2.0l - Multiport Fuel Injection - Engine Code(s): Cbfa & Ccta Audi A3 8P рестайлинг 2

CLEAN WORKING CONDITIONS AND FUEL SYSTEM WORK INSTRUCTIONS

Even a little contamination can lead to faults. When working on the fuel supply and on the fuel injection system, observe the following guidelines for a clean working environment

1. Before loosening, connections and surrounding areas must be cleaned thoroughly with engine or brake cleaner, and then cleaned area must be dried completely.
2. Plug open lines and connections immediately with appropriate protective caps.
3. Place removed parts on a clean surface and cover them. Use lint-free cloths.
4. Only install clean components: Remove the replacement parts from their packaging just prior to installing them. Do not use parts that have been stored unpacked (for example in tool boxes etc.).
5. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.
6. Protect the disconnected connectors from dirt and moisture and only connect when they are dry.

FUEL INJECTORS, CLEANING

Special tools and workshop equipment required

1. Ultrasonic Cleaning Unit VAS 6418
2. Injection Module Mounting Plate VAS 6418/1
3. Cleaning fluid VAS 6418/2

Cleaning

Remove the fuel injectors. Refer to FUEL INJECTORS .

Note. Follow the safety precautions and the instructions for the ultrasonic device.

The ultrasonic device must be filled with cleaning fluid VAS 6418/2.

Note. Fill the ultrasonic device up to the upper edge of the holes with cleaner (see the magnified area of the illustration).

Insert the injector valve -1- all the way into the VAS 6418/1 -2-.

Dip the fuel injectors with the VAS 6418/1 into the cleaning device.

Scheme 90

Adjust the temperature to 50 degrees using the knob -4-.

Set a cleaning time of 30 minutes using the knob -5-.

Switch the ultrasonic device on with the button -3-.

Note. The time begins counting down once the cleaning temperature reaches 50 degrees.

Replace the combustion chamber seal (Teflon seal) after cleaning each fuel injector. Refer to TEFLON COMBUSTION CHAMBER SEAL .

Then install the fuel injector valves. Refer to FUEL INJECTORS .

ON BOARD DIAGNOSTICS

1. The Engine Control Module (ECM) is equipped with On Board Diagnostics (OBD). Before repairs such as fault finding, check the Diagnostic Trouble Code (DTC) memory first. Also the vacuum hoses and connections must be checked (unmetered air).
2. Fuel hoses in engine compartment must only be secured with spring-type clips. The use of clamp or screw type clips is not permissible.
3. For the electric components to work properly, a voltage of at least 11.5 Volts is required.
4. Do not use sealants containing silicone. Particles of silicone drawn into the engine, will not be burnt in the engine and damage the oxygen sensor.
5. The vehicles have a crash fuel shut-off. It reduces the risk of fire in an accident because the fuel pump relay switches the fuel pump off.
6. This setup also makes it easier to start the engine. When the driver-side door is opened, the fuel pump is activated for 2 seconds so that pressure builds in the fuel system, observe safety measures. Refer to «TEST AND MEASURING INSTRUMENTS DURING TEST DRIVE»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__test-and-measuring-instruments-during-test) .

IGNITION SYSTEM

To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following

1. Individuals with a pacemaker must not stay in the danger area of high voltage systems, for example ignition systems, xenon light.
2. Fuel lines must not be opened when engine is running.
3. Only disconnect and reconnect wires for injection and ignition system, including test leads, when ignition is switched off.
4. If engine is to be cranked at starting RPM without starting (for example for compression testing), disconnect connectors from ignition coils and remove fuse for electric fuel pump.
5. It is possible that the control module will recognize a malfunction and store a Diagnostic Trouble Code (DTC) during some tests. After completing all checks and repairs, check the DTC memory and erase the memory, if necessary.
6. If the DTC memory was erased, a new readiness code must be generated.
7. Cleaning the engine should only be performed with ignition turned off.
8. The battery must only be disconnected and connected with the ignition turned off, since the Engine Control Module (ECM) can otherwise be damaged.
9. If engine is to be cranked at starting RPM without starting (for example for compression testing), disconnect the four connectors for ignition coils, using the ignition coil puller T40039. Also remove fuse from Fuel Pump (FP) control module -J538-.

TEST AND MEASURING INSTRUMENTS DURING TEST DRIVE

If special testing equipment is required during road test, note the following

THROTTLE VALVE CONTROL MODULE -J338-, CLEANING

Note. If a new Engine Control Module (ECM) -J623- is installed, then it must be adapted to the throttle valve control module. The throttle valve connections must not be damaged when cleaning.

Remove the throttle valve control module. Refer to Throttle Valve Control Module -J338 .

Open the throttle valve by hand and hold it in the open position with a suitable object (for example, a plastic or wood wedge) -arrow-.

Scheme 91

Clean throttle valve connections, especially in the area -arrows- of closed throttle valve, with standard acetone and a brush.

Scheme 92

Wipe throttle valve connections with a lint-free cloth.

Allow acetone to dry completely and reinstall cleaned throttle valve control module.

Erase the adaptation values and adapt the ECM to the throttle valve control module. Use a vehicle diagnosis tester.

Scheme 93

1. Spring-Type Clip
2. Air Guide Hose To turbocharger Check the air duct hose for dirt and leaves
3. Mass Airflow (MAF) Sensor -G70- 1.5 Nm Removing and installing, refer to «Mass Airflow Sensor -G70»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__mass-airflow-sensor-g70)
4. Bolts 1.5 Nm For upper section of air filter
5. Bolts 1.5 Nm For upper section of air filter
6. Air Filter Upper Section Clean salt, dirt and leaves from the upper section of the air filter.
7. Filter Always use an original air filter Removing and installing, refer to «AIR FILTER»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__air-filter) Observe change intervals
8. Bolt For the air filter lower section
9. Snow Screen Not installed on all vehicles
10. Air Filter Housing Lower Section Clean the lower section of the air filter from salt, dirt and leaves.
11. Connection for the Water Drain Hose Clean the connection
12. Water Drain Hose Clean the water drain hose
13. Shutter Valve Clean and install
14. Intake Air Guide To lock carrier Clean dirt and leaves from intake air guide

COMPONENT LOCATION OVERVIEW

Components A through V are not shown in the exploded view illustration.

