ Clean
20 - Air duct
21 - Bolt
❑ 2 Nm
3.2 Removing and installing engine cover

panel
Removing
– Carefully pull engine cover panel out of retaining clips one after
the other -arrows- (do not jerk 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.
– Press engine cover panel with both hands first into retaining
clips at rear and then into retaining clips at front.
3. Air cleaner 17
3.3 Removing and installing air filter ele‐

ment
Removing
– Loosen hose clip -1-.
– Unscrew bolts -arrows- and detach air cleaner (top section).
– Take out air filter element.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques
Note
♦ Always use genuine part for air filter element.

♦ Hose connections and hoses in intake system must be free of
oil and grease before assembly. Do not use any lubricants
containing silicone when assembling.
♦ The air cleaner housing MUST be clean.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ To ensure that the air hoses can be properly secured at their
connections, spray rust remover onto the worm thread of used
hose clips before installing.
♦ To prevent malfunctions, cover all critical parts of the engine
air intake tract (intake pipes, etc.) with a clean cloth when
blowing out the air cleaner housing with compressed air.
♦ Observe environmental requirements for disposal.
– Blow out water drain ⇒ Item 19 (page 17) with compressed air.
– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections) using a vacuum cleaner.
– Check for salt residue, dirt and leaves in air hose (engine in‐
take side).
– Check for dirt and leaves in air duct going from lock carrier to
air cleaner housing.
– When installing the air filter element, check that it is properly
centred in the retainer in the bottom section of the air cleaner
housing.
– Carefully fit top section of air cleaner onto bottom section,
without using any force. Make sure that air cleaner (top sec‐
tion) is fitted straight on air filter element (note position of
sealing lip on air filter element).
The remaining installation steps are carried out in the reverse se‐
quence.

3.4 Removing and installing air cleaner

housing
Removing
– Move crankcase breather hose -2- clear at air pipe.
Crankcase breather with separate hose:
– Disconnect crankcase breather hose -1- from air pipe by
pressing release tabs.
– Release hose clips -arrows- and remove air pipe.
Crankcase breather with permanently connected hose:
– Remove air pipe; to do so, loosen hose clips -arrows- and
move air pipe clear to one side (hose -1- remains connected).
All vehicles (continued):

– Remove bolts -3-.
– Pull air cleaner housing -2- at rear upwards off bracket
-arrow- and detach towards rear.
Note
Disregard items marked -1 and 4-.
Installing
Note
♦ Hose connections and hoses in intake system must be free of

oil and grease before assembly. Do not use any lubricants
containing silicone when assembling.
♦ To ensure that the air hoses can be properly secured at their
connections, spray rust remover onto the worm thread of used
hose clips before installing.
– Check for salt residue, dirt and leaves in air hose (engine in‐
take side).
– Check for dirt and leaves in air duct going from lock carrier to
air cleaner housing.
The remaining installation steps are carried out in the reverse se‐
quence.
3. Air cleaner 19
4 Intake manifold
⇒ “4.1 Exploded view - intake manifold (top section)”, page 20
⇒ “4.2 Removing and installing throttle valve module J338 / J544
”, page 21
⇒ “4.3 Removing and installing intake manifold (top section)”,
page 22
⇒ “4.4 Exploded view - intake manifold (bottom section), fuel rail
and injectors”, page 24
⇒ “4.5 Removing and installing intake manifold (bottom section)
with fuel rail”, page 27
4.1 Exploded view - intake manifold (top section)
1 - O-ring
❑ Renew
2 - Intake air temperature
sender - G42- / intake manifold
pressure sender - G71-
3 - Bolt
❑ 5 Nm
4 - Damper element
5 - Bolt
❑ Tightening torque and
sequence ⇒ page 21
6 - Retaining clip
❑ For engine cover
❑ 4x
❑ Clips should make con‐
tact at front at inner stop
on intake manifold
7 - Intake manifold (top sec‐
tion)
⇒ page 22
8 - Seal
❑ Renew
9 - Throttle valve module -
J338-
❑ Cylinder bank 1 (right-
side)
⇒ page 21
❑ After renewing, perform
Adaption in Guided
Functions ⇒ Vehicle diagnostic tester
10 - Bolt
❑ Thread-forming
❑ Allow bolt to engage in existing thread on intake manifold
❑ 9 Nm

11 - O-ring
❑ Renew
12 - Pressure control valve
❑ For crankcase breather
13 - Bracket
14 - Bolt
❑ 4.5 Nm
15 - Bolt
❑ 4.5 Nm
16 - Pressure control valve
❑ For crankcase breather
17 - O-ring
❑ Renew
18 - O-ring
❑ Renew
19 - Buffer
❑ For intake manifold (top section)
20 - Throttle valve module 2 - J544-
❑ Cylinder bank 2 (right-side)
❑ After renewing, perform Adaption in Guided Functions ⇒ Vehicle diagnostic tester
21 - Seal
❑ Renew
22 - Connection
23 - Bolt
❑ Thread-forming
❑ Allow bolt to engage in existing thread on intake manifold
❑ 9 Nm
24 - Seals
❑ Renew
Intake manifold (top section) - tightening torque and sequence

– Tighten bolts in 2 stages in the sequence shown:
Stage Bolts Tightening torque
1. -1 … 10- 8 Nm
2. -1 … 10- 11 Nm
4.2 Removing and installing throttle valve

module -J338- / -J544-
Removing
– Pull off engine cover panel ⇒ page 17 .
4. Intake manifold 21
Removing

