FUEL SYSTEM
Note the following when working on the fuel system
| WARNING | There is a risk of injury because the fuel is under very high pressure. Reduce the fuel pressure down to residual pressure before opening the high pressure area of the fuel injection system. To reduce the remaining residual pressure, place a clean cloth around the connector and carefully loosen connector. |
Procedures before opening high pressure fuel injection system, refer to Removal and Installation .
To prevent personal injury and damage to the injection and ignition system, observe the following
- The ignition must be turned off before connecting or disconnecting injection and ignition system wiring or tester cables.
- Wash the engine only when the ignition is turned off.
- If electrical connectors were disconnected and the engine was started, then malfunctions have been stored in the Engine Control Module (ECM). "Generate readiness code" in "Guided Functions" see vehicle diagnosis tester.
| CAUTION | Danger of causing damage to other electronic components when disconnecting the battery. Complete the steps for disconnecting the battery. Always turn off the ignition before disconnecting the battery. |
Disconnect the battery. Refer to Removal and Installation .
BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM
| WARNING | The injection system is separated into a high-pressure section (maximum approximately 120 bar) and a low-pressure section (approximately 6 bar). Before opening high pressure area, fuel pressure must be reduced to a residual pressure of approximately 6 bar. Refer to Removal and Installation . |
COOLING SYSTEM
Note the following when working on the cooling system
| WARNING | Risk of scalding due to hot steam and hot coolant. The coolant system is under pressure when the engine is warm. Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure. |
| CAUTION | The vehicle could overheat if the cap is installed incorrectly. The cap must click tight when closing it. |
VEHICLES WITH STOP/START
Pay attention to the following when working on a vehicle with Stop/Start
| WARNING | Danger of injury through automatic motor starting with vehicles with the Start/Stop System. For vehicles with an activated Start/Stop System (recognizable from a notification in the instrument cluster), the motor can be started automatically if needed. Make sure the Start/Stop System is disabled when working on the vehicle (turn off ignition, if needed, turn the ignition back on). |
TEST DRIVES WITH THE USE OF TEST AND MEASURING DEVICES
If testing equipment must be used during a road test, observe the following
| WARNING | Distraction and testing equipment that is not secured properly can cause accidents. The passenger airbag could pose a risk if it deploys in a collision. Operating testing equipment while driving causes it to shift position. There is an increased risk of injury due to unsecured testing equipment. Always secure testing equipment on the rear seat using a strap and have a second person in the rear seat operate it. |
EXHAUST SYSTEM
Note the following when working on the exhaust system
| CAUTION | Danger of damaging the decoupling element. Decoupling element must not be bent more than 10°. Do not load decoupling element on cable. Do not damage wire mesh at decoupling element. |
SUBFRAME
Note the following whenever working on the subframe
| CAUTION | The suspension components could be damaged. Do not rest the vehicle on its wheels if the subframe mount, the steering gear or the subframe crossbrace are not installed correctly. Do not support the vehicle on the subframe or the subframe crossbrace, for example, by a floor jack or similar device. |
CLEAN WORKING CONDITIONS
Even a little contamination can lead to faults. Observe the following guidelines for cleanliness when working on the fuel system, injection system and turbocharger
- Before loosening, connections and surrounding areas must be cleaned thoroughly with engine or brake cleaner, and then cleaned area must be dried completely.
- Seal the open lines and connections immediately with clean plugs, for example, from the engine bung Set VAS 6122.
- Place removed parts on a clean surface and cover them with lint-free cloths.
- Carefully cover over opened components or seal, if repairs are not performed immediately.
- Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored out of their original packaging (for example in tool boxes etc.).
- If system is open, do not work with compressed air and do not move the vehicle.
- Make sure no fuel gets onto the fuel hoses. If necessary, wipe off the fuel hoses immediately.
- Protect disconnected electrical connectors from dirt and moisture and only connect if dry.
ENGINE NUMBER
The engine number ("engine code" and "serial number") are located at the front of the engine/transmission joint.
In addition, a sticker with "engine code" and "serial number" is affixed to the toothed belt guard.
The engine code is also included on the vehicle data plates.
ENGINE CONTAMINANTS
- To prevent foreign objects from entering when working on the engine, seal open intake and exhaust channels with suitable plugs, for example from the engine bung Set VAS 6122.
CONTACT CORROSION
Contact corrosion can occur if incorrect fasteners (bolts, nuts, washers, etc.) are used.
For this reason, only install connecting elements that are treated with a special coating.
Also, rubber or plastic parts and adhesive consist of non-conductive materials.
If there are doubts about the suitability of parts, generally use new parts.
Note. Only original replacement parts are recommended, they are checked and compatible with aluminum. Audi accessories are recommended. Damage due to contact corrosion is not covered by warranty.
LINES, ROUTING AND SECURING
- Mark the individual fuel, hydraulic and vacuum lines for the EVAP canister system as well as the electrical wires before disconnecting and/or removing them. This will prevent a mix-up when reconnecting them. If necessary, draw sketches or take pictures.
- Due to the limited space inside the engine compartment, be especially careful when working near moving or hot parts. This will also prevent damaging the lines.
COOLERS, CONDENSERS AND CHARGE AIR COOLERS
When assembled correctly, the radiator, condenser and turbocharger may have slight impressions on their fins. This is not damage. Do no replace the cooler, condenser or turbocharger because of impressions like that.
ENGINE DATA
| Code Letters | CAEB | |
|---|---|---|
| Displacement | Liter | 1.984 |
| Output | KW at RPM | 155/6000 |
| Torque | Nm at RPM | 350/1500 |
| Bore | Diameter mm | 82.5 |
| Stroke | Mm | 92.8 |
| Compression ratio | 9.6 | |
| (Research Octane Number (RON) | 95 2) | |
| Injection system/ignition system | FSI | |
| Ignition sequence | 1-3-4-2 | |
| Knock control | Yes | |
| Turbocharger | Yes | |
| Exhaust gas recirculation (EGR) | No | |
| Variable intake manifold | No | |
| Variable valve timing | Yes | |
| Secondary air injection (AIR) | No | |
| 1) Unleaded RON 95 is also permissible, although with reduced power. 2) Unleaded RON 91 is also permissible, although with reduced power. | ||
FUEL SYSTEM, CHECKING FOR LEAKS
Let the engine run a few minutes at a moderate speed.
Turn off the ignition.
Check the entire fuel system for leaks.
If there are leaks in spite of correct tightening specifications, the corresponding component must be replaced.
Then perform a road test and depress the accelerator pedal all the way at least one time.
Then check the high pressure area again for leaks.
VACUUM SYSTEM, CHECKING
Special tools and workshop equipment required
- Hand Vacuum Pump VAS 6213
Procedure
Check all vacuum lines in the vacuum system for
- Cracks
- Damage caused by animals
- Crimps
- Leaks and leakage
Check the vacuum line leading to and from the solenoid valve.
If there is a fault, check the vacuum lines for the named component, but also all the vacuum lines.
If using the VAS 6213 does not produce any pressure or if the pressure drops again right away, then check the hand vacuum pump and the connection hoses for leaks.
CYLINDER BORE, CHECKING
A shadow or a shiny spot on the wall of the cylinder does not mean the cylinder bore is damaged as long as the cross-grinding is still visible.
Always measure the cylinder bore in 3 places laterally and longitudinally using cylinder gauge VAS 6078 or inside micrometer set 18-100 mm US1033/S.
SPECIAL TOOLS
Special tools and workshop equipment required
Scheme 2
- Hand Vacuum Pump VAS 6213
- Engine Bung Set VAS 6122
See also:
• Removal and Installation
• Removal and Installation