Scheme 94

1. Camshaft Adjustment Valve 1 -N205- Component location (Scheme 101)Removing and installing, refer to «REMOVAL AND INSTALLATION»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta)
2. Wastegate Bypass Regulator Valve -N75- Installed directly on turbocharger (Scheme 122)
3. Turbocharger Recirculating Valve -N249- Installed directly on turbocharger (Scheme 122)
4. Ignition Coils with Power Output Stages Ignition Coils with Power Output Stages Removing and installing, refer to «IGNITION COILS WITH POWER OUTPUT STAGES»(/audi/a3/8p-2-2008-2013/remont/ignition-system/#20l-ignitionglow-plug-system-engine-codes-cbfa-ccta__ignition-coils-with-power-output-stages) Ignition coil 1 with power output stage -N70- Ignition coil 2 with power output stage -N127- Ignition coil 3 with power output stage -N291- Ignition coil 4 with power output stage -N292- The ignition coils must be pulled out of the cylinder head using the ignition coil puller T40039
5. Engine Control Module -J623- Removing and installing, refer to «Engine Control Module -J623»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__engine-control-module-j623)
6. High Pressure Pump Component location (Scheme 97)Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__high-pressure-pump)
7. Fuel Pressure Regulator Valve -N276- Component location (Scheme 97)
8. Engine Coolant Temperature (ECT) Sensor on Radiator Outlet -G83- Component location (Scheme 110)
9. Vacuum Diaphragm for the Charge-Motion Valves Component location (Scheme 98)
10. Intake Manifold Runner Control (IMRC) Valve -N316- Component location (Scheme 98)
11. Engine Speed Sensor -G28- Component location (Scheme 106)
12. Charge Air Pressure Sensor -G31- Component location (Scheme 111)
13. Electrical Connector from Knock Sensor (KS) 1 -G61- Component location (Scheme 108)
14. Electrical Connector from the Camshaft position (CMP) sensor -G40- Component location (Scheme 108)
15. 8-Pin Harness Connector for Fuel Injectors Component location (Scheme 108)
16. Throttle Valve Control Module -J338-, Electronic Power Control (EPC) Throttle Drive -G186- EPC throttle drive angle sensor 1 -G187- and EPC throttle drive angle sensor 2 -G188- After replacing the throttle valve control module -J338-, it must be adapted to the Engine Control Module (ECM) -J623-. Use a vehicle diagnosis tester.
17. Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80
18. Intake Air Temperature (IAT) Sensor -G42- 11 Nm
19. Knock Sensor (KS) 1 -G61- 20 Nm Knock Sensor (KS) 2 -G66- (not installed on all vehicles) Removing and installing, refer to «Knock Sensor 1 -G61»(/audi/a3/8p-2-2008-2013/remont/ignition-system/#20l-ignitionglow-plug-system-engine-codes-cbfa-ccta__knock-sensor-1-g61)
20. Engine Coolant Temperature (ECT) Sensor -G62- Component location (Scheme 109)
21. Camshaft Position (CMP) Sensor -G40- Installation location below the cover with the oil separator (Scheme 107)
22. Fuel Pressure Sensor -G247- 27 Nm Component location (Scheme 99)Removing and installing, refer to «Fuel Pressure Sensor -G247»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__fuel-pressure-sensor-g247)
23. Intake Manifold Runner Position Sensor -G336- Installed locations (Scheme 100)
24. Oil Pressure Switch -F1- Oil pressure switch Installed locations (Scheme 113)Removing and installing, refer to «DESCRIPTION AND OPERATION»(/audi/a3/8p-2-2008-2013/remont/lubrication-system/#20l-lubrication-engine-codes-cbfa-ccta) A - Oil Pressure Switch -F22 Engine code CCZA B - Oil Pressure Regulation Valve -N428 Engine code CCZA C - Data Link Connector (DLC) In knee bolster on driver's side D - Mass Airflow (MAF) Sensor -G70- and Intake Air Temperature (IAT) Sensor 2 -G299 Component location (Scheme 102) Removing and installing, refer to «Mass Airflow Sensor -G70»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__mass-airflow-sensor-g70) E - Fuel Pump (FP) Control Module -J538 Component location (Scheme 103)F - Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19 Installed location on engine codes CCTA (Scheme 115)Installation location, engine code CBFA (Scheme 116)Oxygen sensors, assembly overview, refer to «OXYGEN SENSORS OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__oxygen-sensors-overview) G - Electrical Connector from the Heated Oxygen Sensor -G39- and Oxygen Sensor Heater -Z19- Installed location (Scheme 114)H - Oxygen Sensor after Three Way Catalytic Converter -G130- and Heater for Oxygen Sensor 1 after Catalytic Converter -Z29- Installed location on engine codes CCTA (Scheme 118)Installation location, engine code CBFA (Scheme 120)Oxygen sensors, assembly overview, refer to «OXYGEN SENSORS OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__oxygen-sensors-overview) I - Electrical Connector from the Oxygen Sensor (O2S) after Three Way Catalytic (TWC) Converter -G130- and Heater for Oxygen Sensor (O2S) 1 after Catalytic Converter -Z29- Installed location on engine codes CCTA (Scheme 117)Installation location, engine code CBFA (Scheme 119)J - Oxygen Sensor 3 after Catalytic Converter -G287- and Heater for Oxygen Sensor 3 after Catalytic Converter -Z64- Only installed on vehicles with engine code: CBFA Installation location, engine code CBFA (Scheme 120)Oxygen sensors, assembly overview, refer to «OXYGEN SENSORS OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__oxygen-sensors-overview) K - Electrical Connector from the Oxygen Sensor (O2S) 3 after Catalytic Converter -G287- Only installed on vehicles with engine code: CBFA Installation location, engine code CBFA (Scheme 119)L - Brake Lamp Switch - F- and Brake Pedal Switch -F63- Component location (Scheme 105)Removing and installing, refer to «Removal and Installation»(/audi/a3/8p-2-2008-2013/remont/anti-locktraction-control/#anti-lock-brake-system) M - Accelerator Pedal Position Sensor -G79- and Accelerator Pedal Position Sensor 2 -G185- Component location (Scheme 96)On accelerator pedal (both sensors are stored in one housing) If the accelerator pedal module or Engine Control Module (ECM) is replaced in vehicles with automatic transmission, the kick-down function must be adapted. Removing and installing, refer to «REMOVAL AND INSTALLATION»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#fuel-supply-system-gasoline-engines) N - Clutch Position Sensor -G476- Only for vehicles with manual transmission Component location (Scheme 104)Removing and installing, see transmission - clutch, refer to «REMOVAL AND INSTALLATION»(/audi/a3/8p-2-2008-2013/remont/clutches-manual-hydraulic/#clutch-manual-transmission-02q-fwd) O - Relay and Fuse Carrier in E-Box Relay and fuse assignment, refer to appropriate SYSTEM WIRING DIAGRAM P - Coolant Fan Control (FC) Module -J293- Component location (Scheme 112)Q - Fuel Injectors Removing and installing, refer to «FUEL INJECTORS»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__fuel-injectors) Cylinder 1 Fuel Injector -N30- Cylinder 2 Fuel Injector -N31- Cylinder 3 Fuel Injector -N32- Cylinder 4 Fuel Injector -N33- R - After-Run Coolant Pump -V51- Component location (Scheme 124)S - Secondary Air Injection (AIR) Pump Motor -V101- Only installed on vehicles with engine code: CBFA Removing and installing, refer to «REMOVAL AND INSTALLATION»(/audi/a3/8p-2-2008-2013/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cbfa-ccta) T - Secondary Air Injection (AIR) Solenoid Valve -N112- Only installed on vehicles with engine code: CBFA Component location (Scheme 121)V - Secondary Air Injection Sensor 1 -G609- Only installed on vehicles with engine code: CBFA Component location (Scheme 121)

Scheme 95

2 - Accelerator pedal module, electrical connector

Removing and installing, refer to REMOVAL AND INSTALLATION .

Scheme 96

2 - Fuel Pressure Regulator Valve -N276

Scheme 97

1 - Intake manifold flap vacuum diaphragm

Note. The intake manifold flaps are the same as the channel separating plates.

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

1 - Fuel pump control module -J538- connector

2 - Fuel pump control module -J538

3 - Transfer fuel pump -G6

Scheme 103

Removing and installing, refer to REMOVAL AND INSTALLATION

Scheme 104

Removing and installing, refer to Removal and Installation

Scheme 105

Scheme 106

Scheme 107

1 - From the camshaft position sensor -G40- and intake manifold runner position sensor -G336

2 - From the Knock Sensor (KS) 1 -G61

3 - 8-pin harness connector for fuel injectors

Scheme 108

Note. Under the intake manifold (the intake manifold is not shown in the illustration).

Scheme 109

Scheme 110

Scheme 111

1

Coolant FC control module, connector

Note. The Coolant FC control module is integrated in the coolant fan -V7-.

