3.2l - Fuel Injection System - Engine Code(s): Bub & Cbra Audi A3 8P рестайлинг

SAFETY PRECAUTIONS

To prevent personal injury and damage to the injection and ignition system, observe the following

1. The ignition must be switched off before connecting or disconnecting injection and ignition system wiring or tester cables.
2. Only clean engine with ignition switched off.
3. If electrical connectors were disconnected, faults are saved in ECM

Connect vehicle diagnosis, testing and information system VAS 5051B while ignition is switched off.

Start "Guided Functions" operating mode.

Generate readiness code in ECM.

Disconnect battery REMOVAL AND INSTALLATION .

Note the following when working on the fuel system

If it is necessary to use testing and measuring devices on road tests, observe the following

CLEAN WORKING CONDITIONS

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. Immediately seal off lines and connections with clean plugs or protective caps.
3. Place parts that have been removed on a clean surface and cover them. Use lint-free cloths.
4. Carefully cover over opened components or seal, if repairs are not performed immediately.
5. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored unpacked (e.g. in tool boxes etc.).
6. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.
7. Protect disconnected electrical connectors from dirt and moisture and only connect if dry.

COMPONENT LOCATIONS

Note. Component location of Clutch Position Sensor -G476- on vehicles with manual transmission (Scheme 179)

Scheme 176

1. 3-pin harness connector For Knock Sensor (KS) 1 -G61
2. Knock Sensor (KS) 1 -G61- Component location (Scheme 193)
3. Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80
4. Heated Oxygen Sensor (HO2S) -G39- before catalytic converter with Oxygen Sensor (O2S) Heater -Z19- Component location (Scheme 181) Removing and installing «OXYGEN SENSORS BEFORE CATALYTIC CONVERTER»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra__oxygen-sensors-before-catalytic-converter)
5. Connectors For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- with Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater -Z29- and Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- with Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater -Z30- Component location (Scheme 182)
6. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- with Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater -Z29- Component location (Scheme 183) Removing and installing «OXYGEN SENSORS AFTER CATALYTIC CONVERTER»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra__oxygen-sensors-after-catalytic-converter)
7. Heated Oxygen Sensor (HO2S) 2 -G108- before catalytic converter with Oxygen Sensor (O2S) 2 Heater -Z28- Component location (Scheme 181) Removing and installing «OXYGEN SENSORS BEFORE CATALYTIC CONVERTER»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra__oxygen-sensors-before-catalytic-converter)
8. Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- with Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater -Z30- Component location (Scheme 183) Removing and installing «OXYGEN SENSORS AFTER CATALYTIC CONVERTER»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra__oxygen-sensors-after-catalytic-converter)
9. Motronic engine control module -J220- Removing and installing «ENGINE CONTROL MODULE»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra__engine-control-module)
10. Positive Crankcase Ventilation (PCV) Heating Element -N79
11. Throttle valve control module -J338- With Throttle Drive (for Electronic Power Control (EPC)) -G186-, Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) -G187- and Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) -G188
12. Connectors For Heated Oxygen Sensor (HO2S) -G39- before catalytic converter with Oxygen Sensor (O2S) Heater -Z19- and Heated Oxygen Sensor (HO2S) 2 -G108- before catalytic converter with Oxygen Sensor (O2S) 2 Heater -Z28- Component location (Scheme 180)
13. Mass air flow (MAF) sensor -G70
14. Instrument Cluster With Malfunction Indicator Lamp (MIL) -K83
15. Throttle Position (TP) Sensor -G79- and Accelerator Pedal Position Sensor 2 -G185- Component location (Scheme 177)
16. Brake Light Switch -F- and Brake Pedal Switch -F47- Component location (Scheme 178)
17. Secondary Air Injection Sensor 1 -G609- For engine code CBRA only Component location (Scheme 187)
18. Secondary Air Injection (AIR) Pump Relay -J299- Component location (Scheme 185)
19. Motronic engine control module (ECM) power supply relay -J271- Component location (Scheme 184)
20. Fuel pump (FP) relay -J17- Component location (Scheme 184)
21. Camshaft position (CMP) sensor 2 -G163- Component location (Scheme 191)
22. Camshaft Adjustment Valve 1 (exhaust) -N318- Brown harness connector Component location (Scheme 191)
23. Camshaft Adjustment Valve 1 -N205- Black harness connector Component location (Scheme 191)
24. Camshaft Position (CMP) sensor -G40- Component location (Scheme 191)
25. Engine Coolant Temperature (ECT) Sensor -G62- Component location (Scheme 192)
26. Engine speed (RPM) sensor -G28- Component location (Scheme 188)
27. Actuator for intake manifold change-over
28. Secondary Air Injection (AIR) Pump Motor -V101
29. Intake Manifold Tuning (IMT) Valve -N156- Component location (Scheme 190)
30. Secondary air injection (AIR) solenoid valve -N112- For vehicles with vacuum-actuated secondary air injection combination valve For engine code CBRA and secondary air injection (AIR) solenoid valve 2 -N320- Component location (Scheme 189)
31. Knock Sensor (KS) 2 -G66- Component location (Scheme 194)
32. 3-pin harness connector For Engine Speed (RPM) Sensor -G28- Component location (Scheme 188)
33. Ignition coils with power output stages Cylinder 1 Ignition Coil 1 with Power Output Stage -N70- Cylinder 2 Ignition Coil 2 with Power Output Stage -N127- Cylinder 3 Ignition Coil 3 with Power Output Stage -N291- Cylinder 4 Ignition Coil 4 with Power Output Stage -N292- Cylinder 5 Ignition Coil 5 with Power Output Stage -N323- Cylinder 6 Ignition Coil 6 with Power Output Stage -N324
34. Fuel injector Cylinder 1 Cylinder 1 Fuel Injector -N30- Cylinder 2 Cylinder 2 Fuel Injector -N31- Cylinder 3 Cylinder 3 Fuel Injector -N32- Cylinder 4 Cylinder 4 Fuel Injector -N33- Cylinder 5 Cylinder 5 Fuel Injector -N83- Cylinder 6 Cylinder 6 Fuel Injector -N84- Checking injection quantity, leaks and spray pattern of fuel injectors «FUEL INJECTORS, CHECKING INJECTION QUANTITY, SPRAY PATTERN AND SEAL»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra__fuel-injectors-checking-injection-quantity-spray) Removing and installing «FUEL INJECTORS»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra__fuel-injectors)