– Unplug electrical connector -1-.
– Remove bolts -arrows- and detach throttle valve module.
Installing
⇒ “4.1 Exploded view - intake manifold (top section)”,
page 20
Note
Renew seal.
– Install engine cover panel ⇒ page 17 .
4.3 Removing and installing intake manifold

(top section)
♦ Hose clip pliers - VAS 6362-

Removing
– Drain coolant from coolant pipe (front) -arrow- ⇒ Rep. gr. 19 .
Removing

– Unscrew bolts -arrows- and move pressure control valves
-2- and -4- for crankcase breather system clear to one side.
– Release hose clips -1, 3 and 5- and disconnect coolant hoses
and vacuum hose.
– Unplug electrical connectors -arrows- at throttle valve mod‐

ules.
– Release hose clips -1- and -2- and detach hoses coming from
activated charcoal filter.
– Slacken and remove bolts in the sequence: -10 ... 1-.

– Disconnect vacuum hose -3-.
– Detach intake manifold (top section) and disconnect vacuum
hoses -1-.
Caution
Risk of irreparable damage to engine.

♦ Block off the intake ports in the cylinder heads with clean
cloths to prevent small items from dropping into the ports.
Installing
⇒ Fig. ““Intake manifold (top section) - tightening torque and
sequence”“ , page 21
Note
♦ Renew gaskets and O-rings.

– Tighten bolts for intake manifold (top section) ⇒ page 21 .

– Fill up with coolant ⇒ Rep. gr. 19 .
4.4 Exploded view - intake manifold (bottom section), fuel rail and injectors

1 - Seals
❑ Renew
2 - Intake manifold (bottom
section)
⇒ page 27
3 - Seal
❑ Renew if damaged
❑ When renewing lever
out with screwdriver
❑ Press in by hand
4 - Bolt
❑ 2.5 Nm
tiometer
side): intake manifold
flap potentiometer -
G336-
❑ Cylinder bank 2 (left-
side): intake manifold
flap potentiometer 2 -
G512-
❑ Before removing, re‐
move intake manifold
(top section)
❑ Adaption must be per‐
formed after this compo‐
nent has been renewed;
use a ⇒ Vehicle diag‐
nostic tester
6 - Bolt
❑ 2.5 Nm
7 - Vacuum unit
❑ For intake manifold flaps
❑ After renewing, check vacuum system for leaks ⇒ page 5
8 - Screw plug
❑ 25 Nm
9 - Fuel rail
❑ Removing and installing ⇒ “6.1 Removing and installing injectors”, page 38 ⇒ page 27
10 - Sleeve
11 - Retaining clip
❑ For fuel rail
12 - Bolt
❑ Tightening torque and sequence ⇒ page 27
13 - High-pressure pipe
WARNING
The fuel system oper‐
ates at extremely high
pressure. This can
cause injury.
The
♦ pressure in the high-
pressure section of the
injection system must be
reduced to a residual
pressure prior to opening
the system.
❑ Reducing fuel pressure in high-pressure section of injection system ⇒ page 4

❑ Connections must not be damaged
❑ Do not alter shape
❑ Removing and installing ⇒ “5.3 Removing and installing high-pressure pipe”, page 34
❑ Lubricate thread lightly with engine oil
❑ 25 Nm
14 - Bolt
❑ 9 Nm
15 - Bolt
❑ 2.5 Nm
16 - Union nut
❑ 25 Nm
17 - Seals
❑ Renew
18 - Support ring
❑ Renew
❑ Via this support ring, the fuel rail exerts the clamping force that holds the injector in the cylinder head
19 - O-ring
❑ Renew
❑ Lubricate lightly with clean engine oil
20 - Spacer ring
❑ Renew if damaged
21 - Injector
22 - Sealing element
❑ Renew
23 - Combustion chamber ring seal
❑ Renew
❑ Do not apply grease or use any other lubricants

Intake manifold (bottom section) - tightening torque and sequence

– Tighten bolts -arrows- in stages and in diagonal sequence; fi‐
nal torque 9 Nm.
Fuel pressure sender -G247- / -G624-

♦ At front of fuel rail
♦ Cylinder bank 1 (right-side): fuel pressure sender - G247-
-arrow-
♦ Cylinder bank 2 (left-side): fuel pressure sender 2 - G624-
♦ Removing and installing ⇒ page 44
♦ 25 Nm
Fuel pressure sender for low pressure - G410-

♦ Behind oil filter housing -arrow-
♦ 15 Nm
4.5 Removing and installing intake manifold

(bottom section) with fuel rail
♦ Hand vacuum pump - VAS 6213-
Removing
WARNING

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

tem ⇒ page 4 .
– Remove intake manifold (top section) ⇒ page 22 .
– Disconnect vacuum hose -2- and -3- and take change-over
valve -1- out of bracket.
– Remove bolts -arrows- and detach vacuum reservoir.
– Unscrew bolts -arrows- and detach bracket -1- for vacuum

reservoir.
– Remove bolts -arrows- and union nuts -1, 2- and move fuel
supply line to one side.

– Unplug electrical connector -1- and disconnect vacuum hose

-2-.
– Unplug electrical connectors -arrows- at injectors.