Scheme 112

1 - Reduced oil pressure switch -F378- (engine code CCZA)

2 - Reduced oil pressure switch -F378- connector (engine code CCZA)

3 - Oil pressure switch -F1- (engine codes CCTA and CBFA)

3 - Oil pressure switch -F22- (engine code CCZA)

4 - Oil pressure switch -F1- connector or oil pressure switch -F22

Scheme 113

1. Electrical connector for the Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) heater -Z19

Scheme 114

1. Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) heater -Z19

Scheme 115

1. Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) heater -Z19

Scheme 116

Arrow- electrical connector for the oxygen sensor after three way catalytic converter -G130- and heater for oxygen sensor 1 after catalytic converter -Z29

Scheme 117

1. Oxygen sensor after three way catalytic converter -G130- with heater for oxygen sensor 1 after catalytic converter -Z29

Note. The arrow in the illustration points in the direction of travel.

Scheme 118

1 - Electrical connector for the O2S sensor 3 after catalytic converter -G287- and heater for oxygen sensor 3 after catalytic converter -Z64

2 - Electrical connector for the O2S sensor after three way catalytic converter -G130- and heater for oxygen sensor 1 after catalytic converter -Z29

Scheme 119

1 - Oxygen sensor 3 (O2S) after catalytic converter -G287- and heater for oxygen sensor 3 after catalytic converter -Z64

2 - Oxygen sensor after three way catalytic converter -G130- and heater for oxygen sensor 1 after catalytic converter -Z29

Note. The arrow in the illustration points in the direction of travel.

Scheme 120

1 - Electrical connector from the AIR solenoid valve -N112

2 - Air Sensor 1 -G609

3 - AIR solenoid valve -N112

Scheme 121

1 - Turbocharger, Removing and installing, refer to REMOVAL AND INSTALLATION

2 - Tighten the wastegate bypass regulator valve -N75- to 3 Nm.

3 - Tighten the turbocharger recirculating valve -N249- to 7 Nm (observe installation location, next illustration)

Scheme 122

Scheme 123

Scheme 124

1. Fuel Injector With combustion chamber seal (Teflon seal), always replace Replace O-rings Note correct installation position Removing and installing, refer to «FUEL INJECTORS»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__fuel-injectors)
2. Support Ring
3. Fuel Rail Removing and installing, refer to «INTAKE MANIFOLD WITH FUEL RAIL»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__intake-manifold-with-fuel-rail)
4. High Pressure Pump With fuel pressure regulator valve -N276- There is an electric fuel pump located in the tank that supplies the fuel to the mechanical high pressure pump. When installing, make sure that no dirt enters the fuel system. The fuel system must be without pressure to install the high-pressure pump, releasing fuel pressure, refer to «RELEASING PRESSURE IN HIGH PRESSURE AREA»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__releasing-pressure-in-high-pressure-area) Do not install fuel lines with tension Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__high-pressure-pump)
5. Roller Tappet
6. Fuel Pressure Regulator Valve -N276
7. High Pressure Pump Bolts Tighten by hand in a diagonal sequence and then tighten to 5 Nm Final specification for M8 bolts = 20 Nm Do not tilt the high pressure pump
8. Fuel Supply Line Connectors 40 Nm Replace
9. Fuel Supply Line Union Nut 20 Nm
10. Channel Separating Plates (intake manifold flaps)
11. Gasket Replace
12. Intake Manifold Removing and installing, refer to «INTAKE MANIFOLD WITH FUEL RAIL»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__intake-manifold-with-fuel-rail)
13. Channel Separating Plate Vacuum Diaphragm (intake manifold flaps)
14. Throttle Valve Control Module -J338-, Electronic Power Control (EPC) Throttle Drive -G186- EPC throttle drive angle sensor 1 -G187- and EPC throttle drive angle sensor 2 -G188- After replacing the throttle valve control module -J338-, it must be adapted to the Engine Control Module (ECM) -J623-. Use a vehicle diagnosis tester.
15. Intake Manifold Bolts 9 Nm
16. Intake Manifold Runner Position Sensor -G336- Adapt the intake manifold runner position sensor -G336- to the engine control module -J623- after removing, installing or replacing the intake manifold runner position sensor -G336- or the intake manifold. Use a vehicle diagnostic tester in "Guided Functions".
17. Fuel Pressure Sensor -G247- 27 Nm Coat the threads with clean engine oil. Always replace the connections and tighten them to 40 Nm. Component location (Scheme 99)Removing and installing, refer to «Fuel Pressure Sensor -G247»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__fuel-pressure-sensor-g247)

HIGH PRESSURE PUMP OVERVIEW

Scheme 125

1. Fuel Supply Line from the Fuel Tank
2. High Pressure Pump Bolt First tighten the bolts diagonally hand-tight, then to 5 Nm and then to 20 Nm. Do not tilt the high pressure pump
3. High Pressure Pump There is an electric fuel pump located in the tank that supplies the fuel to the mechanical high pressure pump. When installing, make sure that no dirt enters the fuel system. The fuel system must be without pressure, releasing fuel pressure, refer to «RELEASING PRESSURE IN HIGH PRESSURE AREA»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__releasing-pressure-in-high-pressure-area) Do not install fuel lines with tension Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__high-pressure-pump)
4. O-ring Replace
5. Roller Tappet Remains inserted in the vacuum pump after removing the high pressure pump
6. Connecting Piece No replacement part, it is part of the high pressure pump Do not loosen
7. Adapter 40 Nm There is an adapter between the connection and the fuel supply line, depending on the date of manufacture. If the adapter is there, then it must be replaced.
8. High Pressure Fuel Line 20 Nm Do not install fuel line with tension
9. High Pressure Pump Bolt First tighten the bolts diagonally hand-tight, then to 5 Nm and then to 20 Nm. Do not tilt the high pressure pump
10. Connections for the Fuel Supply Line on the Fuel Rail 25 Nm Replace
11. Fuel Rail Removing and installing, refer to «FUEL RAIL»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__fuel-rail)

Scheme 126

1. Bolt for Intake Air Temperature (IAT) Sensor -G42- 5 Nm
2. Intake Air Temperature (IAT) Sensor -G42
3. Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80- With double check-valve, checking, refer to «DOUBLE CHECK-VALVE, CHECKING»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__double-check-valve-checking)
4. Intake Manifold Removing and installing, refer to «INTAKE MANIFOLD WITH FUEL RAIL»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__intake-manifold-with-fuel-rail)
5. Channel Separating Plate Vacuum Diaphragm (intake manifold flaps)
6. Intake Manifold Runner Control (IMRC) Valve -N316
7. Fuel Injectors Replace the O-ring and Teflon® ring Note correct installation position Removing and installing, refer to «FUEL INJECTORS»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__fuel-injectors)
8. Intake Manifold Support
9. Bolt for the Intake Manifold Support 23 Nm
10. Nut for the Intake Manifold Support 10 Nm
11. Bolts for the Throttle Valve Control Module -J338 5 Nm
12. Throttle Valve Control Module -J338-, Electronic Power Control (EPC) Throttle Drive -G186- EPC throttle drive angle sensor 1 -G187- and EPC throttle drive angle sensor 2 -G188- After replacing the throttle valve control module -J338-, it must be adapted to the Engine Control Module (ECM) -J623-. Use a Vehicle Diagnosis Tester.
13. Seal Replace

OXYGEN SENSORS OVERVIEW

1. Electrical connector for the Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor Heater (O2S) -Z19

1. Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor Heater (O2S) -Z19

1. Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19

Arrow- electrical connector for the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor (O2S) 1 after catalytic converter -Z29

1. Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor (O2S) 1 after catalytic converter -Z29

Note. The arrow in the illustration points in the direction of travel.

1 - Oxygen Sensor (O2S) 3 after catalytic converter -G287- and Heater for Oxygen Sensor (O2S) 3 after catalytic converter -Z64

2 - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor (O2S) 1 after catalytic converter -Z29

Note. The arrow in the illustration points in the direction of travel.