Scheme 177

1. To disconnect electrical harness connector -2-, press release button and pull off wiring -1-.

Note. Illustration depicts allocation for left-hand drive.

Scheme 178

1. On pedal bracket.
2. Removing and installing «Removal and Installation»(/audi/a3/8p-2004-2008/remont/mechanical-hydraulic/#mechanical-components-brake-system) .

Scheme 179

1. On clutch master cylinder.
2. Removing and installing «REMOVAL AND INSTALLATION»(/audi/a3/8p-2004-2008/remont/clutches-manual-hydraulic/#clutch-manual-transmission-02q-fwd) .

Scheme 180

1. Heated Oxygen Sensor (HO2S) 2 -G108- before catalytic converter with Oxygen Sensor (O2S) 2 Heater -Z28
2. Heated Oxygen Sensor (HO2S) -G39- before catalytic converter with Oxygen Sensor (O2S) Heater -Z19

Scheme 181

1. In front exhaust pipe.

1. Heated Oxygen Sensor (HO2S) 2 -G108- before catalytic converter with Oxygen Sensor (O2S) 2 Heater -Z28
2. Heated Oxygen Sensor (HO2S) -G39- before catalytic converter with Oxygen Sensor (O2S) Heater -Z19

Scheme 182

1. At the right of the underbody under the vehicle underbody cover.

1. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- with Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater -Z29
2. Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- with Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater -Z30

Scheme 183

1. In catalytic converters.

1. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- with Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater -Z29
2. Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- with Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater -Z30

Scheme 184

1. In E-box, engine compartment.

R3 - Fuel pump (FP) relay -J17

R4 - Motronic engine control module (ECM) power supply relay -J271

Scheme 185

1. On 6-pin relay carrier -arrow- below engine compartment E-box; terminal 5.

Scheme 186

1. On relay carrier under E-Box, engine compartment.

To remove relay carrier under E-Box in engine compartment, pull out -arrow- and pull off Secondary Air Injection (AIR) Pump Relay -J299- -1- from position in relay carrier.

Scheme 187

1. Near throttle valve control module -J338

1. Secondary Air Injection Sensor 1 -G609

1. Removing and installing «REMOVAL AND INSTALLATION»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra) .

Note. Ignore -arrows-.

