How to Overhaul & Installation the Engine Controls - Removal Audi A4 B5 рестайлинг

INTRODUCTION

Removal, overhaul and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

Note. Most components are a simple unbolt and bolt-on procedure. For component locations, see COMPONENT LOCATIONS .

ACCESSORY DRIVE BELT

Note. DO NOT install drive belt in opposite direction. Damage to belt may occur.

Removal & Installation

1. Mark direction of accessory drive belt travel before removing belt (if reusing belt). Remove belt guard. Using a 17-mm wrench, rotate tensioner clockwise to loosen belt tensioner. Secure belt tensioner using Drift (3204). (Scheme 1)
2. Remove accessory drive belt. Ensure belt has no splits, cracks or other damage. Replace accessory drive belt if necessary. To install, reverse removal procedure. Install drive belt onto tensioning pulley last. Using a 17-mm wrench, hold tensioner and remove drift. Allow tensioner to move against drive belt. Install drive belt guard.

Scheme 1

FUEL SYSTEM

FUEL PRESSURE RELEASE

Loosen fuel filler cap to release pressure in fuel tank. Remove fuel pump relay. Fuel pump relay is located in position 4 of micro-electric center in driver's footwell. Start engine. Allow engine to run until it stalls. Turn ignition off. Disconnect negative battery cable. Slight pressure may remain in system. Before disconnecting any fuel system line, cover connector with a clean shop towel. Reinstall fuel pump relay.

FUEL FILTER

In all models fuel filter is located on frame rail near fuel tank. In some cases in may be necessary to remove the aerodynamic trim panel from under vehicle to gain access to fuel tank and filter. Before removing or replacing fuel filter, release fuel pressure. See FUEL PRESSURE RELEASE . Whenever fuel lines are removed from fuel filter on fuel filters that use hose clamps to secure fuel lines, ensure that clamps are in good working order or replace as necessary. On fuel filter that use banjo style fittings, always replace sealing rings with NEW parts. Anytime fuel filter has been removed, after installation start vehicle and check for leaks.

Scheme 2

FUEL INJECTORS

Note. Fuel is under high pressure. Before opening system, release fuel pressure. See FUEL PRESSURE RELEASE .

Removal & Installation (A4 1.8L)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/audi/a4/b5-1999-2001/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal__fuel-pressure-release) . Remove engine cover. Disconnect all 4 fuel injector harness connectors. Disconnect harness connectors for Intake Air Temperature (IAT) sensor, Camshaft Position (CMP) sensor and Throttle Valve Control Module (TVCM).
2. Remove 2 retaining bolts for fuel supply rail. Disconnect fuel pressure regulator vacuum hose. Pulling up, remove fuel rail with injectors from intake plenum. Set fuel rail on clean shop towels at rear of engine compartment.
3. Disengage retaining clip and remove fuel injector. To install, reverse removal procedure. Replace all "O" ring seals with new parts, lightly lubricating "O" rings with clean engine oil. Ensure all fuel injectors are seated correctly. Check injector retaining clips are fit correctly. Tighten retaining bolts for fuel supply rail to 89 INCH lbs. (10 N.m).

Removal & Installation (A4 & S4 2.7 L & 2.8 L)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/audi/a4/b5-1999-2001/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal__fuel-pressure-release). Remove engine cover. Disconnect all 6 fuel injector harness connectors. Disconnect fuel pressure regulator vacuum hose.
2. Remove retaining bolts for fuel supply rail. Pulling up, remove fuel rail with injectors from intake plenum. (Scheme 3) Set fuel rail on clean shop towels at rear of engine compartment.
3. Disengage retaining clip and remove fuel injector. To install, reverse removal procedure. Replace all "O" ring seals with new parts, lightly lubricating "O" rings with clean engine oil. Ensure that all fuel injectors are seated correctly. Check injector retaining clips for proper fit. Tighten retaining bolts for fuel supply rail to 89 INCH lbs. (10 N.m).

Scheme 3

FUEL PUMP

Note. Obtain radio code before disconnecting battery.

Removal & Installation (A4 Front Wheel Drive Only)

1. Observe fuel system warnings and notes. Turn ignition off and remove ignition key from vehicle. Disconnect negative battery cable. Working in luggage compartment, remove fuel pump access plate. Note orientation of fuel lines. Mark and remove fuel lines. (Scheme 4) Disconnect fuel pump and fuel level sensor harness connector. Using Union Nut Wrench (3217), remove union nut. Remove cover flange and "O" ring seal. Disconnect fuel level sensor harness connector from inside of flange cover. Disconnect return line from inside of cover flange. (Scheme 5)
2. Insert Fuel Pump Wrench (3307) through opening in fuel tank, turn inner section of surge housing about 15 degrees to the left. (Scheme 6) Remove fuel pump assembly through opening. Remove supply line from fuel pump. Remove power and ground wires from fuel pump.
3. Install new fuel pump to inner surge housing. Connect power and ground wires to fuel pump. Connect fuel supply line to fuel pump. Install fuel pump assembly through opening. Place inner surge housing into outer surge housing so that notch (1) on inner housing matches mark (2) on outer surge housing. (Scheme 7) When installing inner surge housing an audible click should be heard when housing is seated. Using fuel pump wrench turn inner surge housing about 15 degrees to the right. Notch (1) on inner housing should now match mark (3) on outer surge housing.
4. Connect return line and fuel level sensor harness connector to cover flange. Using NEW "O" ring seal install cover flange. Install union nut, using union nut wrench torque nut to 44 ft. lbs. (60 N.m). Connect harness connector and fuel lines. Re-install cover plate. Connect negative battery cable. Reprogram radio, clock and power windows as necessary.