– Cylinder head (right-side): Unplug electrical connector -1- at
fuel rail.
– Unscrew high-pressure pipe -2- from connection on fuel rail.
To do so, counterhold at hexagon flats with an open-end span‐
ner and loosen union nut.
Note
Do not attempt to bend high-pressure pipe to a different shape.
– Remove union nut -1-.

– Loosen bolts -arrows- in diagonal sequence and remove.
– Pull off intake manifold (bottom section) with fuel rail.
Caution
Risk of irreparable damage to engine.

♦ Block off the intake manifolds (bottom section) with clean
cloths to prevent small objects from dropping into the en‐
gine through the intake ports in the cylinder heads.
Installing
• Tightening torque
⇒ Fig. ““Intake manifold (bottom section) - tightening torque
and sequence”“ , page 27
Note
♦ If an injector has been pulled out of the cylinder head, the tef‐
lon ring seal must be renewed.
♦ Renew gaskets and O-rings.
♦ Lubricate O-rings of injectors lightly with clean engine oil.
Caution
Risk of damage to intake manifold flaps.

♦ If the intake manifold flaps are closed, they can catch on
the guide plates in the cylinder head -arrows- when the
intake manifold (bottom section) is installed.
– Connect hand vacuum pump - VAS 6213- to vacuum unit for

actuating intake manifold flaps, as shown in illustration.
– Operate hand vacuum pump to produce a vacuum.
• This will cause the intake manifold flaps to open.
– Install intake manifold (bottom section) and press fuel rail
evenly onto injectors.
– Tighten bolts for intake manifold (bottom section) ⇒ page 27 .

– Disconnect vacuum hose of hand vacuum pump - VAS 6213-
from vacuum unit for actuating intake manifold flaps.
– Install high-pressure pipe
⇒ “5.3 Removing and installing high-pressure pipe”,
page 34 .
– Install intake manifold (top section)
⇒ “4.3 Removing and installing intake manifold (top section)”,
page 22 .
Note
After installation, check vacuum system for leaks ⇒ page 5 .

5 High-pressure pump
⇒ “5.1 Exploded view - high-pressure pump”, page 31
⇒ “5.2 Removing and installing high-pressure pump”, page 32
⇒ “5.3 Removing and installing high-pressure pipe”, page 34
5.1 Exploded view - high-pressure pump
WARNING
Risk of injury - fuel sys‐
tem operates under high
pressure.
The
♦ fuel pressure in the
high-pressure section of
the injection system must
be reduced to a residual
the system.
❑ Reducing fuel pressure

in high-pressure section
of injection system
⇒ page 4
❑ Tighten connecting
piece to 40 Nm (always
make sure that connect‐
ing piece is tightened to
specified torque before
installing fuel line)
❑ Connections must not
be damaged
❑ Lubricate thread lightly
with engine oil
⇒ “5.3 Removing and in‐
stalling high-pressure
pipe”, page 34
2 - Union nut
❑ Connections must not
be damaged
❑ Lubricate thread lightly
with engine oil
❑ 25 Nm
3 - High-pressure pump
❑ Cylinder bank 1 (right-side): with fuel metering valve - N290-
❑ Cylinder bank 2 (left-side): with fuel metering valve 2 - N402-
4 - Bolt
❑ 22 Nm
5 - O-ring
❑ Renew
5. High-pressure pump 31
6 - Roller tappet
7 - Union nut
❑ 25 Nm
WARNING
Risk of injury - fuel sys‐
tem operates under high
pressure.
The
♦ fuel pressure in the
high-pressure section of
the injection system must
be reduced to a residual
the system.
❑ Reducing fuel pressure in high-pressure section of injection system ⇒ page 4

❑ Tighten connecting piece to 40 Nm (always make sure that connecting piece is tightened to specified
torque before installing fuel line)
❑ Removing and installing ⇒ “5.3 Removing and installing high-pressure pipe”, page 34
9 - Bolt
❑ 9 Nm
High-pressure pipe - tightening torques

– Tighten each union nut by hand until it makes contact, making
sure that high-pressure pipe is not under tension.
– Tighten union nuts -arrows- to 25 Nm; to do so, counterhold
at hexagon flats of threaded connection on fuel rail with an
open-end spanner.
– Do not tighten bolt -1- for retainer until high-pressure pipe has
been tightened; tightening torque ⇒ Rep. gr. 17 ; Spray nozzle
valve - exploded view .
5.2 Removing and installing high-pressure

pump
♦ Adapter -T40257-
♦ Wrench -T40263-

Removing
WARNING

cause injury.

tem ⇒ page 4 .
– Unplug electrical connector -1- for fuel metering valve.
– Detach high-pressure pipes at connections on high-pressure
pump. To do so, counterhold at hexagon flats with an open-
end spanner and loosen union nuts -2- and -3-.
– Unscrew bolts -arrows- and detach high-pressure pump.
Note
– Pull roller tappet out of cylinder head.

Installing
⇒ “5.1 Exploded view - high-pressure pump”, page 31
Note
♦ Renew O-ring for high-pressure pump.

♦ The connections of the high-pressure pipes must not be dam‐
aged.
– Check roller tappet -1- for damage and renew if necessary.

– Lightly lubricate roller tappet with oil and fit in cylinder head so
that guide -2- is in correct position -arrow-.
– Remove front noise insulation -1- ⇒ Rep. gr. 66 .
– Fit adapter -T40257- onto wrench -T40263- .