Scheme 188

1. At front on engine.

1. 3-pin harness connector
2. Engine speed (RPM) sensor -G28

Scheme 189

1. Secondary air injection (AIR) solenoid valve -N112
2. Secondary Air Injection (AIR) Solenoid Valve 2 -N320- (for engine code CBRA only)

Scheme 190

1. On vacuum reservoir at front on engine.

Scheme 191

1. Left on cylinder head.

1. Camshaft Position (CMP) sensor -G40
2. Camshaft position (CMP) sensor 2 -G163
3. Camshaft Adjustment Valve 1 -N205
4. Camshaft Adjustment Valve 1 (exhaust) -N318

Scheme 192

1. At left front on cylinder head

Scheme 193

1. At right rear on cylinder block.

1. Knock Sensor (KS) 1 -G61
2. 3-pin harness connector

Scheme 194

1. At front on cylinder block.

Scheme 195

1. Lower section for air duct
2. Air duct
3. Air duct cover
4. Rubber grommet
5. 10 Nm
6. 5 Nm
7. 3 Nm
8. Air guide hose
9. Mass air flow (MAF) sensor -G70- Removing and installing «MASS AIR FLOW SENSOR»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra__mass-air-flow-sensor)
10. Seal Replace if damaged
11. Upper part of air filter housing Removing and installing «AIR FILTER ELEMENT»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra__air-filter-element)
12. Air filter element Removing and installing «AIR FILTER ELEMENT»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra__air-filter-element) Observe change intervals 808
13. Lower part of air filter housing Removing and installing «AIR FILTER HOUSING»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra__air-filter-housing)
14. 10 Nm
15. Rubber grommet
16. 10 Nm
17. Air filter housing bracket
18. Gasket
19. 2 Nm

Scheme 196

1. Change-over roller
2. Bearing bushing
3. O-ring Replace
4. Metal screw
5. Bearing cap
6. Intake manifold
7. 20 Nm
8. 20 Nm
9. Seal
10. Connection for crankcase ventilation With Positive Crankcase Ventilation (PCV) Heating Element -N79
11. O-ring
12. Throttle valve control module -J338
13. 10 Nm
14. 20 Nm
15. Heat shield for exhaust manifold With intake manifold support
16. Gasket Replace Insert in intake manifold
17. 13 Nm
18. Metal screw
19. Vacuum actuator
20. Low pressure connection To Intake Manifold Tuning (IMT) Valve -N156
21. O-ring Replace
22. Bearing bushing

FASTENER TIGHTENING SPECIFICATIONS

TEST DATA

WIRING AND COMPONENTS, CHECKING WITH 121-POINT ADAPTER CABLE ON ECM

Special tools and workshop equipment required

1. Adapter cable V.A.G 1598/31 (test box)

Note. Adapter cable V.A.G 1598/31 (test box) is designed so that it can be simultaneously connected to the wiring harness at the Engine Control Module (ECM) and also to the ECM itself. This is advantageous because electronic engine control remains fully functional (e.g. measurement of signals with engine running) when the test box is attached. Respective test procedures note whether Engine Control Module (ECM) must also be connected to the test box. Always use connector test set V.A.G 1594 C to connect measuring equipment (e.g. voltage tester V.A.G 1527 B, portable multimeter V.A.G 1526 C, etc.)

Procedure

Remove Engine Control Module (ECM) ENGINE CONTROL MODULE .

Connect adapter cable V.A.G 1598/31 (test box) to multi-pin harness connectors of wiring harness.

Scheme 197

Clamp test box Ground (GND) clip to Ground (GND) -arrow-.

The procedures will indicate whether the engine control module is to be connected to the test box.

Perform test as described in the respective repair procedures.

Install Engine Control Module (ECM) after completing test ENGINE CONTROL MODULE .

SYSTEM PRESSURE, FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING

Note. Fuel pressure regulator is integrated in fuel filter and cannot be replaced individually.

Special tools and workshop equipment required

1. Hose clamps up to 25 mm dia. 3094
2. Fuel Inj. Pressure Gauge-CIS K-Jetronic V.A.G 1318 with adapters V.A.G 1318/11, V.A.G 1318/17 and V.A.G 1318/23

Test Conditions

1. Fuel Pump (FP) Relay OK.
2. Fuel Pump (FP) OK, checking «DIAGNOSIS AND TESTING»(/audi/a3/8p-2004-2008/remont/fuel-system/#fuel-supply-system-gasoline-engines) .
3. Fuel filter OK.
4. Battery voltage at least 12.5 V.

Test Sequence

Scheme 198

Measuring fuel pressure

Pull off cover over fuse holder in left instrument panel and pull out Fuse 27 (on fuse panel C) SC27.

Disconnect fuel supply line -2- at right rear in engine compartment, to do so pull up release button.

Scheme 199

Note. Ignore -1-.

Disconnect fuel supply line -arrow- on fuel rail line.

Scheme 200

Install a fuel-resistant assisting hose on fuel rail line.

Note. Use hose clamps -arrows- to secure assisting hose.

Connect Fuel Inj. Pressure Gauge-CIS K-Jetronic V.A.G 1318 with adapters V.A.G 1318/11, V.A.G 1318/17 and V.A.G 1318/23.

Open shut-off valve of pressure gauge set.

1. The lever points in the direction of flow.

Start engine and let run at idle.

Measure fuel pressure.

