2.0l - Multiport Fuel Injection - Engine Code(s): Caeb (avant) Audi A4 B8

FUEL SYSTEM

Note. By removing the fuse -in the fuse panel in the instrument panel on the driver side-, the voltage supply to >>terminal 30<< for the fuel pump control module is interrupted. Refer to appropriate SYSTEMS WIRING DIAGRAM.

IGNITION SYSTEM

To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following

Scheme 270

1. Individuals with a pacemaker must not stay in the danger area of the high voltage systems, for example ignition system, xenon light.
2. Fuel lines must not be opened when engine is running.
3. Only disconnect and reconnect wires for injection and ignition system, including test leads, when ignition is switched off.
4. If the engine is to be cranked at starting RPM without starting (for example for compression testing), disconnect connectors from the ignition coils and remove fuse for electric fuel pump.
5. It is possible that the control module will recognize a malfunction and store a Diagnostic Trouble Code (DTC) during some tests. After completing all checks and repairs, check the DTC memory and erase the memory, if necessary.
6. If the DTC memory was erased, a new readiness code must be generated.
7. Cleaning the engine should only be performed with the ignition turned off.
8. If the engine is to be cranked at starting RPM without starting (for example for compression testing), disconnect the four connectors for the ignition coils, using the ignition coil puller T40039. Refer to «IGNITION COILS WITH POWER OUTPUT STAGES»(/audi/a4/b8-2007-2012/remont/ignition-system/#20l-ignitionglow-plug-system-engine-codes-caeb-avant__ignition-coils-with-power-output-stages) . Remove the fuse for the fuel pump control module -J538-.

Note. The fuse is located in the fuse carrier in the instrument panel. By removing the fuse -in the fuse panel in the instrument panel on the driver side-, the voltage supply to >>terminal 30<< for the Fuel Pump (FP) control module is interrupted. Refer to appropriate SYSTEMS WIRING DIAGRAM.

TEST AND MEASURING INSTRUMENTS DURING TEST DRIVE

If special testing equipment is required during a road test, note 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. Plug open lines and connections immediately with appropriate protective caps.
3. Place removed parts on a clean surface and cover them. Use lint-free cloths.
4. Only install clean components: Remove the replacement parts from their packaging just prior to installing them. Do not use parts that have been stored unpacked (for example in tool boxes etc.).
5. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.

Scheme 271

1. The Engine Control Module (ECM) is equipped with On Board Diagnostics (OBD). Before repairs such as fault finding, check the Diagnostic Trouble Code (DTC) memory first. Also the vacuum hoses and connections must be checked (unmetered air).
2. Fuel hoses in the engine compartment must only be secured with spring-type clips. The use of clamp or screw type clips is not permissible.
3. For the electric components to work properly, a voltage of at least 11.5 Volts is required.
4. Do not use sealants containing silicone. Particles of silicone drawn into the engine, will not be burnt in the engine and damage the oxygen sensor.
5. The vehicles have a crash fuel shut-off. It reduces the risk of fire in an accident because the fuel pump relay switches the fuel pump off.
6. This setup also makes it easier to start the engine. When the driver-side door is opened, the fuel pump is activated for 2 seconds so that pressure builds in the fuel system, observe safety measures. Refer to «TEST AND MEASURING INSTRUMENTS DURING TEST DRIVE»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__test-and-measuring-instruments-during-test) .
7. If it is difficult to disconnect the connectors, use a release tool f/ rev. light switch conn. T40138.

Scheme 272

1. 1 - Hose Clamp
2. 2 - Air Guide Hose
3. 3 - Hose Clamp
4. 4 - Air Ducts Clipped inside the air filter housing Clean air duct of dirt and leaves
5. 5 - Air Ducts Clean air duct of dirt and leaves
6. 6 - Air Ducts Tightened to the lock carrier to 2 Nm Clean air duct of dirt and leaves
7. 7 - Rubber Grommet
8. 8 - Water Drain Hose Clean water drain hose of dirt and leaves (important)
9. 9 - Water Drain Hose Guide
10. 10 - Warm Air Intake (cold climate countries only) Slide the warm air intake into the air filter as far as the stop and then turn it clockwise until it engages.
11. 11 - Air Filter Housing Lower Section Clean the lower section of the air filter from salt, dirt and leaves. Check water drain for dirt, clean if necessary (important)
12. 12 - Air Filter Housing Lower Section Mount Audibly latches Do not use lubricant
13. 13 - Intake Air Switch-Over Valve -N335- The components (bypass flap with intake air switch-over valve) are not installed in all equipment packages and/or in all country versions
14. 14 - Bolt Only if the intake air switch-over valve is installed
15. 15 - Air Filter Always use an original air filter Removing and installing, refer to «AIR FILTER»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant) Clean snow screen also (if present)
16. 16 - Attachment for the Air Filter Housing Lower Section
17. 17 - Air Filter Upper Section Clean the upper section of the air filter from salt, dirt and leaves.
18. 18 - Bolt
19. 19 - O-ring Replace if damaged
20. 20 - Mass Airflow Sensor Mass Airflow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42-, removing and installing, refer to «Mass Airflow Sensor -G70»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)