– Position adapter on bolts of vibration damper.
• The semi-circular recess -arrow A- on the adapter -T40257-
must point to the semi-circular recess -arrow B- on the vibra‐
tion damper.
Note
Disregard notch on adapter -T40257- .
– Rotate crankshaft in direction of engine rotation -arrow- and at

the same time press roller tappet into cylinder head until it
reaches its lowest point.
– Fit high-pressure pump and press downwards in guide as far
as stop.
– Tighten bolts by hand in several stages until they make con‐
tact.
– Tighten bolts alternately to specified torque.
– Lubricate threads of both union nuts lightly with engine oil.

– First tighten union nut by hand until it makes contact, making
sure that high-pressure pipe is not under tension.
– Tighten union nut with torque wrench - V.A.G 1331- and open
end spanner insert (AF 17) - V.A.G 1331/6- ; to do so, coun‐
terhold at hexagon flats of threaded connection on high-pres‐
sure pump with an open-end spanner.
– Install engine cover panel ⇒ page 17 .
5.3 Removing and installing high-pressure

pipe

♦ Torque wrench - V.A.G 1331-
♦ Open end spanner insert, AF 17 - V.A.G 1331/6-
♦ Socket insert AF 14, flared ring spanner - V.A.G 1331/8-
Removing
WARNING

cause injury.

tem ⇒ page 4 .

– Unscrew bolts (left and right) -arrows- and detach bracket

-1- for vacuum reservoir.
– Remove bolt -1-.

– Detach high-pressure pipes (left and right) from connections
-arrows- on fuel rail. To do so, counterhold at hexagon flats
with an open-end spanner and loosen union nut.
– Detach high-pressure pipe.
Note
Installing
⇒ Fig. ““High-pressure pipe - tightening torques”“ , page 32
Note
♦ The connections of the high-pressure pipe must not be dam‐

aged.
♦ Do not attempt to bend high-pressure pipe to a different shape.
– Lubricate threads of both union nuts lightly with engine oil.

– Tighten union nuts using torque wrench - V.A.G 1331- and

open end spanner insert (AF 17) - V.A.G 1331/6- ⇒ page 32 .
– Install intake manifold (top section) ⇒ page 22 .
6 Injectors
⇒ “6.1 Removing and installing injectors”, page 38
⇒ “6.2 Cleaning injectors”, page 42
6.1 Removing and installing injectors

♦ Tool set for FSI engines - T10133-
Removing
Note
Injectors must only be installed when the engine is cold.
– Remove corresponding intake manifold (bottom section)

⇒ page 27 .
– Cover open inlet ports with a clean cloth.
– Unplug electrical connector at injector that is to be removed.
– Slide stop sleeve -T10133/18- over injector.

– Carefully knock against stop sleeve several times to loosen

injector.
Note
♦ Use a torque wrench to pull out injector.

♦ Adjust torque wrench to 5 Nm.
– Guide puller -T10133/2A- into groove on injector.

– Then apply puller T10133/16A .
– Pull out injector by turning bolt with torque wrench -1-.
– If injector does not come loose after limit torque of 5 Nm is
reached, remove puller and repeat procedure using stop
sleeve to loosen injector.
Note
♦ Observe correct torque to avoid irreparable damage to injec‐

tor.
♦ The combustion chamber ring seal must always be renewed
prior to reinstalling the injector
⇒ “6.1.1 Renewing combustion chamber ring seal (teflon ring
seal)”, page 40 .
Dismantling injector
– Pull support ring -4-, O-ring -3- and spacer ring -2- off injector
-1-.
– Unclip sealing element -5-.
– Carefully remove old combustion chamber ring seal -6-. To do
so, cut open combustion chamber ring seal using knife or prise
open with small screwdriver and then pull off.
Note
The injector must be renewed if the groove is damaged.
6. Injectors 39
6.1.1 Renewing combustion chamber ring

seal (teflon ring seal)
Note
♦ Renew combustion chamber ring seal and O-ring.

♦ Renew spacer ring if damaged.
– Before installing injectors, thoroughly clean apertures for in‐

jectors in cylinder head using supplied nylon brush -
T10133/4- .
– Before new combustion chamber ring seal is fitted, any com‐
bustion residue must be removed from ring groove and injector
stem using a clean cloth.
– Fit assembly cone -T10133/5- with new combustion chamber

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

ber ring seal onto assembly cone -T10133/5- as far as it will
go.

– Turn round assembly sleeve -T10133/6- and slide combustion

chamber ring seal into groove.
Note
The combustion chamber ring seal is widened when it is pushed

onto the injector. After pushing it on, it therefore has to be com‐
pressed again. This is done in two stages, as described below.
– Push calibration sleeve -T10133/7- onto injector as far as it will

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

go and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/8- off again by turning it in the
opposite direction.
– Before installing new injector -1-, lubricate new O-ring -3- light‐
ly with clean engine oil.
Note
♦ The combustion chamber ring seal -6- must not be lubricated.

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

der head (do not use oil or grease). Ensure that the injector is
properly seated in the cylinder head.
6. Injectors 41
Note
♦ It should be possible to insert injector easily. If necessary wait

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

inder head.
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install intake manifold (bottom section) ⇒ page 27 .
6.2 Cleaning injectors

♦ Ultrasonic cleaning unit - VAS 6418-
♦ Mounting plate for injection modules - VAS 6418/1-
♦ Cleaning fluid - VAS 6418/2-
Cleaning
– Remove injectors
⇒ “6.1 Removing and installing injectors”, page 38 .
Note
Observe safety precautions and operating instructions for ultra‐

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

apertures (see detail in illustration).