1. Specified value: Approximately 4.0 bar positive pressure

Switch off ignition.

If specification is not obtained

Check delivery quantity of Fuel Pump (FP) DIAGNOSIS AND TESTING .

Checking seal and residual pressure

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

1. After 10 minutes there must be a residual pressure of at least 3.0 bar.

If residual pressure drops below 3.0 bar

Start engine and let run at idle.

Wait until pressure has built-up, and then switch off ignition. Simultaneously close shut-off valve of pressure gauge K-Jetronic V.A.G 1318.

Scheme 201

1. Lever stands perpendicular to direction of flow -arrow-.

Observe pressure drop on pressure gauge.

If pressure drops again

Check line connections and O-rings on the fuel rail and fuel injectors for leaks.

Check pressure gauge for leaks.

If pressure does not drop

Open shut-off valve of pressure gauge (lever in direction of flow).

Remove rear seat bench Removal and Installation .

Unclip catches -arrows- of right connector flange cover.

Scheme 202

Disconnect fuel return line -arrow- by pressing release button.

Scheme 203

Connect adapter piece 1318/17-1 to fuel return line.

Scheme 204

Clamp off adapter piece using a Hose clamps up to 25 mm dia. 3094.

Note. Hose clamps up to 25 mm dia. 3094 must not be placed directly on fuel line, otherwise it may be damaged.

Cover return line connection with a cloth.

Start engine and let run briefly at idle.

Wait until pressure has built-up, and then switch off ignition.

Observe pressure drop on pressure gauge.

If pressure does not drop now, check-valve of fuel pump is malfunctioning.

Replace fuel pump REMOVAL AND INSTALLATION .

If pressure drops again

Replace fuel filter with integrated fuel pressure regulator Removal and Installation .

Note. Before disconnecting pressure gauge, release pressure by opening shut-off valve. Hold a container in front of connection for this.

Assembly is in reverse order of disassembly, noting the following

Insert Fuse 27 (on fuse panel C) SC27 again in fuel holder in left instrument panel.

Install rear seat bench Removal and Installation .

FUEL INJECTORS, CHECKING INJECTION QUANTITY, SPRAY PATTERN AND SEAL

Special tools and workshop equipment required

1. Remote control V.A.G 1348/3 A with adapter cable V.A.G 1348/3-2
2. Connector test kit V.A.G 1594 C or V.A.G 1594 A
3. Adapter cable V.A.G 1598/31 (test box)
4. Injector quantity testing device V.A.G 1602

Test Conditions

1. Fuel pressure OK, checking «SYSTEM PRESSURE, FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra__system-pressure-fuel-pressure-regulator-and) .

Test Sequence

Remove intake manifold INTAKE MANIFOLD .

Remove fuel rail with fuel injectors installed FUEL RAIL WITH FUEL INJECTORS . Fuel line remains connected.

Checking for Leaks

Open E-Box cover in engine compartment and pull out Fuse 33 (on fuse panel B) SB33.

Connect remote control V.A.G 1348/3 A with adapter cable V.A.G 1348/3-2 to terminal of Fuel Pump (FP) fuse and to battery plus (+).

Connect battery Ground (GND) cable.

Press switch on remote control connection V.A.G 1348/3 A.

1. Fuel Pump (FP) must run.

Check seal of fuel injectors via visual inspection.

1. With Fuel Pump (FP) running, only 1 to 2 drops per minute should escape from each fuel injector.

If fuel loss is greater

Replace faulty fuel injector FUEL INJECTORS .

Re-insert Fuse 33 (on fuse panel B) SB33 in E-Box in engine compartment.

Injection Quantity, Checking

Connect adapter cable V.A.G 1598/31 (test box) to wiring harness to Engine Control Module (ECM) WIRING AND COMPONENTS, CHECKING WITH 121-POINT ADAPTER CABLE ON ECM . The Engine Control Module (ECM) is not connected.

Bridge terminals 1 and 65 at test box using wires from adapter test kit V.A.G 1594 C.

Disconnect electrical harness connectors for fuel injectors.

Place a fuel injector into a graduated measuring glass of injection quantity test device V.A.G 1602.

Connect one terminal of fuel injector to plus wire and an alligator clip from connector test kit V.A.G 1594 C to engine Ground (GND).

Scheme 205

Connect second terminal of fuel injector to remote control V.A.G 1348/3 A using adapter cable V.A.G 1348/3-2.

Connect alligator clip to battery plus (+).

Bridge terminals 1 and 65 at test box using wires from adapter test kit V.A.G 1594 C.

Connect battery Ground (GND) cable if necessary.

Switch ignition on.

1. Fuel Pump (FP) must run.

Press switch on remote control connection V.A.G 1348/3 A for 30 seconds.

