SAFETY PRECAUTIONS
Observe the following if test and measuring instruments are required during a test drive
| WARNING | Distraction and improperly secured test equipment can lead to accidents. Risk of passenger airbag deploying in an accident. Operating testing and measuring equipment while driving creates a distraction. There is an increased risk of injury due to unsecured testing and measuring equipment. Always secure testers on the rear seat with a strap and have a second person on the rear seat to operate them. |
To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following
- Do not touch or remove ignition wires when engine is running or turning at starter speed.
- Always switch ignition off before disconnecting or reconnecting wires for the ignition system, including high voltage wiring and test leads.
- If engine is to be cranked at starting RPM without starting (for example for compression testing), disconnect connectors from ignition coils and from fuel injectors. After performing work, check and erase DTC memory.
- Cleaning the engine should only be performed with ignition switched off.
- The battery must only be disconnected and connected with the ignition switched off, since the engine control module (ECM) can otherwise be damaged.
IGNITION SYSTEM
- The engine control module is equipped with on board diagnostics (OBD).
- For the electric components to work properly, a voltage of at least 11.5 Volts is required.
- 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.
- If the engine only starts briefly and then turns off again after troubleshooting, repair or checking of the components, it may be that the immobilizer is blocking the engine control module (ECM). DTC memory must then be checked and if necessary, control module must be adapted.
Scheme 7
- Knock Sensor 1 -G61- Contacts gold plated
- Knock Sensor 2 -G66- Contacts gold plated
- Ignition Coil with Power Output Stage -(N70, N127, N291, N292)- 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) To remove, use the ignition coil puller T40039
- Spark Plug 30 Nm Removing and installing, refer to «SPARK PLUGS, REMOVING AND INSTALLING»(/audi/a3/8p-2004-2008/remont/procedures/#how-to-diagnosis-the-maintenance-maintenance-procedures)
- Bolt 20 Nm Tightening specifications affect function of Knock Sensor (KS)
- Bolt 10 Nm
- Camshaft Position Sensor -G40- Contacts gold plated
- O-ring If damaged, replace O-ring
TEST DATA
| Engine data | 2.0L Turbo FSI engine | ||
|---|---|---|---|
| Idle speed Idle speed cannot be adjusted, it is regulated by idle stabilization | 640 to 800 RPM | ||
| RPM limited by switching off fuel injectors and closing throttle valve | Approximately 6500 RPM | ||
| Ignition timing is regulated by control module. It is not possible to adjust the ignition timing. | |||
| Ignition/Glow Plug System | Single coil ignition system with 4 ignition coils (output stages integrated), that are connected directly to spark plugs via the ignition cables; The ignition coils can be pulled out of the cylinder head using ignition coil puller T40039 | ||
| Ignition sequence | 1-3-4-2 |
FASTENER TIGHTENING SPECIFICATIONS
| Component | Bolt Size | Nm |
|---|---|---|
| Camshaft Position Sensor | 10 | |
| Knock Sensor | 20 | |
| Spark Plug | 30 |
IGNITION COILS WITH POWER OUTPUT STAGES
Special tools and workshop equipment required
- Ignition Coil Puller T40039
Removing
Remove engine cover. Refer to ENGINE COVER WITH AIR FILTER ELEMENT .
Remove both bolts -1- of the connector strip.
Scheme 8
Pull all ignition coils approximately 30 mm out of spark plug shaft using T40039.
Scheme 9
Unlatch the electrical connections -arrows- and disconnect all the connections at the same time from the ignition coils.
Scheme 10
Using the T40039 remove all ignition coils from the spark plug shaft.
Installing
Insert all ignition coils loosely into each spark plug shaft.
Align the ignition coils to the connectors and then connect all of the connectors simultaneously onto the ignition coils.
Scheme 11
Press the ignition coils uniformly onto the spark plugs by hand (do not use an impact tool).
KNOCK SENSOR 1
Removing
Remove the electrical connector -2- from the knock sensor 1 -G61-.
Scheme 12
Remove the coolant pump with the coolant thermostat. Refer to COOLANT PUMP .
Note. The knock sensor 1 is located below the intake manifold behind the coolant pump.
Remove the knock sensor 1.
Installing
Installation is in reverse order.
- Tightening specification, refer to «IGNITION ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/ignition-system/#20l-ignitionglow-plug-system-engine-codes-bpy)
SPECIAL TOOLS
Special tools and workshop equipment required
Scheme 13
- Ignition Coil Puller T40039