– Insert injectors -1- all the way into mounting plate for injection
modules - VAS 6418/1- -2-.
– Set rotary knob -4- to a temperature of 50°C.
– Select a cleaning time of 30 minutes with rotary knob -5-.
– Switch on ultrasonic unit with button -3-.
Note
The time set starts to elapse as soon as a cleaning temperature

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

ring seal) for each injector
⇒ “6.1.1 Renewing combustion chamber ring seal (teflon ring
seal)”, page 40 .
– Then re-install injectors
⇒ “6.1 Removing and installing injectors”, page 38 .
6. Injectors 43
7 Senders and sensors

⇒ “7.1 Removing and installing fuel pressure sender G247 / G624
”, page 44
⇒ “7.2 Checking fuel pressure and residual pressure (up to high-
pressure pump)”, page 44
7.1 Removing and installing fuel pressure

sender -G247- / -G624-
Removing
– Unplug electrical connector -arrow-.
– Unscrew fuel pressure sender.
Installing
⇒ Fig. ““Fuel pressure sender -G247- / -G624- ”“ , page 27
7.2 Checking fuel pressure and residual pressure (up to high-pressure pump)

Special tools and workshop

equipment required
♦ K-Jetronic pressure tester -
V.A.G 1318-
♦ Adapter - V.A.G 1318/11-
♦ Adapter set - V.A.G
1318/17A-
♦ Connector - V.A.G
1318/23-
♦ Remote control - V.A.G
1348/3A- for V.A.G 1348
with adapter cable -V.A.G
1348/3-3-
♦ Auxiliary measuring set -
V.A.G 1594C-
♦ Fuel-resistant measuring
container
Test conditions
• Battery voltage at least 12.5 Volt.
• Fuel filter OK.
• Fuel tank at least 1/4 full.
• Fuel pump control unit - J538- OK; checking in Guided Fault
Finding ⇒ Vehicle diagnostic tester.
Preparations
• Ignition off.
– Remove rear seat bench ⇒ Rep. gr. 72 .
– Unscrew cover for flange -arrows-.
7. Senders and sensors 45

– Unplug electrical connector -1- on flange.
Note
Disregard -item 2-.
– Lift cover -1- by its handle -arrow-.
– Connect remote control - V.A.G 1348/3A- for V.A.G 1348 to

contact -1- using adapter cable -V.A.G 1348/3-3- and test lead
from auxiliary measuring set - V.A.G 1594C- .
– Tape off 2nd connector contact of adapter cable -V.A.G
1348/3-3- with insulating tape -arrow- to prevent short circuits.
– Connect contact -5- to vehicle body (earth) using a test lead
from auxiliary measuring set - V.A.G 1594C- .
– Move switch of remote control - V.A.G 1348/3A- for V.A.G
1348 to front of engine compartment.
– Release retainer -arrow A- and open cover -arrow B-.

– Connect crocodile clip to jump start socket - U6- -item A- in

terminal 30 wiring junction 2 - TV22- located in plenum cham‐
ber.
– Remove filler cap from fuel filler neck.
WARNING
Risk of injury - fuel system operates under high pressure.

♦ To reduce the pressure in the fuel system, wrap a clean
cloth around the connection and carefully loosen the con‐
nection.
– Push down protective sleeve -1- and disconnect fuel supply

line.
– First press hose connector -2- downwards -arrow A-, then
press release tabs -arrow B-.
– Pull off hose connector, keeping release tabs depressed.
– Screw connector - V.A.G 1318/23- and adapter -V.A.G

1318/17-1A- onto K-Jetronic pressure tester - V.A.G 1318- .
– Fit -V.A.G 1318/17-1A- onto disconnected fuel line.
– Connect adapter -V.A.G 1318/11- to -V.A.G 1318- .
– Attach test hose -arrow- and hold end of hose in measuring
container.
– Open cut-off valve on pressure tester.
• Lever points in direction of flow.
– Bleed fuel system by pressing remote control briefly.
7. Senders and sensors 47

Checking fuel pressure

– Close cut-off valve on pressure tester.
• Lever is at right angle to direction of flow -arrow-.
– Press and hold remote control switch until K-Jetronic pressure
tester - V.A.G 1318- shows no further increase in pressure.
• Specification: approx. 5.5 bar (4.5 ... 8.0 bar)
– If specification is not attained, check delivery rate of fuel pump
⇒ Rep. gr. 20 .
Checking residual pressure
– Check system for leaks and check residual pressure by watch‐
ing the drop in pressure on the K-Jetronic pressure tester -
V.A.G 1318- .
• After 10 minutes pressure should still be at least 3.0 bar.
If the residual pressure drops below 3 bar:
♦ Check union between K-Jetronic pressure tester - V.A.G
1318- and fuel supply line for leaks.
♦ Check K-Jetronic pressure tester - V.A.G 1318- for leaks.
♦ Check fuel lines and their connections for leaks.
♦ Check fuel filter with integral fuel pressure regulator ⇒ Rep.
gr. 20 .
♦ If fuel filter is OK, renew fuel pump ⇒ Rep. gr. 20 .
Note
Before removing the pressure tester, release the fuel pressure by

opening the cut-off valve. Hold end of test hose into measuring
container -arrow-.
– Re-attach fuel supply line (make sure that all parts are clean
and that there are no leaks).