Scheme 4

Scheme 5

Scheme 6

Scheme 7

SECONDARY FUEL PUMP (ALL WHEEL DRIVE VEHICLES ONLY)

Note. Obtain radio code before disconnecting battery.

PCM REPLACEMENT

Note. When using Volkswagen Audi Group (VAG) 1551 scan tool, follow manufacturer's instructions for operation. VAG 1551 scan tool is necessary to perform adaptation of throttle valve control module to PCM.

Note. It is only necessary to perform this procedure when installing a NEW PCM in vehicle.

1. PCM is located in left rear corner of engine compartment inside electronics box. Code PCM. See PCM CODING. After coding PCM, verify no DTCs are stored in memory. Ensure throttle valve is in closed throttle position.
2. Connect VAG 1551 scan tool to Data Link Connector (DLC). Following manufacturer's instructions, access Basic Setting 60 information using VAG 1551 scan tool. After confirming correct VAG 1551 scan tool display, "adaptation" will begin with ignition on and engine off.
3. PCM will learn the closed throttle position, Wide Open Throttle (WOT), and other positions of throttle valve control module. PCM will store these values in permanent memory. Vehicle may idle unevenly and there may be a temporary loss of driveability until PCM has completed a learning process. PCM will not complete learn function if a DTC is stored in memory.
4. Using VAG 1551, generate a PCM readiness code. A PCM readiness code resets 8 specific values to zero. Follow scan tool prompts for generating a PCM readiness code.

PCM CODING

Note. When using Volkswagen Audi Group (VAG) 1551 scan tool, follow manufacturer's instructions for operation. VAG 1551 scan tool is necessary to perform PCM coding.

If Powertrain Control Module (PCM) is replaced, it is necessary to code new PCM. If new PCM is not properly coded, the following problems may occur

1. Driveability problems (i.e., harsh shifting).
2. False malfunctions stored in PCM memory.
3. Increased fuel consumption.
4. Increased exhaust emissions.
5. Reduction in transmission life.
6. All PCM functions are not carried out (i.e., EVAP system operation).

Connect VAG 1551 scan tool to Data Link Connector (DLC). Following manufacturer's instructions, access PCM coding information using VAG 1551 scan tool. For PCM coding options, see appropriate PCM CODING OPTIONS table.

As an example, a properly coded PCM for an A4 model with Front Wheel Drive (FWD) without traction control and 5-speed manual transmission would look like 06001 on the VAG 1551 scan tool.

Note. After coding PCM and starting engine for first time, allow engine to idle for several minutes so PCM can go through a learn function. Idle speed may be erratic while PCM is learning.

PCM CODING OPTIONS (A4)

1. Remove accessory drive belts. Rotate engine crankshaft engine by hand to Top Dead Center (TDC) position. (Scheme 8) Remove vibration damper pulley. Remove 4 lower belt cover fasteners. Remove lower belt cover. Remove upper belt cover.
2. Using a piece of chalk, mark timing belt running direction. Using Torx T45 tool, loosen timing belt tensioner. Push timing belt tensioner down and remove timing belt.

Scheme 8

Scheme 9

1. Align mark on timing drive sprocket with mark on cylinder head cover and/or toothed belt guard. (Scheme 8) Install timing belt. Install lower belt cover. Install vibration damper pulley and torque to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal__torque-specifications).
2. Using a 2-hole spanner, rotate timing belt tensioner until tensioner piston No. 1 is all the way extended and tensioner piston No. 2 lifts up approximately.04" (1 mm). (Scheme 9) Tighten timing belt tensioner Torx screw by hand (enough to hold tensioner).
3. Rotate crankshaft 2 revolutions in running direction and bring back to TDC. Check if upper edge of tensioner piston No. 2 lines up within area "A". (Scheme 10) When tensioner piston No. 2 is within area "A", this corresponds to a dimension "D" of.98-1.14" (25-29 mm). Adjust if necessary.
4. If upper edge of tensioner piston No. 2 is within area "B", this is acceptable. If upper edge of tensioner piston No. 2 is within area "C", readjust and/or check belt drive (including pulley) for wear. If tensioner piston No. 2 is within an acceptable area, tighten Torx screw to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal__torque-specifications).

Scheme 10

1. Remove accessory drive belt. Remove timing belt covers. Rotate engine crankshaft engine by hand to Top Dead Center (TDC) position. Check camshaft position. Large holes in camshaft sprockets should face toward each other.
2. If camshaft sprockets do not face toward each other, turn crankshaft one more revolution. Remove Crankshaft Position (CKP) sensor from left side of cylinder block. Look and feel for TDC hole in crankshaft through opening in block. Thread crankshaft Holder (3242) into CKP sensor opening and tighten slightly. Remove accessory drive belt tensioner.
3. Lock camshafts at TDC No. 3 cylinder using Timing Fixture (VAG 3243). Locating plates are used to position camshafts. Each locating plate has a large hole and a small hole. When installing timing fixture, ensure large holes on locating plates face each other. (Scheme 11)
4. Lock crankshaft at TDC No. 3 cylinder with Crank Locating Pin (V.A.G. 3242) inserted through threaded hole in block where reference sensor usually is, and into locating notch in crankshaft. (Scheme 12) Remove timing belt. To install, reverse removal procedure. Remove timing fixture and locating pin.

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• COMPONENT LOCATIONS
• FUEL PRESSURE RELEASE
• FUEL PRESSURE RELEASE
• TORQUE SPECIFICATIONS