Perform measurement at all fuel injectors using a new measuring glass for each.

Note. Also check spray pattern when testing injection quantity. Spray pattern must be the same for all injectors.

After all 6 fuel injectors have been activated, place measuring glasses on an even surface.

1. Specified value of injection quantity for each fuel injector: 128 to 4.73 fl oz

If measured value of one or more fuel injectors is not within tolerance range

Shut off Fuel Pump (FP) (switch off ignition) and replace malfunctioning fuel injector FUEL INJECTORS .

If measured values of all fuel injectors are outside specified range

Check fuel pressure SYSTEM PRESSURE, FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING .

Install fuel injectors together with fuel rail FUEL INJECTORS .

Install intake manifold INTAKE MANIFOLD .

AIR FILTER ELEMENT

Removing

Disconnect vacuum hose -2- from air duct hose, if present.

Scheme 206

Disconnect air guide hose -1- from Throttle Valve Control Module -J338-.

Disconnect Mass Air Flow (MAF) Sensor -G70- electrical connector -3-.

Unbolt upper section of air filter housing -arrows-.

Remove air filter element.

Installing

Installation is in reverse order of removal, noting the following.

For trouble-free function of the Mass Air Flow (MAF) sensor, it is important to observe the following notes and perform the work procedures exactly.

Note. In the event the air filter element is severely soiled or completely saturated, dirt particles or moisture may penetrate the MAF sensor and falsify the measured air mass value. This results in a reduction of power, since a lower injection quantity is calculated. Always use an original equipment air filter element. Air filter housing must always be clean. Secure all hose connections using hose clamps appropriate for the model type. Note the following when blowing out air filter housing with compressed air: To prevent malfunctions, cover critical air-flow engine components such as Mass Air Flow (MAF) sensor, air duct pipes etc. with a clean cloth. Observe disposal regulations!

Blow out the water drain (small hole in lower section of air filter housing) with compressed air.

Clean air filter housing (upper and lower sections) of salt residue, dirt or leaves (use vacuum cleaner if necessary).

Check Mass Air Flow (MAF) sensor and air duct hose (clean air side) for salt residue, dirt and leaves.

Check air duct from lock carrier to air filter housing for dirt and leaves.

When installing air filter element, make sure it is put on centered in mount in lower section of air filter housing.

Place upper section of air filter housing on to lower section or air filter housing carefully and without using excessive force. When doing this, make sure that upper section of air filter housing is not placed tilted on the air filter element (pay attention to sealing lip of air filter element).

Make sure that air duct hose is connected securely to Mass Air Flow (MAF) sensor.

AIR FILTER HOUSING

Removing

Remove air filter element AIR FILTER ELEMENT .

Pull off air guide cover -1-, to do so disengage clips sideways.

Scheme 207

Unclip air duct -2-.

Remove lower section of air filter housing -arrows-.

Scheme 208

Installing

Installation is in reverse order of removal, noting the following.

Note. Air filter housing must always be clean. Secure all hose connections using hose clamps appropriate for the model type. Note the following when blowing out air filter housing with compressed air: To prevent malfunctions, cover critical air-flow engine components such as Mass Air Flow (MAF) sensor, air duct pipes etc. with a clean cloth.

Blow out the water drain (small hole in lower section of air filter housing) with compressed air.

Clean air filter housing (upper and lower sections) of salt residue, dirt or leaves (use vacuum cleaner if necessary).

Check Mass Air Flow (MAF) sensor and air duct hose (clean air side) for salt residue, dirt and leaves.

Check air duct from lock carrier to air filter housing for dirt and leaves.

Place upper section of air filter housing on to lower section or air filter housing carefully and without using excessive force. When doing this, make sure that upper section of air filter housing is not placed tilted on the air filter element (pay attention to sealing lip of air filter element).

MASS AIR FLOW SENSOR

Removing

Disconnect air duct hose from Mass Air Flow (MAF) Sensor -G70-.

Remove bolts -arrows-.

Scheme 209

Carefully pull Mass Air Flow (MAF) Sensor -G70- out of guide at upper section of air filter housing.

Installing

Installation is in reverse order of removal, noting the following.

For trouble-free function of the Mass Air Flow (MAF) sensor, it is important to observe the following notes and perform the work procedures exactly.

Note. Replace O-ring. In the event the air filter element is severely soiled or completely saturated, dirt particles or moisture may penetrate the MAF sensor and falsify the measured air mass value. This results in a reduction of power, since a lower injection quantity is calculated. Always use an original equipment air filter element. Use a silicon-free lubricant to install the air duct hose. Secure all hose connections using hose clamps appropriate for the model type.

Check Mass Air Flow (MAF) sensor and air duct hose (clean air side) for salt residue, dirt and leaves.