8 Lambda probes
⇒ “8.1 Overview - Lambda probes”, page 49
⇒ “8.2 Removing and installing Lambda probes”, page 49
8.1 Overview - Lambda probes
Note
♦ New Lambda probes are coated with an assembly paste.

♦ In the case of a used Lambda probe, coat only the thread with high-temperature paste; refer to ⇒ Electronic
parts catalogue for high-temperature paste.
♦ The assembly paste / high-temperature paste must not make contact with the slots on the Lambda probe
body.
1 - Lambda probe 2 after cata‐

lytic converter - G131-
❑ With Lambda probe 2
heater after catalytic
converter - Z30-
⇒ page 49
❑ 55 Nm
❑ With Lambda probe
heater 2 - Z28-
⇒ page 49
❑ 55 Nm
❑ With Lambda probe
heater - Z19-
⇒ page 49
❑ 55 Nm
4 - Lambda probe after catalyt‐
ic converter - G130-
❑ With Lambda probe 1
heater after catalytic
converter - Z29-
⇒ page 49
❑ 55 Nm
8.2 Removing and installing Lambda

probes
8. Lambda probes 49
♦ Lambda probe open ring spanner set - 3337-
Removing
Lambda probe - G39- / Lambda probe 2 - G108- before catalytic
converter:
Note
The preparations are described for cylinder bank 1 (left-side).

– To remove Lambda probe 2 - G108- , remove throttle valve
module 2 - J544- as well ⇒ page 21 .
Lambda probe after catalytic converter - G130- / Lambda probe 2
after catalytic converter - G131- :
– Remove corresponding throttle valve module ⇒ page 21 .
Continued for cylinder bank 1 (right-side):

– Detach electrical connectors from bracket and unplug.
2 - For Lambda probe after catalytic converter - G130-
3 - For Lambda probe - G39-
– Unscrew Lambda probe using a tool from Lambda probe open
ring spanner set - 3337- :
1 - Lambda probe after catalytic converter - G130-
Note
For illustration purposes, the installation position is shown with

the engine removed.

Continued for cylinder bank 2 (left-side):

– Detach electrical connectors from bracket and unplug.
2 - For Lambda probe 2 - G108-
3 - For Lambda probe 2 - G131- (after catalytic converter)
– Unscrew Lambda probe using ring spanner -3337/7- :
4 - Lambda probe 2 after catalytic converter - G131-
Note
For illustration purposes, the installation position is shown with

the engine removed.
Installing
⇒ “8.1 Overview - Lambda probes”, page 49
Note
♦ New Lambda probes are coated with an assembly paste.

♦ In the case of a used Lambda probe, coat only the thread with
high-temperature paste; refer to ⇒ Parts catalogue for high-
temperature paste.
♦ The assembly paste / high-temperature paste must not make
contact with the slots on the Lambda probe body.
♦ When installing, the Lambda probe wire must always be reat‐
tached at the same locations to prevent it from coming into
contact with the exhaust pipe.
8. Lambda probes 51
9 Engine control unit

⇒ “9.1 Wiring and component check with isolator boxes VAS 6606
”, page 52
⇒ “9.2 Removing and installing engine control unit J623 ”,
page 53
9.1 Wiring and component check with isola‐

tor boxes -VAS 6606-
♦ Isolator box, 198-pin - VAS 6606/1-1-
♦ Sheets -VAS 6606/1-1-
♦ Sheets -VAS 6606/2-1-
♦ Sheets -VAS 6606/3-1-
♦ Set of cables -VAS 6606/7-1- and -VAS 6606/7-2-
Note
♦ Always make sure that the cables are properly connected.

♦ Do not use damaged or worn tools and accessories.
♦ Observe operating instructions.
– 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 53 .

– 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 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-
♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle attach‐
ment -2- from wiring harness repair set - VAS 1978 B-
♦ Small, commercially available mole grips -3-
9. Engine control unit 53

Note
♦ The engine control unit -1- is bolted to the protective housing

-5-. To make it more difficult to unscrew the shear bolts -4- for
locking plate -2-, their threads have been coated with locking
fluid.
♦ The protective housing has to be removed before the connec‐
tors can be unplugged from the engine control unit (e.g. to
connect the test box or renew the engine control unit).
Removing
– When renewing engine control unit, select diagnosis object
“Replace engine control unit” in “Guided Functions” mode of
⇒ Vehicle diagnostic tester.
– Switch off ignition and take out ignition key.
– Remove bolts -3-.
– Unclip retaining clips -2- from mounting and detach plenum
chamber cover -1-.
– Remove nut -1- and swivel filler neck for washer fluid reservoir
slightly upwards -arrow A-.
– Pull filler neck -2- with filler pipe out of washer fluid reservoir
and through opening in body -arrow B-.
– Remove bolts -arrows- and detach cover for electronics box in

engine compartment.
Note
Disregard -item 1-.

