2.0l - Multiport Fuel Injection - Engine Code(s): Bpy Audi A3 8P рестайлинг

SAFETY PRECAUTIONS

Observe the following if test and measuring instruments are required during a test drive

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

Scheme 90

1. For safety reasons, if the battery is not disconnected, fuse SC 27 from the fuel pump control module -J538- must be removed before opening the fuel system, otherwise the fuel pump will be activated by the driver's door contact switch.
2. Individuals with a pacemaker must not stay in the danger area of high voltage systems, for example ignition systems, xenon light.
3. Fuel lines must not be opened when engine is running.
4. Only disconnect and reconnect wires for injection and ignition system, including test leads, when ignition is switched off.
5. 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.
6. It is possible that the control module will recognize a malfunction and store a DTC during some tests. Therefore after completing all checks and repairs the DTC memory must be checked and if necessary erased.
7. If the DTC memory was erased, the readiness code must be newly generated.
8. Cleaning the engine should only be performed with ignition switched off.
9. The battery must only be disconnected and connected with the ignition switched off, since the engine control module (ECM) can otherwise be damaged.
10. 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. Refer to «IGNITION COILS WITH POWER OUTPUT STAGES»(/audi/a3/8p-2004-2008/remont/ignition-system/#20l-ignitionglow-plug-system-engine-codes-bpy__ignition-coils-with-power-output-stages) . Also remove fuse SC 27 from fuel pump control module -J538-.

Note. By removing fuse SC 27, the voltage supply to terminal 30 for the fuel pump control module is interrupted.

CLEAN WORKING CONDITIONS

When working on the fuel supply/injection system, pay careful attention to the following 6 rules of cleanliness

1. Thoroughly clean all connections and the surrounding area before disconnecting.
2. Place parts that have been removed on a clean surface and cover them. Use lint-free cloths.
3. Carefully cover over opened components or seal, if repairs are not performed immediately.
4. Install only clean parts: remove the replacement parts from their packaging just before installing them. Do not use parts that have been stored unpacked (for example in Tools boxes etc.).
5. When the system is open: do not work with compressed air. Do not move vehicle.
6. Disconnected connectors: protect against dirt and moisture. Connect only when dry.

BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM

High Fuel Pressure, Reducing

Connect vehicle diagnosis, testing & info. system VAS 5051B.

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 at 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 special hook 3370 -arrow-.

Scheme 91

With the engine at idle, pull the fuse -SC 27- in the fuse holder in the driver side instrument panel from the fuel pump control module -J538-.

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-.

Switch 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.

Perform the following steps are completing all work

Install the fuse.

Erase the DTC memory and, using guided fault finding, generate the readiness code in the engine control module vehicle diagnosis, testing and information system VAS 5051B.

ON BOARD DIAGNOSTICS

1. The engine control module is equipped with On Board Diagnostics (OBD). Before repairs such as fault finding, check the 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 Set up also makes it easier to start the engine. When the driver-side door is opened, the Fuel Pump (FP) is activated for 2 seconds so that pressure builds in the fuel system, observe safety measures. Refer to «SAFETY PRECAUTIONS»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__safety-precautions) .

COMPONENT LOCATIONS OVERVIEW

Components A through N are not depicted in the exploded view illustration.