Check air duct up to the air filter element for dirt. Clean air filter housing (upper and lower sections) of salt residue, dirt or leaves (wash out or use vacuum cleaner if necessary).

Install upper section of air filter housing AIR FILTER ELEMENT .

Tightening Specifications

INTAKE MANIFOLD

Special tools and workshop equipment required

1. Drift T10060
2. Puller For Ignition Coil T10095 A
3. Assembly tool T10118

Removing

Note. All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

Remove tool formed insert under luggage compartment floor covering.

Remove cover -arrow- for battery compartment

Scheme 210

Remove formed insert from over battery.

With ignition switched off, disconnect Battery Ground (GND) wire -arrow-.

Scheme 211

Remove center noise insulation fasteners -1 to 3-.

Scheme 212

Remove right noise insulation fasteners -1 to 3-.

Scheme 213

Disconnect vacuum hose -2- from air duct hose.

Disconnect air guide hose -1- from Throttle Valve Control Module -J338-.

Disconnect Mass Air Flow (MAF) Sensor -G70- electrical connector -3-.

Remove upper section of air filter housing -arrows-.

Remove filter element.

Remove air duct cover -1-.

Unclip air duct -2-.

Remove lower part of air duct -arrows-.

Scheme 214

Remove lower section of air filter housing -arrows-.

Disconnect secondary air hose at position indicated by -arrow-.

Scheme 215

Free up air hose to Secondary Air Injection (AIR) pump.

Separate electrical connectors -2- and -3-.

Scheme 216

Disconnect crankcase ventilation hose -1-.

Remove throttle valve control module -J338- from intake manifold -arrows- and lay it aside.

Scheme 217

Disconnect electrical harness connectors to ignition coils, to do so attach assembly tool T10118 on release button -arrow- and carefully disconnect harness connector.

Scheme 218

Attach Puller For Ignition Coil T10095 A on ignition coils -arrow- as depicted in the illustration and pull out ignition coils in succession.

Scheme 219

Remove ignition wiring harness strip and set it aside.

Note. Depending on the construction version, low pressure connectors were used in the version shown. To disconnect, slide back rubber cap -1- and slide release button -2- to the rear.

Disconnect vacuum hoses -2 through 5- at rear of the intake manifold.

Scheme 220

Note. Ignore -1-.

Remove wiring connection from intake manifold -arrows- and lay back with hoses connected.

Remove intake manifold bolts -arrows-.

Scheme 221

Remove top mounting bolts for fan shroud -top arrows-.

Scheme 222

Remove oil dipstick.

Note. Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

Swing tensioning device in direction of -arrow- to relieve tension on ribbed belt.

Scheme 223

Secure tensioner using drift T10060 or using an angled hex socket head wrench.

Remove ribbed belt.

Free up coolant hose at bottom on fan shroud.

Scheme 224

Disconnect electrical harness connector -3- at Secondary Air Injection (AIR) Pump Motor -V101-.

Free up cable.

Remove bracket -2- coolant pipe.

Remove bolts -1-.

Loosen bolt -4- and remove Secondary Air Injection (AIR) pump with bracket.

Disconnect electrical harness connectors -1- for coolant fans at bottom on fan shroud.

Remove mounting bolts for fan shroud at bottom -bottom arrows-.

Pull out fan shroud downward with both fans.

Disconnect electrical harness connector -1- for A/C clutch on A/C compressor and free up electrical wire.

Scheme 225

Remove bolts -arrow- for A/C compressor.

Securely tie A/C compressor with connected coolant hoses at front on the longitudinal member.

Remove electrical wire -1- on generator.

Scheme 226

Separate electrical connector -2-.

Note. Ignore -3-.

Remove upper idler roller -1-.

Scheme 227

Remove mounting bolts -2- and -3- for generator.

Note. Generator can be removed from bracket only with the upper mounting bolt still installed.

Remove generator with electrical wiring connected from accessory assembly bracket.

Remove generator downward and to the left.

Disconnect electrical harness connector -arrow- at After-Run Coolant Pump -V51-.

Scheme 228

Remove bolts -1 to 5- and remove accessory assembly bracket.

Pull After-Run Coolant Pump -V51-, with coolant hoses connected, downward out of rubber loops of retainer. Spray rubber loops with silicon-free lubricant if necessary.

Note. Coolant pump remains on the engine with coolant hoses connected.

Disengage for Engine Speed (RPM) Sensor -G28- connector -arrow- from bracket on oil dipstick guide tube.

Scheme 229

Remove bolt -3- and remove oil dipstick guide tube -2-.

Scheme 230

Remove bolt -4- and remove vacuum reservoir -1- from intake manifold.