1 - Electrical connector for the Oxygen Sensor (O2S) 3 after catalytic converter -G287- and Heater for Oxygen Sensor (O2S) 3 after catalytic converter -Z64

2 - Electrical connector for the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor (O2S) 1 after catalytic converter -Z29

Note. New oxygen sensors are coated with assembly paste; the paste must not get into the slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with oxygen sensor slots. Hot bolt paste, Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.

1. Tightening Specifications: 55 Nm

Engine code CCTA: Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) heater -Z19- in front of the catalytic converter, Removing and installing, refer to Heated Oxygen Sensor -G39- AND Oxygen Sensor Heater -Z19- BEFORE CATALYTIC CONVERTER .

Engine code CBFA: Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) heater -Z19-, Removing and installing, refer to Heated Oxygen Sensor -G39- AND Oxygen Sensor Heater -Z19- BEFORE CATALYTIC CONVERTER .

Engine codes CCTA: Oxygen Sensor (O2S) behind three way catalytic converter -G130- and Heater for Oxygen Sensor (O2S) 1 after catalytic converter -Z29- Removing and installing, refer to Oxygen Sensor after Three Way Catalytic Converter -G130- AND Heater for Oxygen Sensor 1 after Catalytic Converter -Z29 .

Engine code CBFA: Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor (O2S) 1 after catalytic converter -Z29-, Removing and installing Oxygen Sensor after Three Way Catalytic Converter -G130- AND Heater for Oxygen Sensor 1 after Catalytic Converter -Z29 .

Engine code CBFA: Oxygen Sensor (O2S) 3 after Three Way Catalytic Converter -G287- and Heater for Oxygen Sensor (O2S) 3 after catalytic converter -Z64-, Removing and installing Oxygen Sensor 3 after Catalytic Converter -G287- AND Heater for Oxygen Sensor 3 after Catalytic Converter -Z64 .

RELEASING PRESSURE IN HIGH PRESSURE AREA

Special tools and workshop equipment required

1. Special Hook 3370

High Fuel Pressure, Reducing

Connect a vehicle diagnosis tester.

Start engine and run at idle speed.

Select "engine electronics" in OBD.

Then select "Measured values" read out.

Select measured value block 140.

With the engine running in idle, the fuel pressure will be displayed in display field 3.

1. Specified value: between 35 and 45 bar

Pry off the left cover on the instrument panel using 3370 -arrow-.

Scheme 127

While the engine is idling, remove the fuse -in the fuse holder inside the instrument panel on the driver side- from the Fuel Pump (FP) control module -J538-, refer to appropriate SYSTEM WIRING DIAGRAM.

Scheme 128

Check the fuel pressure on the tester.

1. The fuel pressure decreases rapidly because the mechanical high pressure pump is no longer supplied with fuel from the transfer fuel pump -G6-.

Turn the ignition off as soon as the fuel pressure drops to approximately 8 bar.

Note. The fuel pressure must not drop below 6 bar, because otherwise the engine will shut off (risk of catalytic converter damage).

After reducing fuel pressure, place a clean cloth around the connection and open the high pressure system immediately. Escaping fuel must be absorbed.

Note. If the high pressure system is not opened immediately, the pressure will increase because of post-heating. The ignition can no longer be switched on, otherwise the pressure will increase again.

Final Procedures

Install the fuse.

Erase the Diagnostic Trouble Code (DTC) memory and generate the readiness code in the Engine Control Module (ECM) in "Guided Functions".

FASTENER TIGHTENING SPECIFICATIONS

TECHNICAL DATA

DOUBLE CHECK-VALVE, CHECKING

Special tools and workshop equipment required

1. Hand Vacuum Pump VAS 6213
2. Connector Test Set V.A.G 1594C

Test Conditions

1. The Evaporative Emission (EVAP) canister purge regulator valve 1 -N80- was tested with a vehicle diagnosis tester and is OK.

Remove the engine cover carefully.

Remove the connector -1- and the ventilation hose -3- from the EVAP canister purge regulator valve 1 -2-.

Scheme 129

Set the slide ring -1- on the VAS 6213 to the -A- position for "vacuum."

Scheme 130

Connect the VAS 6213 to the EVAP canister purge regulator valve 1.

Scheme 131

Using the lines, connect the contacts on the EVAP canister purge regulator valve 1 -1- to the battery. This opens the EVAP canister purge regulator valve 1.

Then activate the VAS 6213 several times.

1. Vacuum must build up.

Disconnect the battery again (interrupt the power supply).

No Vacuum

Replace the double check-valve -1-.

The double check-valve, the EVAP canister purge regulator valve 1 and the plastic hoses are one component and can only be replaced completely.

FUEL PRESSURE AND RESIDUAL PRESSURE BEFORE HIGH PRESSURE PUMP, CHECKING

Special tools and workshop equipment required

1. Pressure Tester VAS 6550 with Hose VAS 6550/1 and VAS 6550/2
2. Measuring container, fuel-resistant

Test Conditions

1. Battery voltage at least 12.5 V.
2. Fuel filter OK.
3. Fuel tank at least 1 / 4 full.
4. Fuel Pump (FP) control module -J538- OK; checking
5. The ignition is off.

Test Sequence

Disconnect the fuel supply line -arrow- by pulling the release button.

Scheme 132

Connect the VAS 6550 to the fuel supply line with the VAS 6550/1 and VAS 6550/2.

Scheme 133

Make sure the drain valve (hose in the center) is closed and the shut-off valves (left and right) are open.

Turn the ignition on.

The fuel pump runs for approximately 5 seconds and the fuel pressure builds.

Read the fuel pressure on the VAS 6550.

1. Specified value: 4.0 to 7.0 bar

If the specification is not obtained

Check fuel pump delivery rate. Refer to DIAGNOSIS AND TESTING .

Residual Pressure, Checking

Check for leaks and for residual pressure by observing the pressure loss on the VAS 6550.

1. After 10 minutes there must be a residual pressure of at least 3 bar.

If the residual pressure drops below 3 bar

1. Check the threaded connection between the VAS 6550 and fuel supply line for leaks.
2. Check VAS 6550 for leaks.
3. Check fuel lines and their connections for leaks.
4. Replace fuel filter with integrated fuel pressure regulator. Refer to «REMOVAL AND INSTALLATION»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#fuel-supply-system-gasoline-engines) . Then repeat test.
5. If the fuel filter is OK, replace fuel pump. Refer to «REMOVAL AND INSTALLATION»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#fuel-supply-system-gasoline-engines) .

Assembly is performed in the reverse order of removal, noting the following

The ignition must be off.

Note. Open the drain valve (hose in the center) and release the fuel pressure before removing the pressure tester. Hold the hose in a measuring container while doing this.

Connect the fuel supply line -arrow- (make sure it is clean and there are no leaks).

FUEL PRESSURE SENSOR -G247-, CHECKING

Special tools and workshop equipment required

1. Assembly Tool T10118
2. Socket Wrench Insert 27 mm VAS 5301/7
3. Pressure Sensor Tester VAS 6394/1
4. Adapter VAS 6394/2
5. Test Adapter VAS 5570
6. Torque Wrench V.A.G 1331

Procedure

Remove engine cover. Refer to ENGINE COVER .

Remove the fuel pressure sensor. Refer to Fuel Pressure Sensor -G247 .

In place of the fuel pressure sensor install the VAS 6294/2 and tighten it using the tightening specification for the fuel pressure sensor.

Scheme 134

1. Tightening specifications, refer to «FUEL RAIL OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta)

Open the sealing plug -2- for the VAS 6394/1 and install the removed -G247- and tighten it.