Scheme 92

1. 1 - Wastegate Bypass Regulator Valve -N75- Installed directly on turbocharger «TURBO CHARGER COMPONENTS»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)
2. 2 - Turbocharger Recirculating Valve -N249- Installed directly on turbocharger «TURBO CHARGER COMPONENTS»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)
3. 3 - Engine Control Module -J623 Removing and installing, refer to «ENGINE CONTROL MODULE»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__engine-control-module)
4. 4 - Ignition Coils with Power Output Stages Removing and installing, refer to «IGNITION COILS WITH POWER OUTPUT STAGES»(/audi/a3/8p-2004-2008/remont/ignition-system/#20l-ignitionglow-plug-system-engine-codes-bpy__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. 5 - Heated Oxygen Sensor -G39- and Oxygen Sensor Heater -Z19- Component location «HEATED OXYGEN SENSOR (HO2S) -G39- -ARROW»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy) Removing and installing, refer to «HEATED OXYGEN SENSOR AND OXYGEN SENSOR HEATER BEFORE CATALYTIC CONVERTER»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__heated-oxygen-sensor-and-oxygen-sensor)
6. 6 - Low Fuel Pressure Sensor -G410- -35 °C (-95 °F)
7. 7 - Fuel Pressure Regulator Valve -N276
8. 8 - Camshaft Adjustment Valve 1 -N205- Removing and installing, refer to «Removal and Installation»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy)
9. 9 - Engine Coolant Temperature Sensor -G62- Component location «ENGINE COOLANT TEMPERATURE SENSOR -G62- -1»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)
10. 10 - 6-Pin Harness Connector For heated oxygen sensor -G39- and oxygen sensor heater -Z19- (black) «ELECTRICAL HARNESS CONNECTOR»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)
11. 11 - Single Piston High Pressure Pump Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__high-pressure-pump)
12. 12 - Component Not Installed
13. 13 - Intake Flap Motor -V157- with Intake Manifold Runner Position Sensor -G336- The intake manifold runner position sensor -G336- must be adapted to the engine control module -J623- after removing or replacing the fuel rail vehicle diagnosis, testing and information system VAS 5052 guided functions.
14. 14 - EVAP Canister Purge Regulator Valve 1 -N80
15. 15 - Connector For camshaft position sensor -G40- and fuel pressure sensor -G247- Component location «COMPONENT LOCATIONS BENEATH INTAKE MANIFOLD»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)
16. 16 - Charge Air Pressure Sensor -G31- Component location «CHARGE AIR PRESSURE SENSOR -G31- -1»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)
17. 17 - Engine Speed Sensor -G28- Component location «ELECTRICAL HARNESS CONNECTORS»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)
18. 18 - 8-Pin Harness Connector for Fuel Injectors Component location «COMPONENT LOCATIONS BENEATH INTAKE MANIFOLD»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)
19. 19 - Throttle Valve Control Module -J338-, EPC Throttle Drive -G186- EPC throttle drive angle sensor 1 -G187- and EPC throttle drive angle sensor 2 -G188- After the replacing the throttle valve control module -J338-, it must be adapted to the engine control module -J623- (basic Set ting, display group 60) see vehicle diagnosis and service system VAS 5052 Guided Functions.
20. 20 - Intake Air Temperature Sensor -G42- 11 Nm
21. 21 - Fuel Pressure Sensor -G247- 22 Nm Component location «FUEL PRESSURE SENSOR -G247- -1»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy) Removing and installing, refer to «FUEL PRESSURE SENSOR»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__fuel-pressure-sensor)
22. 22 - Camshaft Position (CMP) Sensor -G40- Electrical harness connector «CAMSHAFT POSITION SENSOR -G40- -1»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)
23. A - Data Link Connector (DLC) In knee bolster on driver's side
24. B - Mass Air Flow Sensor -G70- In upper section of air filter «MASS AIR FLOW SENSOR -G70- -1»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy) Removing and installing, refer to «MASS AIR FLOW SENSOR»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__mass-air-flow-sensor)
25. C - Knock Sensor 1 -G61- For cylinder 1 and 2 20 Nm Component location «COMPONENT LOCATIONS BENEATH INTAKE MANIFOLD»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy) 3-pin connector for knock sensor I -G61- «ELECTRICAL HARNESS CONNECTORS»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy) Removing and installing, refer to «KNOCK SENSOR 1»(/audi/a3/8p-2004-2008/remont/ignition-system/#20l-ignitionglow-plug-system-engine-codes-bpy__knock-sensor-1)
26. D - Knock Sensor 2 -G66- For cylinder 3 and 4 20 Nm Component location «COMPONENT LOCATIONS BENEATH INTAKE MANIFOLD»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy) Knock sensor 2 -G66- 3-pin connector «ELECTRICAL HARNESS CONNECTORS»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy) Removing and installing, refer to «KNOCK SENSOR 1»(/audi/a3/8p-2004-2008/remont/ignition-system/#20l-ignitionglow-plug-system-engine-codes-bpy__knock-sensor-1)
27. E - Fuel Pump Control Module -J538- Component location «FUEL PUMP (FP) CONTROL MODULE -J538- -1»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy) If fuel pump control module -J538- is replaced, then perform an adaptation. Refer to «DIAGNOSIS AND TESTING»(/audi/a3/8p-2004-2008/remont/fuel-system/#fuel-supply-system-gasoline-engines) .
28. F - Oxygen Sensor after Three Way Catalytic Converter -G130- and Heater for Oxygen Sensor 1 after Catalytic Converter -Z29- Component location «OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy) Removing and installing, refer to «OXYGEN SENSOR AFTER THREE WAY CATALYTIC CONVERTER AND OXYGEN SENSOR 1 HEATER»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__oxygen-sensor-after-three-way-catalytic)
29. G - Brake Light Switch - F- and Brake Pedal Switch -F63- Component location «PEDAL BRACKET»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__pedal-bracket)
30. H - Accelerator Pedal Position Sensor -G79- and Accelerator Pedal Position Sensor 2 -G185- On accelerator pedal (both sensors are stored in one housing) Component location «INSTALLATION LOCATION ACCELERATOR PEDAL POSITION SENSOR -G79- AND ACCELERATOR PEDAL POSITION SENSOR 2 -G185- (IN DRIVER FOOTWELL)»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)
31. I - Clutch Position Sensor -G476- Only for vehicles with manual transmission Component location «CONNECTOR»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy) Removing and installing, see transmission - clutch, refer to «[For transmission(s) 02Q] Removal and Installation»(/audi/a3/8p-2004-2008/remont/clutches-manual-hydraulic/#clutch-manual-transmission-02q-fwd)
32. J - Relay and Fuse Carrier in E-box For routing, see appropriate SYSTEM WIRING DIAGRAMS information
33. K - Coolant Fan Control Module -J293- Installed on left radiator fan (in direction of travel) Component location «COOLANT FAN CONTROL MODULE -J293»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)
34. L - Fuel Injector In fuel rail pipe Removing and installing, refer to «FUEL INJECTORS»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__fuel-injectors) Cylinder 1 Fuel Injector -N30- Cylinder 2 Fuel Injector -N31- Cylinder 3 Fuel Injector -N32- Cylinder 4 Fuel Injector -N33- Fuel injectors referred to here are high pressure fuel injectors. They inject fuel directly into the cylinder under high pressure (max. approximately 120 bar).
35. M - Oil Pressure Switch -F1- Component location «ELECTRICAL HARNESS CONNECTORS»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)
36. N - Engine Coolant Temperature Sensor on Radiator -G83- Component location «ENGINE COOLANT TEMPERATURE SENSOR ON RADIATOR -G83- -ARROW»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)

Scheme 93

Scheme 94

Scheme 95

1. Tightening specifications of connection 30 Nm must be checked before installing Fuel Pressure Sensor -G247-.

Scheme 96

Scheme 97

1. If fuel pump control module is replaced, an adaptation must be performed. Basic Set ting, measuring value block 103, refer to «DIAGNOSIS AND TESTING»(/audi/a3/8p-2004-2008/remont/fuel-system/#fuel-supply-system-gasoline-engines)

Scheme 98

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

Scheme 99

Scheme 100

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

Scheme 101

Oxygen Sensor after Three Way Catalytic Converter -G130- and Heater for Oxygen Sensor 1 after Catalytic Converter -Z29- -arrow- on right of vehicle floor