Lay vacuum reservoir aside with lines connected.

Remove bolts -arrows- at front of intake manifold.

Scheme 231

Disconnect vacuum line -arrow- from actuator for intake manifold change-over.

Scheme 232

Note. Ignore -1- and -2-.

Protect intake manifold from damage with a clean cloth -1-.

Scheme 233

Swing intake manifold forward -arrow 1- and then pull slightly to left -arrow 2-.

Note. Seal intake channel in cylinder head with clean cloth or foam pieces so that no small parts can fall in.

Remove right fuel line bracket on cylinder head cover.

Free up wiring harness -1- on cylinder head cover.

Scheme 234

Remove bolts -arrows-.

Pull off fuel rail line -2- with fuel injectors from cylinder head and set aside with fuel line connected.

Swivel intake manifold back into installation position and remove.

Installing

Installation is in reverse order of removal, noting the following

Note. Replace seals. To assist installation of wiring harness -1- to fuel injectors, disconnect from fuel rail line.

Install bracket for assemblies REMOVAL AND INSTALLATION .

Install generator REMOVAL AND INSTALLATION .

Install A/C compressor Removal and Installation .

Install fan shroud REMOVAL AND INSTALLATION .

Install Secondary Air Injection (AIR) pump REMOVAL AND INSTALLATION .

Install ribbed belt REMOVAL AND INSTALLATION .

Connect Ground (GND) cable to battery Removal and Installation .

Tightening Specifications

ENGINE CONTROL MODULE

The multi-pin harness connectors of Engine Control Module (ECM) are equipped with a protective housing secured by a locking mechanism and shear bolts -arrows-. Also to impede removing of the shear bolts, their threads are coated with locking compound.

Scheme 235

The protective housing must be removed so that multi-pin harness connectors can be disconnected from Engine Control Module (ECM), e.g. to connect the test box or to replace the ECM.

Special tools and workshop equipment required

1. Hot air gun (from wiring harness repair kit VAS 1978)
2. Attachment nozzle (from wiring harness repair kit VAS 1978)
3. Locking pliers (commercially available)

Removing

Turn ignition and remove ignition key.

Pry off caps on wiper arms using a screwdriver.

Loosen nuts -arrows- by several turns.

Scheme 236

Loosen wiper arms by gently rocking wiper arm. Remove nuts and remove wiper arms.

Unclip spray nozzles -arrow-.

Scheme 237

Push spray nozzle with lines still attached back through opening and into plenum chamber.

Remove rubber seal -1- for plenum chamber cover.

Scheme 238

Remove plenum chamber cover -2-.

Adjust settings on hot air gun as depicted in the illustration, this means potentiometer -2- for temperature setting at maximum heat output and two-stage switch -3- for air quantity at position "3".

Scheme 239

Note. Next, the thread of protective housing in which the shear bolts is threaded in is heated using the heat gun. This step decreases the locking effect of the locking compound on the thread of the shear bolts, thus allowing the shear bolts to be removed more easily. Cover all painted parts to prevent damage from the hot air gun or locking pliers.

Perform the following work steps in succession at both shear bolts -arrows-.

Guide nozzle of hot air gun on to shear bolt of protective housing.

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

Then grasp bolt head using locking pliers and remove shear bolt.

Remove protective housing.

Disengage and disconnect front multi-pin harness connector -2- of Engine Control Module (ECM)..

Scheme 240

Disengage securing clip -arrow-.

Remove Engine Control Module (ECM) -1- from bracket.

Disengage and disconnect rear multi-pin harness connector of Engine Control Module (ECM).

Note. Adaptation values are erased when connectors are disconnected from the Engine Control Module (ECM), DTC memory content remains intact.

Installing

Installation is in reverse order of removal, noting the following

Re-equip Engine Control Module (ECM) with the protective housing.

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

Use new shear bolts.

After installing a new Engine Control Module (ECM), the following work steps must be performed

Activate Engine Control Module (ECM) in "Guided Fault Finding" under diagnostic object "Engine Control Module (ECM), replacing" .

FUEL INJECTORS

Removing

Disconnect fuel line -2-, pull up release button to do so.

Note. Ignore -1-.

Remove intake manifold and fuel rail INTAKE MANIFOLD .

Pull off retaining clip and remove relevant fuel injector.

Installing

Installation is in reverse order of removal, noting the following

1. Replace O-rings at all opened connection points. (Never remove plastic cap from valve head to replace front O-ring - lift off O-ring over plastic cap).
2. Lubricate O-rings with clean engine oil.
3. Check that fuel injectors are installed in correct position.
4. Check clips for proper seating.
5. Place fuel rail with secured fuel injectors onto intake manifold, and apply uniform pressure to press it in.

