Installing Audi A4 B6

Installing

Install in reverse order, paying attention to the following

1. Replace the O-rings at all opened connections. (when replacing the front O-ring, ensure that the plastic cap is not removed from the injector head. The O-ring must be pulled off over the plastic cap).
2. Moisten the O-rings with clean engine oil.
3. Make sure that the injectors are installed in the correct positions.
4. Check to make sure that the retainer clamps are properly seated.

1. Position fuel rail with secured injectors on intake manifold and press evenly into place.

Tightening torque

Scheme 458

Special tools and workshop equipment required

1. V.A.G 1348/3A Remote control
2. V.A.G 1594 A Connector test kit
3. V.A.G 1598/31 Test box
4. V.A.G 1602 Injection quantity tester

1. VAS 5051 Vehicle diagnostic, testing and information system
2. VAS 5051/1 Adapter

Requirements

1. Fuel pressure OK, checking. Refer to «System pressure, fuel pressure regulator and residual pressure, checking»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-controls-fuel-injection-ignition-engine-codes-amb__system-pressure-fuel-pressure-regulator-and) .

Work sequence

1. Remove fuel rail including injectors installed from intake manifold. Refer to «Fuel injectors, removing and installing»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-controls-fuel-injection-ignition-engine-codes-amb__fuel-injectors-removing-and-installing) . Fuel hoses remain connected.
2. Connect VAG1598/31 test box at wiring harness to ECM, do not connect to ECM. Refer to «Electrical testing using VAG1598/31 test box»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-controls-fuel-injection-ignition-engine-codes-amb__electrical-testing-using-vag159831-test-box) .

Leak test

1. Jumper terminals 1 and 65 at test box using adapter cables from VAG1594A connector test kit (this step supplies Ground (GND) to one side of relay coil for Fuel Pump (FP) relay).
2. Switch ignition on.

Note. After switching ignition on, Fuel Pump (FP) will run continuously, even with engine not running. This is true because: Fuel Pump (FP) relay is supplied with B+ via central electrics after ignition is switched on. Fuel Pump (FP) relay receives ground (GND) via the jumper in test box.

1. Fuel pump must run.

1. Check proper seal of fuel injectors visually. With Fuel Pump (FP) running, only 1-2 drops per minute may drip out per injector.
2. If fuel loss is greater, stop Fuel Pump (FP) from running (switch off ignition) and replace faulty fuel injector. Refer to «Fuel injectors, removing and installing»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-controls-fuel-injection-ignition-engine-codes-amb__fuel-injectors-removing-and-installing)

Checking injection quantity

1. Insert fuel injector to be tested in a measuring glass from VAG 1602 injection quantity test device.

Scheme 459

1. Connect one terminal of fuel injector to engine Ground (GND) using an adapter cable and an alligator clip from VAG 1594 A connector test kit.
2. Connect second terminal of fuel injector to B+ using VAG 1348/3A remote control, VAG 1348/3-2 adapter cable and assisting cable.
3. Jumper terminals 1 and 65 at test box with leads from adapter set VAG 1594 A.
4. Switch ignition on.

1. Fuel pump must run.

1. Activate VAG 1348/3A remote control for 30 seconds.
2. Perform measurements on all fuel injectors.
3. After all four fuel injectors have been activated, place measuring glasses on an even surface.

1. Specification per injector: 135 ± 10 ml.

1. If measured value of one or more fuel injectors is outside of specified range, switch Fuel Pump (FP) off (switch ignition off) and replace faulty fuel injector. Refer to «Fuel injectors, removing and installing»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-controls-fuel-injection-ignition-engine-codes-amb__fuel-injectors-removing-and-installing) .
2. If measured values for all fuel injectors are outside specified range, check fuel pressure. Refer to «System pressure, fuel pressure regulator and residual pressure, checking»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-controls-fuel-injection-ignition-engine-codes-amb__system-pressure-fuel-pressure-regulator-and) .

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

1. Reinstall fuel injectors together with fuel rail. Refer to «Installing»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-controls-fuel-injection-ignition-engine-codes-amb__installing) .

Scheme 460

Special tools and workshop equipment required

1. V.A.G 1526 A Multimeter
2. V.A.G 1594 A Connector test kit
3. V.A.G 1598/31 Test Box
4. VAS 5051 Vehicle diagnostic, testing and information system

1. VAS 5051/1 Adapter

The fuel pump and certain components of the injection system are supplied with power by way of the Fuel Pump (FP) Relay -J17-.

The Fuel Pump (FP) Relay -J17- is only energized when the engine is running, i.e. the relay is only connected to ground (via the Engine Control Module) when engine speed pulses are detected in the Engine Control Module.

Note. The fuel pump relay is located on the 9-unit- relay carrier on the left in the driver's footwell, position 1.

Requirements

1. Battery voltage at least 12.7 V

Functional check of Fuel Pump (FP) Relay -J17

1. Remove driver's storage compartment

Refer to

1. «68 - INTERIOR EQUIPMENT»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#body-interior)
2. «68 - INTERIOR EQUIPMENT»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

1. Connect vehicle diagnostic, testing and information system VAS 5051. Refer to «VAS 5051 vehicle diagnostic, testing and information system, connecting and selecting functions»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-controls-fuel-injection-ignition-engine-codes-amb__vas-5051-vehicle-diagnostic-testing-and) and select vehicle system "01 -Engine electronics" in selection. Ignition must be switched on.
2. Initiate Output Diagnostic Test Mode (DTM). Refer to «Output Diagnostic Test Mode (DTM)»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-controls-fuel-injection-ignition-engine-codes-amb) and activate ACF solenoid valve -N80-.

1. Fuel pump relay (on the 9-unit-relay carrier in the driver's footwell on the left, position 1) should pull and fuel pump should run.

A - If relay does not respond

1. Check voltage supply of Fuel Pump (FP) Relay -J17-. Refer to «Checking voltage supply of Fuel Pump (FP) Relay -J17»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-controls-fuel-injection-ignition-engine-codes-amb__checking-voltage-supply-of-fuel-pump) .
2. Check activation of Fuel Pump (FP) Relay -J17-. Refer to «Checking activation of Fuel Pump (FP) Relay -J17»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-controls-fuel-injection-ignition-engine-codes-amb__checking-activation-of-fuel-pump-fp) .

B - If relay is energized but fuel pump does not run

1. Check voltage supply for fuel pump and components (via Fuel Pump (FP) Relay -J17-). Refer to «Checking voltage supply of fuel pump and components»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-controls-fuel-injection-ignition-engine-codes-amb) .