Scheme 135

Use the VAS 5570 in order establish the electrical connection between the vehicle and the fuel pressure sensor.

Scheme 136

Connect the vehicle diagnosis tester.

Turn ignition on.

Select "engine electronics" in OBD.

Then select "Measured values" read out.

Select measured value block 140.

The current value is displayed in field 3, which the fuel pressure sensor reports to the Engine Control Module (ECM).

Turn the VAS 6394/1 on by quickly pressing button -A- one time.

Scheme 137

Note. Holding the button -A- for 2 seconds switches on the illumination for 20 seconds.

The VAS 6394/1 should display 0 bar; if this is not the case, then press button -C- one time quickly to set it back to zero.

Connect the VAS 6394/1 pressure line to the VAS 6394/2.

Start the engine.

Compare the pressure displayed on the to the actual value on the vehicle diagnosis tester.

1. The pressures may have a maximum difference of 5 bar.

If the difference is greater than 5 bar, test a new fuel pressure sensor.

Install a new fuel pressure sensor into the VAS 6394/1.

Repeat the test with the new fuel pressure sensor and compare both measured values.

If the measured value do not now match again

Check the electrical connection between the fuel pressure sensor and the ECM. Refer to appropriate SYSTEM WIRING DIAGRAM.

If the Measured Values Now Match

Install the new fuel pressure sensor. Refer to Fuel Pressure Sensor -G247 .

VACUUM SYSTEM, CHECKING

Special tools and workshop equipment required

1. Hand Vacuum Pump VAS 6213

Procedure

Check all vacuum lines in the vacuum system for

1. Cracks
2. Damage caused by animals
3. Crimps
4. Leaks

Check the vacuum line leading to and from the solenoid valve.

If there is a fault, check all the vacuum lines for the named component, but also all the vacuum lines to the other components.

If using the VAS 6213 does not produce any pressure or if the pressure drops again right away, then check the hand vacuum pump and the connection hoses for leaks.

VARIABLE INTAKE MANIFOLD, CHECKING

Only perform the test if there is a loss of torque. That means there is a reduction in engine acceleration.

Special tools and workshop equipment required

1. Hand Vacuum Pump VAS 6213

Test Conditions

1. The Intake Manifold Runner Control (IMRC) valve -N316- was tested with the vehicle diagnosis tester.

If the IMRC valve is OK, perform the following tests

Remove the engine cover carefully.

Start engine and let run at idle.

Have a 2nd person increase engine speed abruptly (press accelerator pedal). Observe the variable intake manifold vacuum actuator.

Scheme 138

1. The actuator must activate -arrow-.

If the change-over does not function as specified

Check the vacuum system for leaks.

Check whether the change-over mechanism moves easily. Do this by actuating the linkage by hand.

Check whether the vacuum lines are correctly connected.

Check that the vacuum hoses are not porous.

Remove the adjusting element vacuum hose -1- for the IMRC valve from the control valve actuator -2-.

Set the slide ring -1- on the VAS 6213 to the -A- position for "vacuum."

Connect the VAS 6213 to the IMRC valve actuator.

Scheme 139

Operate the VAS 6213 several times.

The vacuum actuator must move -arrows-.

Replace the vacuum actuator if it does not move.

WIRING AND COMPONENTS, CHECKING WITH TEST BOX 105 PIN V.A.G 1598/42

Special tools and workshop equipment required

1. Adapter Cable V.A.G 1598/39-1
2. Adapter Cable V.A.G 1598/39-2
3. Test Box 105 Pin V.A.G 1598/42
4. Connector Test Set V.A.G 1594 C
5. Voltage Tester V.A.G 1527 B
6. Portable Multimeter V.A.G 1526 C

Note. The test box has 105 terminals. The connection cable can be separated from the test box. This means that as new Engine Control Module (ECM) connectors are introduced in the future, only a new cable must be designed and no longer the entire test box. The smaller of the two connectors on the ECM is assigned with terminals 1 to 60. The larger of the two connectors is assigned with terminals 1 to 94. For testing at the 60-pin harness connection, the -V.A.G 1598/39-1- is connected to the test box with connector -A-. Components of the 60-pin harness connection, refer to appropriate SYSTEM WIRING DIAGRAM. For testing at the 94-pin harness connection, the -V.A.G 1598/39-2- is connected to the test box with connectors -A- and -B-. Components of the 94-pin harness connection, refer to appropriate SYSTEM WIRING DIAGRAM. The V.A.G 1598/42 is designed so that it can be connected simultaneously to the ECM harness and the ECM itself. This is advantageous because electronic engine control remains fully functional (for example measurement of signals with engine running) when the test box is attached. The procedures will indicate whether the ECM is to remain connected to the test box or not. Always use V.A.G 1594 C to connect measuring equipment (for example V.A.G 1527 B, V.A.G 1526 C, etc.)

The ECM must be removed to disconnect the ECM multi-pin connectors. Refer to Engine Control Module -J623 .

Connect the V.A.G 1598/42 to the wiring harness connector. Attach the ground clip on the test box to the battery negative cable. The procedures will indicate whether the ECM is to be connected to the test box.

Perform test as described in relevant repair sequences.

Installing the ECM

Install in reverse order of removal.

Thereafter, the ECM must be equipped with the metal retainer.

Clean threaded holes for shear bolts of locking compound residue. Cleaning can be performed with a thread cutter (tap).

Always use new shear bolts.

Check the Diagnostic Trouble Code (DTC) memory and erase if necessary.

AIR FILTER

Removing

Remove the bolts -arrows- from the air filter upper section.

Scheme 140

Note. Ignore items 1 through 3.

Lift the upper section of the air filter housing and remove the air filter element.

Installing

Note. Always use an original air filter. Hose connections and charge air system hoses must be free of oil and grease before installing. When installing, do not use any lubricants containing silicone. The air filter housing must be clean. Secure all hose connections using the hose clamps appropriate for the model type, Note the following when blowing out the air filter housing with pressurized air: To prevent malfunctions, cover the critical airflow components, such as the Mass Airflow (MAF) sensor, air intake tubes, etc., with a clean cloth. Observe disposal regulations!

Check the MAF sensor and intake hose (intake air side) for salt residue, dirt, and leaves.

Check the air intake hose from the air duct for dirt.

Remove the snow screen -1- and clean it.

Scheme 141

Note. The snow screen is not installed on all vehicles.

Clean the water drain -arrow- and the lower air filter section.

Scheme 142

Make sure that air filter is properly centered when placed in the mounting of the lower air filter housing section.

Set the upper section of the air filter housing onto lower section of the air filter housing, without using much force. When doing this, make sure that the upper section of the air filter housing is not placed crooked onto the air filter (observe sealing lip of air filter).

Further installation is performed in reverse order.

AIR FILTER HOUSING

Removing

Remove the bolts -arrows- from the upper air filter section.

Lift the upper section of the air filter housing and remove the air filter element.

Remove the air guide from the lock carrier to the air filter housing -2 and 3-.

Open the bolt -1-.

Carefully remove the lower air filter housing.

Installing

Remove the snow screen -1- and clean it.

Note. The snow screen is not installed on all vehicles.

Clean the water drain -arrow- and the lower air filter section.

Disconnect the water drain hose -arrow- from the lower air filter housing and clean any dirt and leaves from the connection and the hose.

Scheme 143

Make sure that air filter is properly centered when placed in the mounting of the lower air filter housing.

Set the upper section of air filter housing onto lower section of the air filter housing, without using much force. When doing this, make sure that the upper section of the air filter housing is not placed crooked onto the air filter (observe sealing lip of air filter).

Further installation is performed in reverse order.

HEATED OXYGEN SENSOR -G39- AND OXYGEN SENSOR HEATER -Z19- BEFORE CATALYTIC CONVERTER

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Disconnect electrical harness connector -1- of the Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19-.