Scheme 102

Scheme 103

Scheme 104

4 - Clutch Position Sensor -G476

Pedal Bracket

Brake light switch -F- and brake pedal switch -F63- -arrow

Scheme 105

Scheme 106

Scheme 107

1 - 3-pin harness connector (green) for knock sensor (KS) 1 -G61

2 - 3-pin harness connector (brown) for knock sensor (KS) 2 -G66

3 - Oil pressure switch -F1

4 - Engine speed sensor -G28

5 - 3-pin connector (gray) for engine speed sensor

Scheme 108

1 - Knock Sensor 1 -G61

2 - Knock Sensor 2 -G66

3 - Oil Pressure Sensor -G10

4 - 3-pin harness connector (brown) for knock sensor 2 -G66

5 - 3-pin connector (gray) for engine speed sensor -G28

6 - Electrical connector for camshaft position sensor -G40- and fuel pressure sensor -G247

7 - 8-pin harness connector for fuel injectors

Scheme 109

Scheme 110

1 - Coolant fan control module, connector

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

Scheme 111

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 (note the installation position)

Note. Note the Installed Position of the Turbocharger Recirculating Valve -N249

Scheme 112

1. Mass Air Flow Sensor -G70- Replace the seal «MASS AIRFLOW SENSOR -G70- -1- SEAL -2- INSTALLED POSITION»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy) . Removing and installing, refer to «MASS AIR FLOW SENSOR»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__mass-air-flow-sensor)
2. Bolt 3 Nm
3. Air Filter Housing/Engine Cover Upper Section Clean the air filter housing-upper section of salt residue, dirt and leaves Follow the removing instructions exactly (the engine cover could break) Removing and installing, refer to «ENGINE COVER WITH AIR FILTER ELEMENT»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__engine-cover-with-air-filter-element)
4. Spring-Type Clip
5. Intake Air Guide To air filter housing Clean dirt and leaves from intake air guide
6. Filter Element Always use an Original air filter Removing and installing, refer to «ENGINE COVER WITH AIR FILTER ELEMENT»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__engine-cover-with-air-filter-element) Observe change intervals, refer to «03 MAINTENANCE, DIAGNOSIS»(/audi/a3/8p-2004-2008/remont/procedures/#how-to-diagnosis-the-maintenance-maintenance-procedures)
7. Air Filter Housing Lower Section Clean the air filter housing-lower section of salt residue, dirt and leaves
8. Bolt 3 Nm
9. Heat Shield
10. Rubber Boot Note installation marking
11. Air Guide Hose Note installation marking To turbocharger Check the air duct hose for dirt and leaves

Scheme 113

The smooth side of the seal must contact the mass airflow sensor (see the magnifying glass).

Scheme 114

1. 1 - Bolt for Intake Air Temperature Sensor -G42- 5 Nm
2. 2 - Intake Air Temperature Sensor -G42
3. 3 - Intake Manifold Removing and installing, refer to «INTAKE MANIFOLD WITH FUEL RAIL»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__intake-manifold-with-fuel-rail)
4. 4 - EVAP Canister Purge Regulator Valve 1 -N80
5. 5 - Bolt for Single-Piston High-Pressure Pump 10 Nm 3 pieces
6. 6 - Fuel Pressure Regulator Valve -N276
7. 7 - High Pressure Pump With fuel pressure regulator valve -N276- and low fuel pressure sensor -G410- An electrical fuel pump, located in the fuel tank, supplies fuel to the mechanical high-pressure pump at a pressure of approximately 6 bar When installing the high-pressure pump, make sure that no dirt enters the fuel system. The fuel system must be pressureless, releasing fuel pressure, refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__before-opening-high-pressure-fuel-injection) Do not install fuel lines with tension Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__high-pressure-pump)
8. 8 - Connection for Fuel Return Line to Fuel Tank There are high pressure pumps with threaded connection and with threaded connection Replace bolt for fuel return flow Tighten connection to 40 Nm (before each installation of the fuel line, check the torque of the connection) Do not install fuel line with tension (be aware of cleanliness) Tightening specification: 25 Nm
9. 9 - Fuel Supply Line to Fuel Rail Tighten connection to 30 Nm (before each installation of the fuel line, check the torque of the connection) Do not install the fuel line with tension and make sure it is clean. Tightening specification: 30 Nm
10. 10 - Intake Flap Motor -V157- with Intake Manifold Runner Position Sensor -G336- The intake manifold runner position sensor -G336- must be adapted to the engine control module -J623- after removing or replacing the fuel rail vehicle diagnosis, testing and information system VAS 5052 guided function. Removing and installing, refer to «INTAKE FLAP MOTOR WITH INTAKE MANIFOLD RUNNER POSITION SENSOR»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__intake-flap-motor-with-intake-manifold)
11. 11 - Bolt for Intake Flap Motor -V157- with Intake Manifold Runner Position Sensor -G336- 7 Nm 3 pieces
12. 12 - Intake Manifold Support
13. 13 - Bolt for the Intake Manifold Support 23 Nm
14. 14 - Throttle Valve Control Module -J338-, EPC Throttle Drive -G186-, EPC throttle drive angle sensor 1 -G187- and EPC throttle drive angle sensor 2 -G188- After the replacing the throttle valve control module -J338-, it must be adapted to the engine control module -J623- (basic Set ting, display group 60) see vehicle diagnosis and service system VAS 5052 guided functions.
15. 15 - Bolt for the Throttle Valve Control Module -J338- 7 Nm 4 pieces
16. 16 - Nut for the Intake Manifold Support 10 Nm
17. 17 - Seal Replace
18. 18 - Fuel Rail Removing and installing, refer to «FUEL RAIL»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__fuel-rail)
19. 19 - Fuel Pressure Sensor -G247- 20 Nm

