Tune-Up - 5-cyl Audi 4000 S

ENGINE IDENTIFICATION

Engine number is stamped on left side of engine just below the cylinder head.

ENGINE CODE

ENGINE COMPRESSION

Check compression with engine warm, all spark plugs removed and throttle wide open. Crank engine through at least 6 compression strokes per cylinder to determine engine compression.

COMPRESSION SPECIFICATIONS

SPARK PLUGS

SPARK PLUG TYPE

SPARK PLUG SPECIFICATIONS

HIGH TENSION WIRE RESISTANCE

Carefully remove ends of wire from spark plug and distributor. Using an ohmmeter, check resistance of wire while gently twisting wire. If resistance is incorrect or fluctuates from infinity to any value, replace wire.

Note. Wire resistance cannot be measured if the wires are marked with this symbol

HIGH TENSION WIRE RESISTANCE

VALVE CLEARANCE

Audi 5 cylinder engines are equipped with hydraulic valve lifters. No adjustment is necessary.

Scheme 4

VALVE ARRANGEMENT

1. E-I-E-I-I-E-I-E-I-E (Front-to-rear).

DISTRIBUTOR

All models are equipped with an electronic, breakerless ignition system. All California and Turbo models have an idle stabilizer unit, which adjusts ignition timing to maintain a constant idle speed.

IGNITION TIMING

Ignition timing is nonadjustable. With engine at TDC of ignition strike, rotor aperture alignment mark must align with reference mark on distributor housing.

IGNITION TIMING (DEGREES BTDC @ RPM)

Scheme 5

IDLE SPEED & MIXTURE

Note. Oxygen sensor system normally requires no adjustment. If problems occur, system operation may be checked. A Multimeter (US 1119) and Adapter (VW 1315 A/1) are required to display the injection differential pressure cycle. Idle speed and CO level must be checked and adjusted together. Idle speed is electronically controlled.

Non-Turbo Models

1. With engine at normal operating temperature, turn off all electrical equipment, including A/C and radiator fan. Do not connect pressure gauge. If injection line has been removed or replaced, run engine several times to 3000 RPM for about 2 minutes.
2. Disconnect and plug crankcase breather hoses. Remove cap from charcoal canister "T" and vent to atmosphere. Connect Tester (VW 1367) and Cable Adapter (VW 1367). Depress "%" button on tester. Remove CO probe receptacle cap and connect CO meter. Ensure fit is snug to prevent exhaust leaks.
3. Connect multimeter with adapter to differential pressure regulator. Remove connector from regulator and connect measuring wire of adapter between connector and regulator. Connect multimeter to measuring wire and turn switch to "DCA 200 mA". NOTE: If engine does not run with wire connected, connections in wire plug may be reversed.
4. Start and run engine at idle speed. With oxygen sensor connected, duty cycle should be 26-30% and idle speed should be 750-850 RPM. If duty cycle is not as specified, turn idle adjusting screw on throttle body. If RPM signal is displayed, check idle stabilizer unit. If duty cycle and RPM values are okay, continue with CO level adjustment.
5. Unplug oxygen sensor connector and check CO level. If CO reading is okay, reconnect oxygen sensor and recheck duty cycle. If CO reading is not as specified, stop engine and remove boot from mixture control unit.
6. Center punch hole in CO adjusting screw plug and drill a 3/32" hole to a depth of 5/32". Do not drill completely through as adjustment screw will be damaged.
7. Install a 1/8" sheet metal screw and remove plug using pliers. Start engine and run at idle. Adjust CO level by turning adjustment screw with Adjusting Wrench (P 377). (Scheme 6) NOTE: Do not push down on adjustment screw and do not accelerate engine with adjusting wrench in place. Remove wrench after each adjustment and accelerate engine briefly before measuring current reading.
8. If CO value is not as specified, check oxygen sensor system. If CO value is okay, reconnect oxygen sensor connector and recheck duty cycle. Disconnect oxygen sensor connector. Observe differential pressure reading on multimeter. Current reading must be 8.5-12.5 mA at sea level, 8-12 mA at 1000 feet above sea level, and 5.5-9.5 mA at 4000 feet above sea level.
9. If current reading is not as specified, check altitude sensor. If current reading is okay, reconnect oxygen sensor and observe current reading on multimeter. If current does not fluctuate, check oxygen sensor. If current does fluctuate, turn engine off. Install new plug in mixture control unit and seat plug flush with unit. Remove all test equipment and reconnect all hoses and wiring.