Remove the HO2S -1- using 3337.

Installing

Note the following when installing

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with oxygen sensor slots. Hot bolt paste, Electrical wire of the oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.

1. Tightening specifications, refer to «OXYGEN SENSORS OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__oxygen-sensors-overview) .

OXYGEN SENSOR AFTER THREE WAY CATALYTIC CONVERTER -G130- AND HEATER FOR OXYGEN SENSOR 1 AFTER CATALYTIC CONVERTER -Z29

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Remove right cover from underbody.

Disconnect the electrical connector -2- on the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor (O2S) 1 after Catalytic Converter -Z29-.

Remove the O2S after TWC -2- using a tool from the 3337.

Installing

Note the following when installing

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with oxygen sensor slots. Hot bolt paste, Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.

1. Tightening specifications, refer to «OXYGEN SENSORS OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__oxygen-sensors-overview)

OXYGEN SENSOR 3 AFTER CATALYTIC CONVERTER -G287- AND HEATER FOR OXYGEN SENSOR 3 AFTER CATALYTIC CONVERTER -Z64

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Remove right cover from underbody.

Disconnect the electrical connector -1- on the Oxygen Sensor (O2S) 3 after catalytic converter -G287- and Heater for Oxygen Sensor (O2S) 3 after catalytic converter -Z64-.

Remove the O2S 3 after catalytic converter -1- using a tool from the 3337.

Installing

Note the following when installing

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with oxygen sensor slots. Hot bolt paste, Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.

1. Tightening specifications, refer to «OXYGEN SENSORS OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__oxygen-sensors-overview)

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Disconnect electrical harness connector -1- of the Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19-.

Remove the HO2S -1- using 3337.

Installing

Note the following when installing

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with oxygen sensor slots. Hot bolt paste, Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.

1. Tightening specifications, refer to «OXYGEN SENSORS OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__oxygen-sensors-overview)

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Remove right cover from underbody.

Disconnect the connector -arrow- on the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and heater for Oxygen Sensor (O2S) 1 after catalytic converter -Z29-.

Remove the O2S after TWC -1- using a tool from the 3337.

Installing

Note the following when installing

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with oxygen sensor slots. Hot bolt paste, Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.

1. Tightening specifications, refer to «OXYGEN SENSORS OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__oxygen-sensors-overview)

ENGINE CONTROL MODULE -J623

Special tools and workshop equipment required

1. Hot Air Blower VAS 1978/14A with nozzle attachment from the Wiring Harness Repair Kit VAS 1978 B
2. Commercially available pliers

Note. Some Engine Control Modules (ECMs) are not equipped with a protective housing. The removal and installation of the protective housing depends on the engine and transmission combination. The ECM -1- has a protective housing -2 and 5-. To make removing the shear bolts -4- for the retaining tabs -2- more difficult, the threads are coated with locking compound. The protective housing must be removed to disconnect the connectors from the ECM.

Removing

If the ECM was replaced, select diagnostic object "Replacing engine control module " in "Guided Functions" using a vehicle diagnostic tester.

Turn off the ignition and remove the key.

Pry off the caps on the windshield wiper arms using a screwdriver.

Loosen the nuts -arrows- by several turns.

Scheme 144

Loosen wiper arms by tilting slightly from windshield wiper axle.

Remove the nuts and remove the windshield wiper arms from the wiper axles.

Note. If the wiper arm cannot be removed in this way, use a standard puller.

Remove rubber seal -1- and remove plenum chamber cover -2-.

Scheme 145

Open the clamp -arrow- and remove the ECM.

Scheme 146

Note. Cover painted surfaces with a cloth to protect against scratches.

To increase the difficulty with which the ECM connectors can be accessed, the ECM is secured in a metal housing with retaining tabs and shear bolts.

Scheme 147

The threads of the shear bolts -4- (that are not installed in the ECM) are coated with a locking compound. For this reason, the threads must be heated with the heat gun to remove both bolts.

The threads of both shear bolts -3- (that are installed in ECM) are not coated with a locking compound. The threads in the ECM housing must not be heated and do not require to be heated (unintentional heating of the ECM).

Set the adjustment on the heat gun as shown in the illustration, with the temperature potentiometer -2- set to maximum heat and the two-stage airflow switch -3- set to level 3.

Scheme 148

Warm threads on the connector side of the shear bolts as shown in illustration.

Switch on heat gun and heat the bolt for approximately 20 to 30 seconds.

Scheme 149

Remove shear bolts with suitable locking pliers (see direction of -arrow-).

Scheme 150

The shear bolts installed in the ECM do not need to be heated for removal. They can be removed without heat.

Disconnect metal retainers from the connectors.

Remove both bolts from the ECM.

Disengage the connectors from the ECM and disconnect the connector.

Remove the used ECM and connect the new ECM.

Installing the ECM

Install in reverse order of removal.

The ECM must be installed with a housing.

Clean threaded holes for shear bolts of locking compound residue. Cleaning can be performed with a thread cutter (tap).

Always use new shear bolts.

Perform the following step after installing a new engine control module

Activate the engine control module in "Guided Functions" under "replace engine control module". Use a vehicle diagnosis tester for this.

ENGINE COVER

Removing

Remove the engine cover carefully. Do not pull the engine cover to one side or jerk it when removing it.

Installing

Carefully press the engine cover into the catch.

In order to prevent causing damage, do not hit the engine cover with your fist or tool.

FUEL INJECTORS

Removing

Remove engine cover.

Remove intake manifold and fuel rail. Refer to INTAKE MANIFOLD WITH FUEL RAIL .

Removing fuel injectors, in the event that they are stuck in the fuel rail

Carefully pull the fuel injectors out of the fuel rail.

Removing fuel injectors, in the event that they are stuck in the cylinder head

Special tools and workshop equipment required

1. Tool Set T10133
2. Puller T10133/2
3. Puller T10133/2-A
4. Removal Tool T10133/16

Note. Puller T10133/2 was changed and is now called T10133/2-A. If the new tool is not available, the old one can be modified.

Modify the T10133/2 to create the T10133/2-A.

Special tools and workshop equipment required

1. Round file approximately 6 mm

File the semicircle as shown in the illustration. The semicircle allows the tool to slide farther onto the fuel injector, thus providing the tool with a larger contact surface.

Mark the modified tool with an "A" at the end of the tool number.

Scheme 151

Scheme 152

1 - Combustion chamber sealing ring (Teflon sealing ring), replace, the ring must not be greased or handled with any other lubricants when installing.

2 - The support ring is being replaced by an intermediate ring. See next illustration (Scheme 157)

3 - Fuel injector

4 - Spacer ring, replace if damaged

5 - O-ring (replace, coat lightly with clean engine oil when installing)

6 - Support ring (via this support ring, fuel rail utilizes the force to hold the fuel injector in place in the cylinder head).

Scheme 153

1 - Intermediate ring, replacing

2 - Mount

3 - Combustion chamber sealing ring (Teflon sealing ring), replace, the ring must not be greased or handled with any other lubricants when installing.

4 - Fuel injector

5 - Spacer ring, replace if damaged

6 - O-ring (replace, coat lightly with clean engine oil when installing)

7 - Support ring (via this support ring, fuel rail utilizes the force to hold the fuel injector in place in the cylinder head).

Cover open intake channels with a clean rag.

Disconnect electrical harness connector at fuel injector that is to be removed.

Guide the T10133/2A in the groove on the fuel injector.

Scheme 154

Then position the T10133/16 and remove the fuel injector by loosening the bolt -1-.

Note. The combustion chamber seal must always be replaced before re-installing the fuel injector. Refer to TEFLON COMBUSTION CHAMBER SEAL .