Scheme 115

1. 1 - Radial Adjustment Replace if damaged
2. 2 - Fuel Injector With combustion chamber seal (Teflon seal), always replace Replace O-rings Note correct installation position Removing and installing, refer to «TEFLON COMBUSTION CHAMBER SEAL»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__teflon-combustion-chamber-seal)
3. 3 - Support Ring
4. 4 - Fuel Rail Removing and installing, refer to «FUEL RAIL»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__fuel-rail)
5. 5 - Fuel Pressure Sensor -G247- 22 Nm Tighten connections to 30 Nm
6. 6 - Low Fuel Pressure Sensor -G410
7. 7 - Fuel Pressure Regulator Valve -N276
8. 8 - Mechanical Single-Piston High-Pressure Pump With fuel pressure regulator valve -N276- and low fuel pressure sensor -G410- An electrical fuel pump, located in the fuel tank, supplies fuel to the mechanical high-pressure pump at a pressure of approximately 6 bar. When installing the high-pressure pump, make sure that no dirt enters the fuel system. The fuel system must be pressureless to install the high-pressure pump, releasing fuel pressure, refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__before-opening-high-pressure-fuel-injection) Do not install fuel lines with tension Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__high-pressure-pump)
9. 9 - EVAP Canister Purge Regulator Valve 1 -N80
10. 10 - Throttle Valve Control Module -J338-, EPC throttle drive -G186-, EPC throttle drive angle sensor 1 -G187- and EPC throttle drive angle sensor 2 -G188- After the replacing the throttle valve control module -J338-, it must be adapted to the engine control module -J623- (basic Set ting, display group 60) see vehicle diagnosis and service system VAS 5052 A guided functions. Removing and installing, refer to «THROTTLE VALVE CONTROL MODULE»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__throttle-valve-control-module)
11. 11 - Intake Air Temperature Sensor -G42- 5 Nm
12. 12 - Bolts for Intake Manifold 9 Nm
13. 13 - Intake Manifold Removing and installing, refer to «INTAKE MANIFOLD WITH FUEL RAIL»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__intake-manifold-with-fuel-rail)

HIGH PRESSURE PUMP ASSEMBLY OVERVIEW

Scheme 116

1. 1 - Channel Separating Plate Removable Check for damages and correct positioning
2. 2 - Valve Lifter Remains inserted in the vacuum pump after removing the high-pressure pump, removable
3. 3 - O-ring Replace
4. 4 - High Pressure Pump An electrical fuel pump, located in the fuel tank, supplies fuel to the mechanical high-pressure pump at a pressure of approximately 6 bar. When installing the high-pressure pump, make sure that no dirt enters the fuel system. The fuel system must be pressureless, releasing fuel pressure, refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__before-opening-high-pressure-fuel-injection) Do not install fuel lines with tension Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__high-pressure-pump)
5. 5 - Fuel Pressure Regulator Valve -N276
6. 6 - Low Fuel Pressure Sensor -G410- 15 Nm
7. 7 - Bolts for High-Pressure Pump 10 Nm
8. 8 - Connection for Fuel Return Line to Fuel Tank There is also high pressure pumps with a hose connection When replacing threaded supports, always leave old sealing ring in pump. It is pinched during initial assembly by the supplier and cannot be removed. The threaded support has a biting edge for sealing for this purpose. Replace the banjo bolt for the fuel return Tighten connection to 40 Nm (before each installation of the fuel line, check the torque of the connection) Do not install fuel return line with tension (be aware of cleanliness) Torque specification: 17 Nm
9. 9 - Connection for the Fuel Supply Line to the Fuel Rail Tighten connection to 30 Nm (before each installation of the fuel line, check the torque of the connection) Do not install fuel line with tension (ensure cleanliness), tightening specifications: 27 Nm
10. 10 - Opening in the Vacuum Pump for the High Pressure Pump
11. 11 - Fuel Injector Replace O-rings Note correct installation position Removing and installing, refer to «TEFLON COMBUSTION CHAMBER SEAL»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__teflon-combustion-chamber-seal)

OXYGEN SENSORS ASSEMBLY OVERVIEW

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 sensor slots. 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

Heated oxygen sensor -G39- and oxygen sensor heater -Z19-, Removing and Installing. Refer to HEATED OXYGEN SENSOR AND OXYGEN SENSOR HEATER BEFORE CATALYTIC CONVERTER .

Oxygen sensor after three way catalytic converter -G130- and heater for oxygen sensor 1 after catalytic converter -Z29-, removing and installing. Refer to OXYGEN SENSOR AFTER THREE WAY CATALYTIC CONVERTER AND OXYGEN SENSOR 1 HEATER .

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 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 117

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 .

THROTTLE VALVE CONTROL MODULE, CLEANING

Note. If a new engine control module -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 throttle valve control module -J338-. Refer to THROTTLE VALVE CONTROL MODULE .

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

Scheme 118

Clean the throttle valve thoroughly, especially around the area -arrows- of the closed throttle, with acetone which conforms to DIN 53247 and a brush.

Scheme 119

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 engine control module to the throttle valve control module vehicle diagnosis, testing and information system VAS 5052 guided functions.

TECHNICAL DATA

FASTENER TIGHTENING SPECIFICATIONS

FUEL PRESSURE AND RESIDUAL PRESSURE BEFORE HIGH PRESSURE PUMP, CHECKING

Special Tools And Workshop Equipment Required

1. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
2. Adapter V.A.G 1318/11
3. Adapter V.A.G 1318/17-1 from Adapter Kit V.A.G 1318/17
4. Double Connection V.A.G 1318/23
5. Remote Control V.A.G 1348/3 A with Adapter Cable V.A.G 1348/3-3
6. Connector Test Set V.A.G 1594 C or V.A.G 1594 A
7. Measuring container, fuel-resistant

Test Conditions

1. Battery voltage at least 12.5 Volts.
2. Fuel filter OK.
3. Fuel tank at least 1 / 4 full.
4. Fuel Pump (FP) Control Module -J538- OK; checking
5. Ignition switched off.

Test Sequence

Remove rear seat bench. Refer to Removal and Installation .

Unclip the retainers -arrows- of the cover for sealing flange.