Scheme 6

Turbo Models

1. With engine at normal operating temperature, turn off all electrical equipment, including A/C and radiator fan. Do not connect pressure gauge. Throttle valve must be in idle position. Throttle valve and coolant thermo-time switches must not be defective. TDC sensor must be fully seated in transaxle. If injection line has been removed or replaced, run engine several times to 3000 RPM for about 2 minutes.
2. Disconnect wire from terminal No. 1 of ignition coil. Disconnect and plug crankcase breather hose at valve cover. Remove cap from charcoal canister "T" and vent to atmosphere. Connect Tester (VW 1367) and Cable Adapter (VW 1367). Remove CO probe receptacle cap and connect CO meter. Ensure fit is snug to prevent exhaust leaks. Start engine and adjust idle speed.
3. Using Cable Adapter (US 1112), connect test lead to Blue/Black oxygen sensor test wire connector. Depress "%" button on tester. Start engine and run at idle. Disregard RPM reading. With oxygen sensor connected, CO value must be as specified. "OXS-Duty Cycle" must fluctuate between 25% and 65%.
4. If CO reading exceeds 1.2% with "OXS-Duty Cycle" reading of 25-65%, check ignition system, exhaust system and fuel distributor. If "OXS-Duty Cycle" is less than 25%, or greater than 65%, perform CO adjustment as follows: Stop engine and remove air intake duct from airflow meter. Center punch hole in CO adjusting screw plug and drill a 3/32" hole to a depth of 5/32". Do not drill completely through as adjustment screw will be damaged.
5. Install a 1/8" sheet metal screw and remove plug using pliers. Reinstall air intake duct. Start engine and accelerate to 2000 RPM briefly, then return to idle. Adjust CO level to 42-58% (fluctuating) by turning adjustment screw with Adjusting Wrench (P 377). (Scheme 6) NOTE: Do not push down on adjustment screw and do not accelerate engine with adjusting wrench in place. Remove wrench after each adjustment and accelerate engine briefly before measuring current reading.
6. Readjust idle speed if required. Turn engine off. Install new plug in mixture control unit and seat plug flush with unit. Remove all test equipment and reconnect all hoses and wiring.

IDLE SPEED & CO LEVEL SPECIFICATION

IDLE MIXTURE

Note. Mixture adjustment is performed during idle speed and CO level adjustment. Mixture adjustment is not a normal tune-up procedure on fuel injected engines.

EMISSION CONTROL

See EMISSIONS section.

All models are equipped with electronic ignition. All California and Turbo models have an idle stabilizer unit, which adjusts ignition timing to maintain a constant idle speed.

IGNITION COIL RESISTANCE - OHMS @ 68°F (20°C)

Fuel Injection

All models are equipped with Bosch (CIS-E) Continuous Injection System-Electronic.

FUEL PUMP PERFORMANCE

BATTERY

BATTERY SPECIFICATIONS

STARTER

All models are equipped with Bosch starters.

ALTERNATOR

All models use a Bosch alternator.

ALTERNATOR SPECIFICATIONS

ALTERNATOR REGULATOR

All models use Bosch, nonadjustable regulators which are integral with the alternator.

ALTERNATOR OPERATING VOLTAGE @ 80°F (27°C)

BELT ADJUSTMENT

BELT ADJUSTMENT

SERVICE INTERVALS

REPLACEMENT INTERVALS

CAPACITIES

FLUID CAPACITIES