TEFLON COMBUSTION CHAMBER SEAL

Special tools and workshop equipment required

1. Puller T10133/2A
2. Hammer T10133/3
3. Nylon Brush T10133/4
4. Assembly Cone T10133/5
5. Assembly Sleeve T10133/6
6. Calibration Sleeve T10133/7
7. Calibration Sleeve T10133/8

Note. The combustion chamber seal must always be replaced before re-installing the fuel injector.

Carefully remove the old Teflon® seal with the appropriate tool (for example with cut the seal open with a razor and spread the seal open with a small screwdriver and pull it forward and off.) When doing this, make sure not to damage the groove and circumferential rib in the groove base.

Note. If the groove is damage, the fuel injector must be replaced.

Before installing the new Teflon® seal, the seal groove and the shaft of the fuel injector must be cleaned of combustion residue using a clean rag.

Note. A fuel injector with "angled connector" is shown in the illustration. Do not pay attention to this for the remainder of the procedure, because it is unrelated to replacement of the combustion chamber seal.

Place the T10133/5 with the new Teflon® seal -1- onto the fuel injector -2-.

Scheme 155

Using the T10133/6, push the Teflon® seal further onto the T10133/5 until the Teflon seal is engaged in the seal groove. When doing this, do not use any lubricants.

Scheme 156

Note. By pushing the Teflon® seal onto the fuel injector, the Teflon® seal is expanded. For this reason, the Teflon® seal must be contracted again, once it has been pushed on. This is done in two steps. The procedure for this is as follows.

The 1st step of calibrating (adapting) the Teflon® seal is performed using the T10133/7.

Using a rotating motion (approximately 180°) and light pressure, push the T10133/7 over the fuel injector up to the stop. Pull the T10133/7 off again, rotating it in the opposite direction.

Scheme 157

The 2nd step of calibrating (adapting) the Teflon® seal is performed using the T10133/8.

Using a rotating motion (approximately 180°) and light pressure, push the T10133/8 over the fuel injector up to the stop. Pull the T10133/8 off again, rotating it in the opposite direction.

Scheme 158

Replace O-ring on fuel injector. Coat the O-ring with clean engine oil before installing it.

The Teflon® seal must not be oiled.

Using the T10133/4 thoroughly clean the high-pressure fuel injector bores in the cylinder head before installing the fuel injectors.

Scheme 159

Note. The Teflon® sealing ring of fuel injector may not be oiled or greased. When installing the injector valve, make sure there is no cleaning product or oil in the holes in the cylinder head.

Press the fuel injector by hand into the bore in the cylinder head (free of oil and grease) until it stops. Make sure the fuel injectors are positioned correctly in cylinder head.

Note. The fuel injector must not be difficult to install. If necessary, wait as the seal continues to pull itself together. Check fuel injectors for correct seating and installation position in cylinder head. If it is difficult to install the fuel injector by hand use the T10133/2A -2- with the T10133/3.

Further installation is in the reverse sequence to removal.

Important: The following points must always be observed

1. The Teflon sealing ring of fuel injector may not be oiled or greased.
2. When installing the injector valve, make sure there is no cleaning product or oil in the holes in the cylinder head.
3. Coat high pressure fuel injector O-rings with clean engine oil so they are easier to guide into the fuel rail.
4. Replace all seals.
5. The fuel rail should be placed on the fuel injectors and pressed on evenly.
6. Install intake manifold with fuel rail, refer to «INTAKE MANIFOLD WITH FUEL RAIL»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__intake-manifold-with-fuel-rail) .

Fuel Pressure Sensor -G247

Special tools and workshop equipment required

1. Assembly Tool T10118
2. Socket 27 mm T40218 or a commercially available 27 mm socket

Removing

Remove the upper engine cover carefully.

Loosen the coolant pipe -arrows- from the intake manifold.

Scheme 160

Disconnect the connector from the fuel pressure sensor using T10118.

Remove the fuel pressure sensor using T40218.

Installing

Install in reverse order of removal.

Check the connection tightening specification before installing the fuel pressure sensor.

1. Connection tightening specification, refer to «FUEL RAIL OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta)
2. Fuel pressure sensor tightening specification, refer to «FUEL RAIL OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta)

FUEL RAIL

Note. Intake manifold must be removed, Intake manifold, removing, refer to INTAKE MANIFOLD WITH FUEL RAIL .

Open hose clamp -1-.

Remove hoses from Evaporative Emission (EVAP) canister.

Open the fuel line on the fuel rail.

Loosen both bolts -arrows- from the fuel rail.

Scheme 161

Remove the fuel rail from the intake manifold.

Installing

Always replace both fuel supply line connections.

Tighten the fuel line.

Further installation is performed in reverse order.

Connect the electrical connector.

Install intake manifold. Refer to INTAKE MANIFOLD WITH FUEL RAIL .

HIGH PRESSURE PUMP

Removing

Note. The high pressure pump can only be removed when the engine is cold. When installing, make sure that no dirt enters the fuel system. Catch escaping fuel with a rag. The O-ring must always be replaced. Always install the fuel high pressure lines so that they are free of tension.

Remove engine cover.

Disconnect the connector -2- from the fuel pressure regulator valve -N276-.

Open both fuel lines -arrows-.

Scheme 162

Remove the 2 bolts -arrows-.

Carefully pull out the high-pressure fuel pump. The roller tappet may remain in the vacuum pump.

Installing

Replace the O-ring for the high-pressure pump.

Insert the roller tappet in the vacuum pump after checking the tappet for damage.

Note. To insert the high pressure pump, the roller tappet must be at its lowest point. If the same or a used high pressure pump is installed, replace the fuel supply line connections (high pressure side). Refer to HIGH PRESSURE PUMP OVERVIEW , see Item 11.

Rotate the crankshaft in direction of engine rotation until the roller tappet is at the lowest point.

Insert the high pressure pump in the vacuum pump.

Tighten the bolts by hand.

Replace the connections on the high pressure pump.

1. Tightening specifications, refer to «HIGH PRESSURE PUMP OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta__high-pressure-pump-overview)

Tighten the bolts crosswise with the required torque.

Tighten the fuel supply line union nut by hand. Align so it is free of stress.

1. Fuel supply line union nut tightening specification, refer to «INTAKE MANIFOLD OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta) .

Connect the electrical connector -2- from the fuel pressure regulator valve.

If the fuse was pulled, insert it again.

Note. Check fuel system for leaks.

INTAKE MANIFOLD WITH FUEL RAIL

If the fuel rail is removed or replaced, the Intake Manifold Runner Position (IMRC) sensor -G336- must be adapted to the Engine Control Module (ECM) -J623-. Use a vehicle diagnosis tester.

Special tools and workshop equipment required

1. Assembly Tool T10118
2. Hose Clip Pliers V.A.G 1921
3. Multipoint Socket T10347
4. Hazet Oil Filter Wrench 2171-1 or an Oil Filter Wrench 3417
5. Multipoint Socket T10347

Removing

Remove engine cover.

Note. To access the fuel injectors, the intake manifold and the fuel rail with the IMRC valves must be removed. The combustion chamber seal (Teflon) and the O-ring must always be replaced. Intake manifold assembly overview, refer to INTAKE MANIFOLD OVERVIEW . Fuel rail - assembly overview, refer to FUEL RAIL OVERVIEW

Disconnect the battery at the negative terminal.

Clean the contact surface from the intake manifold to the cylinder head.

Remove the air duct cover by disengaging the slide clips -arrows-.

Scheme 163

Unclip the lower air guide, disengage the clips to do so -arrows-.

Remove both the lower air guide and the air guide hose.

Scheme 164

Disconnect the connector -1- from the Mass Airflow (MAF) sensor -G70-.