Scheme 120

Disconnect electrical harness connector -arrow- at locking flange.

Scheme 121

Connect V.A.G 1348/3 A with V.A.G 1348/3-3 to contact -1- using an adapter cable from the V.A.G 1594 C.

Scheme 122

Using insulating tape, tape over the second contact of V.A.G 1348/3-3 to prevent a short circuit -arrow-.

Connect contact -5- to vehicle ground (GND) using a jumper cable from the V.A.G 1594 C.

Connect alligator clip to vehicle battery positive.

Remove fuel filler cap from fuel filler tube.

Pull the release button to disconnect the fuel supply line -3-.

Scheme 123

Note. If equipped, the fuel return line -2- and the vacuum line -1- remain connected.

Connect the V.A.G 1318 with the adapter on the connection for the fuel supply line.

Scheme 124

Place the hose -arrow- into a measuring container.

Open the shut-off valve on the V.A.G 1318. The lever points in the direction of flow.

Bleed fuel system by pressing remote control briefly.

Close shut-off valve on V.A.G 1318. Lever stands perpendicular to direction of flow -arrow-.

Scheme 125

Note. The V.A.G 1318 shut-off tap must be on the side of the measuring container.

Hold the switch of the remote control until no more pressure increase is observed on the V.A.G 1318.

1. Specified value: approximately 6 bar (4 to 8 bar)

If the specification is not obtained

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

Residual Pressure, Checking

Check for leaks and residual pressure by observing pressure drop on V.A.G 1318.

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 connection between the V.A.G 1318 and the fuel supply line for leaks.
2. Check the V.A.G 1318 for leaks.
3. Check fuel lines and their connections for leaks.
4. Replace fuel filter with integrated fuel pressure regulator «REMOVAL AND INSTALLATION»(/audi/a3/8p-2004-2008/remont/fuel-system/#fuel-supply-system-gasoline-engines) . Then repeat test.
5. If the fuel filter is OK, replace fuel pump «Removal and Installation»(/audi/a3/8p-2004-2008/remont/fuel-system/#fuel-supply-system-gasoline-engines) .

Assembly is in reverse order of removal, note the following

Ignition must be switched off.

Note. Before disconnecting pressure gauge, release pressure by opening shut-off valve. Hold assisting hose in a container when doing so.

Install the fuel supply line again (check for cleanliness).

LOWER FUEL PRESSURE, CHECKING WITH HIGH PRESSURE PUMP

Note. Fuel pump (FP) control module OK Fuel Pump (FP) OK Fuel filter OK Battery voltage at least 11 Volts

Turn on the ignition.

Connect the vehicle diagnosis and service system VAS 5052 and select the engine control module.

Select engine electronics in OBD.

Then select measured values read out.

Select measured value block 103.

During ignition, the fuel low pressure is displayed in field 1.

Note. By switching the ignition off and on the fuel pump control module -J538- activates the fuel pump for several seconds.

Measure fuel pressure.

1. Specified value: approximately 6 bar (5 to 8 bar)

If the specified value is not attained, check the delivery rate of the electrical fuel pump, refer to DIAGNOSIS AND TESTING

Check fuel pressure and residual pressure with fuel inj. pressure gauge-CIS V.A.G 1318. Refer to FUEL PRESSURE AND RESIDUAL PRESSURE BEFORE HIGH PRESSURE PUMP, CHECKING .

WIRING AND COMPONENTS, CHECKING WITH TEST BOX VAG 1598/42

Special Tools And Workshop Equipment Required

1. Adapter - V.A.G 1598/39-1
2. Adapter - V.A.G 1598/39-2
3. Test Box 105 Pin - V.A.G 1598/42

Note. The test box is designed with 105 pins. 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 the appropriate SYSTEM WIRING DIAGRAMS information. 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 the appropriate SYSTEM WIRING DIAGRAMS information. The V.A.G 1598/42 is designed so that it can be connected simultaneously to the engine control module harness and the engine control module 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. Always use connector test Set V.A.G 1594 C to connect measuring equipment (for example voltage tester V.A.G 1527 B, portable multimeter V.A.G 1526 C, etc.) The procedures will indicate whether the engine control module is to remain connected to the test box or not.

The engine control module (ECM) must be removed to disconnect the ECM multi-pin connectors. Refer to ENGINE CONTROL MODULE .

Connect V.A.G 1598/42 to wiring harness connector. Ground (GND) clip at test box must be clipped to battery minus. The procedures will indicate whether the engine control module is to be connected to the test box.

Perform test as described in relevant repair sequences.

Installing engine control module

Install in reverse order of removal.

Thereafter, the engine control module 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 DTC memory and, if necessary, erase.

ENGINE COVER WITH AIR FILTER ELEMENT

The air filter element is integrated into the engine cover.

Remove Engine Cover

Disconnect electrical harness connector -3- at mass air flow sensor -G70-.

Open clips -1 and 2- and remove air guide hose from mass airflow sensor.

Scheme 126

Open the spring clamp -4- and remove the air intake hose from the engine cover.

Carefully pull the engine cover off at locations -1 - 2 - 3 - 4-, one after the other, otherwise the engine cover could break.

Scheme 127

Cover the open intake hose with a clean rag.

Air Filter Element, Removing

Remove all bolts -arrows-.

Scheme 128

Separate the engine cover, paying attention to the retainer -arrows-.

Scheme 129

Pull the air filter element out of the engine cover.

Scheme 130

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 hose clamps of series-production status. Note the following when cleaning the air filter housing with pressurized air: To prevent malfunctions, cover the critical air flow components, such as the mass air flow sensor, air intake pipes, 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.

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

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

Make sure the intake hose is securely seated on MAF sensor.

Further installation is in reverse order.

MASS AIR FLOW SENSOR

Disconnect electrical harness connector -3- at mass air flow sensor -G70-.

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

Installing

For problem-free operation of the mass airflow sensor -G70- it is very important to observe the following notes and procedures.