Tightening Specifications

OXYGEN SENSORS BEFORE CATALYTIC CONVERTER

Special tools and workshop equipment required

1. Ring spanner 7-piece set for oxygen sensor 3337

Removing

Disconnect vacuum hose -2- from air duct hose.

Disconnect air guide hose -1- at Throttle Valve Control Module -J338-.

Disconnect Mass Air Flow (MAF) Sensor -G70- electrical connector -3-.

Remove upper section of air filter housing -arrows-.

Remove filter element.

Pull off air duct cover -1-.

Unclip air duct -2-.

Unbolt lower section of air filter housing -arrows-.

Disconnect electrical harness connector -1- for Heated Oxygen Sensor (HO2S) 2 -G108- or -2- for Heated Oxygen Sensor (HO2S) -G39-.

Free up electrical wires to oxygen sensors.

Remove Heated Oxygen Sensor (HO2S) 2 -G108- -1- or Heated Oxygen Sensor (HO2S) -G39- -2-.

Installing

Installation is in reverse order of removal, noting the following

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. When reinstalling the previously used oxygen sensor, coat thread with hot bolt paste. Paste must not get on to slits of sensor body. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. When installing, re-install heat insulation sleeves at the same locations.

Tightening Specifications

OXYGEN SENSORS AFTER CATALYTIC CONVERTER

Special tools and workshop equipment required

1. ring spanner 7-piece set for oxygen sensor 3337

Removing

Remove right vehicle underbody cover -arrows-.

Scheme 241

On right side at vehicle floor, disconnect electrical harness connector -1- to Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- or -2- to Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131-.

Remove respective connector coupling from bracket and free up electrical wire to respective oxygen sensor.

Remove Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- -1- or Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- -2-.

Installing

Installation is in reverse order of removal, noting the following

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. When reinstalling the previously used oxygen sensor, coat thread with hot bolt paste. Paste must not get on to slits of sensor body. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.

Tightening Specifications

Scheme 242

1. Fuel rail
2. Secure the fuel line from the connector flange of the fuel tank using hose clamps appropriate for the model type WARNING: Pull out Fuse 27 (on fuse panel C) SC27 in fuse holder in left instrument panel before disconnecting fuel hose.
3. Socket head bolt - 10 Nm
4. O-ring Removing and installing «FUEL INJECTORS»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra__fuel-injectors) Replace Moisten with clean engine oil
5. Retaining clip After installing, check fuel injector is securely fastened
6. Fuel injector
7. O-ring Removing and installing «FUEL INJECTORS»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra__fuel-injectors) Replace Moisten with clean engine oil

Scheme 243

Special tools and workshop equipment required

1. Remote control V.A.G 1348/3 A with adapter cable V.A.G 1348/3-2
2. Connector test kit V.A.G 1594 C or V.A.G 1594 A
3. Adapter cable V.A.G 1598/31 (test box)
4. Injector quantity testing device V.A.G 1602

Scheme 244

Special tools and workshop equipment required

1. Drift T10060
2. Puller For Ignition Coil T10095 A
3. Assembly tool T10118

Special tools and workshop equipment required

Scheme 245

Scheme 246

Scheme 247

Scheme 248

Scheme 249

1. Hot air gun (from wiring harness repair kit VAS 1978)
2. Attachment nozzle (from wiring harness repair kit VAS 1978)
3. Hose clamps up to 25 mm dia. 3094
4. Fuel Inj. Pressure Gauge-CIS K-Jetronic V.A.G 1318 with adapters V.A.G 1318/11, V.A.G 1318/17 and V.A.G 1318/23
5. Adapter cable V.A.G 1598/31 (test box)
6. Ring spanner 7-piece set for oxygen sensor 3337

See also:
• REMOVAL AND INSTALLATION
• Removal and Installation
• REMOVAL AND INSTALLATION
• REMOVAL AND INSTALLATION
• DIAGNOSIS AND TESTING
• Removal and Installation
• REMOVAL AND INSTALLATION
• Removal and Installation
• REMOVAL AND INSTALLATION
• OXYGEN SENSORS BEFORE CATALYTIC CONVERTER
• OXYGEN SENSORS AFTER CATALYTIC CONVERTER
• ENGINE CONTROL MODULE
• FUEL INJECTORS, CHECKING INJECTION QUANTITY, SPRAY PATTERN AND SEAL
• FUEL INJECTORS
• MASS AIR FLOW SENSOR
• AIR FILTER ELEMENT
• AIR FILTER HOUSING
• SYSTEM PRESSURE, FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING
• INTAKE MANIFOLD
• FUEL RAIL WITH FUEL INJECTORS
• WIRING AND COMPONENTS, CHECKING WITH 121-POINT ADAPTER CABLE ON ECM