– Release catches -arrows A- and take out engine control unit

-arrow B-.
To help prevent unauthorised access to the connectors on the

engine control unit, the engine control unit -1- is bolted to a pro‐
tective housing -5- by means of shear bolts -3 and 4- and a locking
plate -2-.
The threads of the two shear bolts -4- which are not screwed into
the engine control unit are secured with locking fluid. To unscrew
these two bolts, the threads must therefore be heated with the hot
air blower.
The threads of the two shear bolts -3- which are screwed into the
engine control unit are not secured with locking fluid. Do not apply
heat to the threads in the control unit housing; this is not neces‐
sary and would cause overheating of the control unit.
Caution
Wiring, connectors, insulation and control units can be burnt

and damaged.
♦ Keep exactly to the following procedure. Observe operat‐
ing instructions for hot air blower.
– Select settings on hot air blower -4- as shown in illustration:

2 - Temperature potentiometer to maximum heat output
3 - Two-stage air flow switch to position “3”
WARNING
Risk of burns.
♦ Parts of the metal locking plate will become very hot as a
result of heating the shear bolts. Try to ensure that only
the thread is heated and none of the nearby components.
These should be covered if necessary.
Apply heat to the threads of the shear bolts on the connector side
as shown in the illustration.
9. Engine control unit 55

Switch on the hot air blower and heat the bolt for approximately
20 ... 30 seconds.
– Unscrew shear bolts using mole grips (see arrow in illustra‐
tion).
– The two shear bolts screwed into the engine control unit do
not need to be heated. They should be removed without being
heated.
– Detach protective housing from control unit connectors.
– Release connectors on engine control unit and unplug con‐
nectors.
– Take out old engine control unit - J623- and install new engine
control unit - J623- .
Installing
Installation is performed in the reverse sequence.
– After installation, the protective housing must be re-fitted on
the engine control unit - J623- .
– Clean threaded holes for shear bolts to remove any residue
from locking fluid. This can be done using a thread tap.
– Use new shear bolts.
– Install cover for electronics box in engine compartment ⇒
Electrical system; Rep. gr. 97 .
– Install filler neck for washer fluid reservoir ⇒ Electrical system;
Rep. gr. 92 .
After installing a new engine control unit, the following operation
must be performed:
– Activate engine control unit using ⇒ Vehicle diagnostic tester
in “Guided Functions” mode, “Replace engine control unit”.

28 – Ignition system
1 General notes and safety precau‐
tions
⇒ “1.1 General notes on ignition system”, page 57
⇒ “1.2 Safety precautions”, page 57
1.1 General notes on ignition system

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

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

equipment while road-testing, or if test equipment is not prop‐
erly secured.
Persons sitting in the front passenger's seat could be injured if
the airbag is triggered in an accident.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Test equipment must always be secured on the rear seat
with a strap and operated from the rear seat by a second
person.
1. General notes and safety precautions 57

To prevent injuries to persons and/or irreparable damage to the

fuel injection and ignition system, the following must be noted:
♦ Do not touch or disconnect ignition coils when the engine is
running or being turned at cranking speed.
♦ The ignition must be switched off before disconnecting or con‐
necting ignition system wiring, high-voltage wires and test
leads.
♦ Always switch off the ignition before cleaning the engine.
♦ Always switch off the ignition before connecting or discon‐
necting the battery, otherwise the engine control unit may be
damaged.
♦ If you want to turn the engine at cranking speed without ac‐
tually starting it (e.g. compression test), first unplug connector
-2- at engine speed sender - G28- .
58 Rep. gr.28 - Ignition system

2 Ignition system
⇒ “2.1 Test data”, page 59
⇒ “2.2 Exploded view - ignition system”, page 59
⇒ “2.3 Removing and installing ignition coils”, page 61
⇒ “2.4 Removing and installing knock sensors G61 / G66 / G198 /
G199 ”, page 62
⇒ “2.5 Removing and installing Hall senders G40 / G163 ”,
page 63
⇒ “2.6 Removing and installing Hall senders G300 / G301 ”, page
64
2.1 Test data

Engine data 4.2 ltr. FSI engine
Idling speed Cannot be adjusted; regulated by idling speed sta‐
bilisation
Ignition timing Not adjustable (determined by control unit)
Ignition system Multi-coil system with 8 ignition coils (output stages
integrated) connected directly to spark plugs via
spark plug connectors
Spark plugs Designations ⇒ Electronic parts catalogue
Tightening torque ⇒ Maintenance ; Booklet 811
Firing order 1-5-4-8-6-3-7-2
2.2 Exploded view - ignition system
2. Ignition system 59
1 - Knock sensor
side): knock sensor 1 -
G61- , knock sensor 3 -
G198-
❑ Cylinder bank 2 (left-
side): knock sensor 2 -
G66- , knock sensor 4 -
G199-
⇒ page 62
2 - Bolt
❑ 20 Nm
3 - O-ring
❑ Renew
4 - Hall sender
side)
❑ Inlet side: Hall sender -
G40-
Hall sender (inlet side)
⇒ page 63
❑ Exhaust side: Hall send‐
er 3 - G300-
Hall sender (exhaust
side) ⇒ page 64
5 - Bolt
❑ 9 Nm
6 - Spark plug
❑ Change interval ⇒
Maintenance tables
❑ Tightening torque ⇒ Maintenance ; Booklet 811 , ⇒ Maintenance ; Booklet 812 or ⇒ Maintenance ;
Booklet 818
7 - Ignition coil
8 - Bolt
❑ 5 Nm
9 - Electrical wiring harness
10 - Engine speed sender - G28-
11 - Bolt
❑ 9 Nm
12 - O-ring
❑ Renew
13 - Hall sender
❑ Cylinder bank 2 (left-side)
❑ Inlet side: Hall sender 2 - G163-
❑ Removing and installing Hall sender (inlet side) ⇒ page 63
❑ Exhaust side: Hall sender 4 - G301-
❑ Removing and installing Hall sender (exhaust side) ⇒ page 64