The smooth side of the seal must contact the mass airflow sensor (see the magnifying glass).

Note. If the air filter is very dirty or soaked, dirt particles or moisture may have contaminated the mass airflow 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 of series-production status.

Replace the seal for the mass airflow sensor. Make sure it is installed correctly otherwise the air could get in.

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 ENGINE COVER WITH AIR FILTER ELEMENT

Further installation is performed in reverse order.

INTAKE MANIFOLD WITH FUEL RAIL

The intake manifold runner position sensor -G336- must be adapted to the engine control module -J623- after removing or replacing the fuel rail vehicle diagnosis, testing and information system VAS 5052 guided function.

Note. To access the fuel injectors, the intake manifold and the fuel rail with intake manifold runner control valve must be removed. (Depending on version, more or fewer work steps may be required). The combustion chamber seal (Teflon) and the O-ring must always be replaced. Intake Manifold Assembly Overview. Refer to INTAKE MANIFOLD ASSEMBLY OVERVIEW . Fuel Rail, Assembly Overview. Refer to FUEL RAIL ASSEMBLY OVERVIEW

Removing

Remove engine cover. Refer to ENGINE COVER WITH AIR FILTER ELEMENT .

Disconnect all electrical harness connectors necessary.

Disconnect vacuum hose between intake manifold and vacuum pump from intake manifold.

Note. This vacuum hose and the vacuum pump (attached to rear of cylinder head) are only installed on vehicles with automatic transmission. Disregard items 1 and 2 in the illustration.

Disconnect hose connections -arrows- from valve cover.

Scheme 131

Note. The fuel system must have no pressure.

Pull the release button to disconnect the fuel supply line -2-.

Scheme 132

Pull the release button to disconnect the fuel return line -3-.

Open both fuel lines at high-pressure pump.

Disconnect electrical connector -1- from fuel pressure sensor -G247-.

Scheme 133

Remove bolt -left arrow- for water line from intake manifold.

Scheme 134

Remove the oil dipstick and remove the bolt -arrow- on the oil dipstick guide tube.

Scheme 135

Open the clamp -2- and remove the air guide pipe from the throttle valve control module -J338-.

Scheme 136

Note. Ignore items -1, 3 and 4-.

Separate the oil dipstick guide tube -2- at the separating point.

Scheme 137

Disconnect electrical connector -1- on throttle valve control module.

Scheme 138

Remove bolts -arrows- and remove throttle valve control module.

Remove the nut -2- and bolt -1- and remove the intake manifold support.

Scheme 139

Remove all bolts from intake manifold.

Carefully pull off intake manifold with fuel rail from cylinder head.

Note. The fuel injectors could remain stuck in the fuel rail.

Fuel rail, removing and installing. Refer to FUEL RAIL

Installing

Installation is in reverse order.

1. Tightening Specifications, Intake Manifold, Assembly Overview, refer to «INTAKE MANIFOLD ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy) .
2. Tightening specifications, see Fuel rail, assembly overview, refer to «FUEL RAIL ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)

FUEL RAIL

The intake manifold runner position sensor -G336- must be adapted to the engine control module -J623- after removing or replacing the fuel rail vehicle diagnosis, testing and information system VAS 5052 guided function.

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

Remove hoses from EVAP canister.

To do so, open hose clamp -1-.

Loosen two bolts -arrows- of fuel rail.

Scheme 140

Pull the hose connection -1- off from intake manifold and remove both bolts -arrows-.

Open both fuel lines -2 and 3-.

Scheme 141

Carefully pry off linkage from intake flap motor -V157- -4-.

Remove intake flap motor -5-.

Pry the fuel rail off from the intake manifold via the retaining tabs -arrows-.

Scheme 142

Remove fuel rail from intake manifold.

Installing

Installation is in reverse order.

Intake manifold, installing. Refer to INTAKE MANIFOLD WITH FUEL RAIL .

THROTTLE VALVE CONTROL MODULE

Removing

Remove engine cover. Refer to ENGINE COVER WITH AIR FILTER ELEMENT .

Remove the noise insulation.

Loosen bolts and clamps -arrows- and remove charge air pipe and hose downward.

Scheme 143

Remove four bolts on throttle valve control module -J338- and remove it.

Installing

Installation is performed in reverse order.

After the replacing the throttle valve control module, it must be adapted to the engine control module -J623- (basic Set ting, display group 60) see vehicle diagnosis and service system VAS 5052 guided functions.

INTAKE FLAP MOTOR WITH INTAKE MANIFOLD RUNNER POSITION SENSOR

For the installation location of the intake flap motor -V157-, see Intake Manifold, Assembly Overview. Refer to INTAKE MANIFOLD ASSEMBLY OVERVIEW .

Special Tools And Workshop Equipment Required

Scheme 144

1. Commercially available 1 / 4 inch ratchet
2. TORX 30

Removing

Remove engine cover. Refer to ENGINE COVER WITH AIR FILTER ELEMENT .

Disconnect the vacuum lines -arrows-.

Scheme 145

Remove the bracket -arrow- for the harness.

Scheme 146

Disconnect the electrical connections -1, 2 and 3-.

Remove bracket for cable connector -arrows- from coolant pipe.

Scheme 147

Note. Open the nut with the left arrow just enough so that the bracket can moved to the side.

Carefully pry off linkage from intake flap motor -4-.

Remove intake flap motor -5-.

Note. The illustration shows the intake manifold removed.

Installing

Installation is in reverse order.

1. Tightening specification, refer to «INTAKE MANIFOLD ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)

FUEL PRESSURE SENSOR

Special TOOLS and workshop equipment required

1. Assembly Tools T10118
2. Double Hexagon Socket, 1/2", 27 mm VAS 5301/7

Removing

Disconnect coolant pipe and oil dipstick guide from intake manifold -arrows- and pull off oil dipstick guide upward from engine.