Scheme 165

Open the hose clamp -2-.

Remove the bolt -4- and the air filter housing with the air intake hose.

Note. Ignore -3-.

Disconnect the vacuum line -arrow- to the Evaporative Emission (EVAP) canister.

Scheme 166

Disconnect the following electrical connectors.

1 - Intake Air Temperature (IAT) sensor -G42

2 - Evaporative Emission (EVAP) canister purge regulator valve 1 -N80

3 - Throttle valve control module -J338

Disconnect the connector -1- from the camshaft position sensor -G40-.

Remove the noise insulation by loosening the fasteners -1 and 2-.

Scheme 167

Open the air guide pipe hose clamps -2-.

Scheme 168

Disconnect electrical harness connector -arrow-.

Remove the bolts -1 and 4- and remove the air guide hose downward from the throttle valve control module.

Remove the air guide hose.

Disconnect the vacuum line -1- at the separating point -2- and remove the crankcase ventilation hose -3-.

Scheme 169

Disconnect fuel supply hose -2- by pressing release ring.

Scheme 170

Note. The fuel system must have no pressure. Use a clean rag to absorb exiting fuel.

Open the spring clamp -upper arrow- and remove the fuel supply line from the high pressure pump.

Open the high pressure fuel line union nut -lower arrow- on the high pressure pump.

Note. Seal the open connections with clean caps and make sure no dirt has entered the fuel system.

Remove the vacuum line -arrow- from the IMRC valve.

Scheme 171

Remove both coolant line bolts -arrows- from the intake manifold.

Disconnect the electronic connector from the fuel pressure sensor -G247- -1-.

Disconnect the connectors -1 and 3- and remove the connector sideways from the retainer.

Loosen the mounting nut -1- slightly and remove the bolt -2- completely.

Scheme 172

Remove the oil filter with a 2171-1 or a 3417.

Scheme 173

Open the cable bracket -arrow- and free up the cable.

Remove the intake manifold bolts using T10347.

Note. The throttle valve control module -J338- must be removed in order to remove any bolts that are not accessible and not using the T10347

Carefully pull the intake manifold with fuel rail away from the cylinder head slightly.

Disconnect the connector -1- from the IMRC sensor and remove the intake manifold.

Note. The fuel injectors could remain stuck in the fuel rail. Seal the intake channels with a clean cloth.

Disconnect the intake manifold from the fuel rail. Refer to FUEL RAIL .

Installing

Mount the intake manifold onto the cylinder head on the stud bolts (lower left and right).

Note. Make sure the fuel injectors are installed correctly.

Further installation is performed in reverse order.

1. Tightening specifications, refer to «INTAKE MANIFOLD OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta) .
2. Tightening specifications, refer to «FUEL RAIL OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta)

MASS AIRFLOW SENSOR -G70

Disconnect electrical connector -1- on Mass Airflow (MAF) sensor -G70-.

Remove both bolts from the MAF sensor and carefully remove the MAF sensor from the air filter housing guide.

Installing

For problem-free operation of the MAF sensor it is very important to observe the following notes and procedures.

Note. If the air filter is very dirty or soaked, dirt particles or moisture may have contaminated the MAF sensor and may be causing false mass airflow values. This results in a reduction of power, since a lower injection quantity is calculated. Always use an original air filter. Use a lubricant (silicone-free) for installing the intake hose. Secure all hose connections using hose clamps appropriate for the model type

Check the MAF sensor and intake hose (intake air side) for salt residue, dirt, and leaves.

Check the intake channels up to the air filter for dirt. If any contaminants are discovered, clean the air filter housing (upper and lower sections) of salt residue, dirt and leaves (if necessary, clean by washing or vacuuming). Air filter, removing and installing, refer to AIR FILTER .

Further installation is performed in reverse order.

THROTTLE VALVE CONTROL MODULE -J338

Removing

Remove engine cover.

Remove noise insulation.

Loosen the screw-type clamps -upper arrows-, remove the screws -lower arrows- and remove the charge air pipe and hose downward.

Scheme 174

Disconnect the electrical connector -1- from the throttle valve control module.

Remove the four bolts -arrows- on the throttle valve control module and then remove the throttle valve control module.

Scheme 175

Installing

Install in reverse order of removal.

Clean the sealing ring surface.

Replace seal.

1. Tightening specifications, refer to «INTAKE MANIFOLD OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta) .

After replacing the throttle valve control module, it must be adapted to the Engine Control Module (ECM) -J623-. Use a vehicle diagnosis tester.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

1. Ring Spanner 7-Piece Set 3337
2. Assembly Tool T10118
3. Tool Set T10133
4. Multipoint Socket T10347
5. Ignition Coil Puller T40039
6. Socket 27 mm T40218 or a commercially available 27 mm socket
7. Hose Clip Pliers V.A.G 1921
8. Adapter Cable V.A.G 1598/39-1
9. Adapter Cable V.A.G 1598/39-2
10. Test Box V.A.G 1598/42
11. Hot Air Blower VAS 1978/14A -1- with Nozzle Attachment -2- from the Wiring Harness Repair Set VAS 1978 B
12. Hand Vacuum Pump VAS 6213
13. Pressure Tester VAS 6550 with Hose VAS 6550/1 and VAS 6550/2
14. Commercially Available Pliers -3
15. Not Illustrated
16. Hazet Oil Filter Wrench 2171-1 or an Oil Filter Wrench 3417
17. Special Hook 3370
18. Removal Tool T10133/16
19. Torque Wrench 5-50 Nm V.A.G 1331
20. Portable Multimeter V.A.G 1526 C
21. Voltage Tester V.A.G 1527 B
22. Connector Test Set V.A.G 1594C
23. Double Hexagon Socket, 1/2", 27 mm VAS 5301/7
24. Test Instrument Adapter/DSO (3-pin) VAS 5570
25. Pressure Sensor Tester VAS 6394/1
26. Adapter VAS 6394/2
27. Ultrasonic Cleaning Unit VAS 6418
28. Injection Module Mounting Plate VAS 6418/1

See also:
• REMOVAL AND INSTALLATION
• IGNITION COILS WITH POWER OUTPUT STAGES
• Knock Sensor 1 -G61
• DESCRIPTION AND OPERATION
• Removal and Installation
• REMOVAL AND INSTALLATION
• REMOVAL AND INSTALLATION
• REMOVAL AND INSTALLATION
• REMOVAL AND INSTALLATION
• RELEASING PRESSURE IN HIGH PRESSURE AREA
• FUEL INJECTORS
• TEFLON COMBUSTION CHAMBER SEAL
• TEST AND MEASURING INSTRUMENTS DURING TEST DRIVE
• Throttle Valve Control Module -J338
• Mass Airflow Sensor -G70
• AIR FILTER
• Engine Control Module -J623
• HIGH PRESSURE PUMP
• Fuel Pressure Sensor -G247
• OXYGEN SENSORS OVERVIEW
• INTAKE MANIFOLD WITH FUEL RAIL
• FUEL RAIL
• DOUBLE CHECK-VALVE, CHECKING
• Heated Oxygen Sensor -G39- AND Oxygen Sensor Heater -Z19- BEFORE CATALYTIC CONVERTER
• Heated Oxygen Sensor -G39- AND Oxygen Sensor Heater -Z19- BEFORE CATALYTIC CONVERTER
• Oxygen Sensor after Three Way Catalytic Converter -G130- AND Heater for Oxygen Sensor 1 after Catalytic Converter -Z29
• Oxygen Sensor 3 after Catalytic Converter -G287- AND Heater for Oxygen Sensor 3 after Catalytic Converter -Z64
• ENGINE COVER
• HIGH PRESSURE PUMP OVERVIEW