14 - Bolt
❑ 9 Nm
2.3 Removing and installing ignition coils

♦ Puller - T40039-
Removing
– Remove corresponding air cleaner housing ⇒ page 19 .
– Unscrew nuts and bolts -arrows- and remove corresponding
bracket -1- for air cleaner housing.
– Remove bolts -1- and -2-.
– Pull ignition coils out of spark plug holes approx. 30 mm using

puller - T40039- .
– Release electrical connectors and detach from ignition coils
simultaneously.
– Pull out ignition coils.
Installing
– Fit all ignition coils loosely into spark plug holes.
– Align ignition coils with connectors and attach all connectors
onto ignition coils simultaneously.
– Press ignition coils onto spark plugs by hand evenly (do not
use tool).
2.4 Removing and installing knock sensors

-G61- / -G66- / -G198- / -G199-
Removing knock sensors -G61- / -G198- (front):
Removing knock sensors -G66- / -G199- (centre of engine):
– Remove high-pressure pipe
page 34 .

All knock sensors (continued):

– Take corresponding electrical connector out of bracket (right-
side) and unplug:
5 - Blue connector for knock sensor 3 - G198-
6 - Orange connector for knock sensor 4 - G199-
7 - Grey connector for knock sensor 2 - G66-
8 - Black connector for knock sensor 1 - G61-
– Remove corresponding bolt and detach knock sensor:
1- Knock sensor 1 - G61-
Installing
Note
Fit all cable ties in the original positions when installing.
– Install high-pressure pipe

page 34 .
2.5 Removing and installing Hall senders -

G40- / -G163-
Removing
– Unscrew bolt -arrow- and remove Hall sender.
Installing
Note
Fit new O-rings.
2.6 Removing and installing Hall senders -

G300- / -G301-
Removing
– Remove corresponding air cleaner housing ⇒ page 19 .
– Unscrew nuts and bolts -arrows- and remove corresponding
bracket -1- for air cleaner housing.
Hall sender 4 - G301-

– Remove bolts -arrows- and pull out guide tube for oil dipstick.
– Carefully bend heat shield -2- slightly to the side.
Hall sender 3 - G300-

– Remove bolts -arrows-.
– Carefully bend heat shield -1- slightly to the side.

– Unscrew bolt -1- and detach Hall sender.
Installing
– Install dipstick guide tube ⇒ Rep. gr. 13 .
Note
Fit new O-rings.

2.7 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 noise insulation ⇒ Rep. gr. 66 .

Direct Petrol Injection and Ignition System (8-Cyl 4 2 LTR 4-Valve) RS4 RS5

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Service

Direct petrol injection and ignition system (8-cyl. 4.2 ltr.

Service Department. Technical Information

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

24 – Mixture preparation - injection

1.1 General notes on self-diagnosis

1. Safety precautions and rules for cleanliness 1

1.2 Safety precautions when working on the

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

♦ Fuel hoses in engine compartment must only be secured with

1.3 Safety precautions when working on the

2 Rep. gr.24 - Mixture preparation - injection

To prevent irreparable damage to the electronic components

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

1.4 Safety precautions when working on ve‐

Risk of injury due to automatic engine start on vehicles with

1.5 Safety precautions when using testers

Accidents can be caused if the driver is distracted by test

1.6 Rules for cleanliness and instructions

1. Safety precautions and rules for cleanliness 3

♦ Seal off open pipes/lines and connections immediately with

1.7 Reducing pressure in high-pressure

The fuel system operates at extremely high pressure. This can

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

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

4 Rep. gr.24 - Mixture preparation - injection

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

Additional steps required

1.8 Checking for leaks in the fuel system

1.9 Checking vacuum system

1. Safety precautions and rules for cleanliness 5

6 Rep. gr.24 - Mixture preparation - injection

2.1 Technical data

2.2 Overview of fitting locations - injection system

1 - Secondary air pump motor

8 Rep. gr.24 - Mixture preparation - injection

❑ Removing and installing ⇒ page 21

1 - Injector, cylinder 1 - N30-

14 - Camshaft control valve 2 - N208-

10 Rep. gr.24 - Mixture preparation - injection

1 - Coolant temperature send‐

1 - Oil pressure switch for re‐

Fitting location of engine control unit - J623-

12 Rep. gr.24 - Mixture preparation - injection

Fitting location of fuel pump control unit - J538-

Fitting location of accelerator pedal module with accelerator po‐

Fitting location of secondary air pump motor -V101- / -V189-

Fitting location of continued coolant circulation pump - V51-

Fitting location of valve for oil pressure control - N428-

Intake air temperature sender - G42- / intake manifold pressure

Intake manifold flap valve - N316- -1-

2.3 Exploded view - vacuum system

Checking vacuum system ⇒ page 5

14 Rep. gr.24 - Mixture preparation - injection

3.1 Exploded view - air cleaner housing

16 Rep. gr.24 - Mixture preparation - injection

3.2 Removing and installing engine cover

3.3 Removing and installing air filter ele‐

♦ Always use genuine part for air filter element.