Disengage connector from fuel pressure sensor -G247- using T10118.

Remove fuel pressure sensor -G247- using VAS 5301/7.

Installing

Installation is in reverse order.

Tightening specifications of connection 30 Nm must be checked before installing fuel pressure sensor.

1. Fuel pressure sensor tightening specifications; refer to fuel rail assembly overview, refer to «FUEL RAIL ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy) .

HIGH PRESSURE PUMP

Note. For safety reasons, if the battery is not disconnected, fuse SC 27 from the fuel pump control module -J538- must be removed before opening the fuel system, otherwise the fuel pump will be activated by the driver's door contact switch. By removing fuse SC 27, the voltage supply to terminal 30 for the fuel pump control module is interrupted. The removal and installation of the high-pressure fuel pump can only be performed on a cold engine. When installing the high-pressure fuel pump, make sure that no dirt enters the fuel system. Catch escaping fuel with a rag. The O-ring must always be replaced. The banjo bolt for the fuel return line (only on high pressure pumps with threaded connection) must always be replaced. High-pressure fuel lines must always be fastened free of tension.

Removing

Remove engine cover. Refer to ENGINE COVER WITH AIR FILTER ELEMENT .

Disconnect electrical connectors from low fuel pressure sensor -G410- -1- and fuel pressure regulator valve -N276- -2-.

Scheme 148

Open both fuel lines at high-pressure pump.

Connections of the old high pressure pumps

Scheme 149

Connections of the new high pressure pumps

Scheme 150

Remove the 3 bolts -arrows-.

Carefully pull out the high-pressure fuel pump. The valve lifter can remain inserted in cylinder head under some circumstances.

Installing

Replace high pressure pump O-ring and coat it lightly with clean engine oil.

Carefully place high pressure pump with the valve lifter in opening in cylinder head (check the valve lifter for damage first).

Tighten the bolts diagonally to the specified torque. Refer to HIGH PRESSURE PUMP ASSEMBLY OVERVIEW

Before installing the fuel lines, check the torque of the connections on the high-pressure pump.

1. Fuel return line connections tightening specifications, refer to «HIGH PRESSURE PUMP ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__high-pressure-pump-assembly-overview) .
2. Fuel supply line connections tightening specifications, refer to «HIGH PRESSURE PUMP ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__high-pressure-pump-assembly-overview) .

Note. If the fuel return line was secured with a banjo bolt, replace the banjo bolt for the fuel return line. If the fuel return line is a hose, secure the connection with a hose clamp.

Tighten the new banjo bolt for the fuel return line hand-tight. Align so it is free of stress.

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

1. Tightening specification for the fuel return line (new banjo bolt), refer to «HIGH PRESSURE PUMP ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__high-pressure-pump-assembly-overview) .
2. Fuel supply line (union nut) tightening specifications, refer to «HIGH PRESSURE PUMP ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__high-pressure-pump-assembly-overview) .

Connect electrical connectors on low fuel pressure sensor and for fuel pressure regulator valve.

Re-insert fuse if it was removed.

Note. Check fuel system for leaks.

FUEL INJECTORS

Removing

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. Tools Set T10133

Note. The puller T10133/2 was changed and is now called the puller 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 Tools to slide farther onto the fuel injector, thus providing the Tools with a larger contact surface.

Mark the modified Tools with an A at the end of the Tools number.

Scheme 151

Scheme 152

1 - Radial compensation, replace if damaged

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

3 - Groove on 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).

Note. With fuel injector installed, the radial adjustment -1- is clipped into the support ring -6-. To remove the fuel injector, the support ring must be separated from the fuel injector in order to install the T10133/2 into the indentation on the fuel injector -3-.

Cover open intake channels with a clean rag.

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

Bend retaining tabs of radial compensation to the side using a screwdriver and pull off support ring from fuel injector.

Scheme 153

Position the puller T10133/2A in the groove on the fuel injector.

Scheme 154

Then position the trim removal wedge 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 high-pressure fuel injector. Refer to TEFLON COMBUSTION CHAMBER SEAL .

TEFLON COMBUSTION CHAMBER SEAL

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

1 - Radial compensation, replace if damaged

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

3 - Groove on 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).

Carefully remove the old Teflon seal with the appropriate Tools (for example, cut the seal open with a razor and spread 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 assembly cone T10133/5 with the new Teflon seal -1- onto the fuel injector -2-.

Scheme 155

Using the assembly sleeve 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 calibration sleeve 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 calibration sleeve 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.

The Teflon seal must not be oiled.

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

Scheme 159

Note. Possibly an opened intake valve hinders the cleaning. In this case, engine must be turned further by hand using a wrench on the crankshaft.

Install fuel injector again with support ring -1- and clip in radial compensation -2- on support ring.

Scheme 160

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.

Using the assembly drift T10133/9, press the fuel injector into the intended bore in the cylinder head until it stops. Make sure fuel injectors are positioned correctly in cylinder head.

Scheme 161

Further installation is in reverse order.

Note. Be sure to note the following points

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-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy__intake-manifold-with-fuel-rail) .

HEATED OXYGEN SENSOR AND OXYGEN SENSOR HEATER BEFORE CATALYTIC CONVERTER

Special TOOLS and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Remove engine cover. Refer to ENGINE COVER WITH AIR FILTER ELEMENT .

Disconnect electrical harness connector -1- of the heated oxygen sensor -G39- and oxygen sensor heater -Z19-.

Remove oxygen sensor -arrow- using Tools from 3337.

Installing

When installing, note the following

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 sensor slots. 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 specification: 55 Nm

OXYGEN SENSOR AFTER THREE WAY CATALYTIC CONVERTER AND OXYGEN SENSOR 1 HEATER

Special TOOLS and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Remove right cover from vehicle underbody.

Disconnect electrical harness connector -arrow- of the oxygen sensor after three way catalytic converter -G130- and heater for oxygen sensor 1 after catalytic converter -Z29-.

Remove the oxygen sensor after three way catalytic converter -1- using a Tools from the 3337.

Installing

When installing, note the following

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 sensor slots. 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 specification: 55 Nm

ENGINE CONTROL MODULE

Special Tools And Workshop Equipment Required

1. Hot air gun from the Wiring Harness Repair Kit VAS 1978A)
2. Nozzle attachment also from the Wiring Harness Repair Kit VAS 1978A
3. Commercially available locking pliers (vise grips)
4. Vehicle Diagnostic, Testing, and Information System VAS 5051B

The engine control module -1- is connected with a metal retainer -2 and 5-. To make removing the shear bolts -4- for the retaining tabs -2- more difficult, the threads are coated with locking compound.

Scheme 162

To disconnect the connectors from the engine control module (ECM) (for example to connect the test box or to replace the ECM), the protective housing must be removed.

The threads of the shear bolts have been coated with a locking compound, to further increase the difficulty of removing the shear bolts.

Removing

If the engine control module is replaced, in guided fault finding select replace engine control module to VAS 5051B.

Turn the ignition and remove the ignition key.

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

Loosen the nuts -arrows- by several turns.

Scheme 163

Loosen wiper arms from the wiper axle by tilting slightly.

Then, remove nuts completely and remove wiper arms from the wiper axles.

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

Unclip the spray nozzles -arrow-.

Scheme 164

Push the spray nozzles, with water lines still attached, back through the opening and into the plenum chamber.

Remove the rubber seal -1- from the plenum chamber cover -2-.

Scheme 165

Remove plenum chamber cover -2-.

The following steps are necessary through MY 2006

Move wiper arms to service position.

To do this, close the hood.

Turn the ignition on and then off again immediately. Within 10 seconds, press the windshield wiper lever downward once (mist wipe).

Note. The wiper arms now go into the service position.

Then open the hood again.

All

Remove ignition key.

Procedure

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 166

Note. Then, the shear bolts are heated with the heat gun. During this step, the holding effect that the locking compound has on the shear bolt threads is reduced, thereby allowing the shear bolts to be removed easier. Cover all painted components to prevent damage that may be caused by the heat gun or the locking pliers.

Direct the heat gun nozzle at the shear bolt of the retaining tab.

Switch on heat gun and heat bolt for approximately 20 to 25 seconds.

Then grab the bolt head with the locking pliers and remove the shear bolt.

The procedure for the second shear bolt is exactly the same.

Then, the engine control module (ECM) can be separated from the protective housing.

Scheme 167

Open clips -arrows- and remove the engine control module.

Scheme 168

Unlock the front connector from the engine control module and disconnect it.

Pull the engine control module (ECM) out from the retainer -arrow- (wiper arms in service position).

Release and pull off the rear connector from ECM.

Installing Engine Control Module

Install in reverse order of removal.

After that, the engine control module -J623- 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).

Use new shear bolts.

The following steps are necessary through MY 2006

Move wiper arms to park position again.

Close the hood to do this.

Switch ignition on and press the windshield wiper lever downward once (mist wipe), the wiper arms will now move back to the park position

Activate the engine control module in the guided functions operating mode under replace engine control module on the VAS 5051B.

Scheme 169

Special Tools And Workshop Equipment Required

1. Fuel Inj. Pressure Gauge- CIS V.A.G 1318
2. Adapter V.A.G 1318/11
3. Adapter V.A.G 1318/17-1 from Adapter Kit V.A.G 1318/17
4. Double Connection V.A.G 1318/23
5. Remote Control V.A.G 1348/3 A with Adapter Cable V.A.G 1348/3-3
6. Connector Test Set V.A.G 1594 C or V.A.G 1594 A

Special Tools And Workshop Equipment Required

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

1. Adapter - V.A.G 1598/39-1
2. Adapter - V.A.G 1598/39-2
3. Test Box 105 Pin - V.A.G 1598/42
4. Assembly Tools T10118
5. Double Hexagon Socket, 1/2", 27 mm VAS 5301/7
6. Tools Set T10133
7. Ring Spanner 7-Piece Set 3337
8. Hot air gun -1- from the Wiring Harness Repair Kit VAS 1978A
9. Nozzle attachment -2- also from the Wiring Harness Repair Kit VAS 1978A
10. Commercially available locking pliers (vise grips) -3
11. Vehicle diagnostic, testing, and information system VAS 5051B

See also:
• IGNITION COILS WITH POWER OUTPUT STAGES
• Removal and Installation
• KNOCK SENSOR 1
• DIAGNOSIS AND TESTING
• [For transmission(s) 02Q] Removal and Installation
• REMOVAL AND INSTALLATION
• 03 MAINTENANCE, DIAGNOSIS
• Removal and Installation
• BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM
• SAFETY PRECAUTIONS
• TURBO CHARGER COMPONENTS
• ENGINE CONTROL MODULE
• HEATED OXYGEN SENSOR AND OXYGEN SENSOR HEATER BEFORE CATALYTIC CONVERTER
• HIGH PRESSURE PUMP
• FUEL PRESSURE SENSOR
• MASS AIR FLOW SENSOR
• OXYGEN SENSOR AFTER THREE WAY CATALYTIC CONVERTER AND OXYGEN SENSOR 1 HEATER
• PEDAL BRACKET
• FUEL INJECTORS
• ENGINE COVER WITH AIR FILTER ELEMENT
• INTAKE MANIFOLD WITH FUEL RAIL
• INTAKE FLAP MOTOR WITH INTAKE MANIFOLD RUNNER POSITION SENSOR
• FUEL RAIL
• TEFLON COMBUSTION CHAMBER SEAL
• THROTTLE VALVE CONTROL MODULE
• FUEL PRESSURE AND RESIDUAL PRESSURE BEFORE HIGH PRESSURE PUMP, CHECKING
• HIGH PRESSURE PUMP ASSEMBLY OVERVIEW