HIGH PRESSURE PUMP OVERVIEW

Scheme 273

1. 1 - Fuel Supply Line from the Fuel Tank
2. 2 - High Pressure Pump Bolt First tighten the bolts diagonally hand-tight, then to 5 Nm and then to 20 Nm. Do not tilt the high pressure pump
3. 3 - High Pressure Pump There is an electric fuel pump located in the tank that supplies the fuel to the mechanical high pressure pump. When installing, make sure that no dirt enters the fuel system. The fuel system must be without pressure to install the high-pressure pump, releasing fuel pressure, refer to «RELEASING PRESSURE IN HIGH PRESSURE AREA»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__releasing-pressure-in-high-pressure-area) Install the fuel lines free of tension Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__high-pressure-pump)
4. 4 - O-ring Replace
5. 5 - Roller Tappet Remains inserted in the vacuum pump after removing the high pressure pump
6. 6 - Connecting Piece No replacement part, it is part of the high pressure pump Do not loosen
7. 7 - Adapter 40 Nm There is an adapter between the connection and the fuel supply line, depending on the date of manufacture. If the adapter is there, replace it.
8. 8 - High Pressure Fuel Line 20 Nm Do not install fuel line with tension
9. 9 - High Pressure Pump Bolt First tighten the bolts diagonally hand-tight, then to 5 Nm and then to 20 Nm. Do not tilt the high pressure pump
10. 10 - Fuel Supply Line Connection on the Fuel Rail 40 Nm Replace
11. 11 - Fuel Rail Removing and installing, refer to «FUEL RAIL»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__fuel-rail)

Scheme 274

1 - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and heater for Oxygen Sensor (O2S) 1 after catalytic converter -Z29

2 - Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) heater -Z19

1. Tightening Specifications: 55 Nm

Scheme 275

1 - Evaporative Emission (EVAP) canister purge regulator valve 1 -N80

2 - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and heater for Oxygen Sensor (O2S) 1 after catalytic converter -Z29

3 - Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) heater -Z19

Component Location for Engine Code CPMA

Scheme 276

6 - Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) heater -Z19

Scheme 277

1 - EVAP canister purge regulator valve 1

2 - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and heater for Oxygen Sensor (O2S) 1 after catalytic converter -Z29

Note. New oxygen sensors are coated with assembly paste; the paste must not get into the slots of the oxygen sensor body. For a used oxygen sensor, only coat the threads with hot bolt paste. This paste must not come into contact with oxygen sensor slots. Hot bolt paste, Wiring connection of oxygen sensor must always be secured in the same position when installing so that the contact with the exhaust pipe is avoided.

Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) heater -Z19-, removing and installing, refer to Heated Oxygen Sensor -G39- AND Oxygen Sensor Heater -Z19 .

Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and heater for Oxygen Sensor (O2S) 1 after catalytic converter -Z29-, removing and installing, refer to Oxygen Sensor after Three Way Catalytic Converter -G130- AND Heater for Oxygen Sensor 1 after Catalytic Converter -Z29 .

FUEL INJECTORS, CLEANING

Special tools and workshop equipment required

1. Ultrasonic Cleaning Unit VAS 6418
2. Injection Module Mounting Plate VAS 6418/1
3. Cleaning Fluid

Cleaning

Remove the fuel injectors. Refer to FUEL INJECTORS .

Note. Follow the safety precautions and the instructions for the ultrasonic device.

The ultrasonic device must be filled with cleaning fluid.

Note. Fill the ultrasonic device up to the upper edge of the holes with cleaner (see the magnified area of the illustration).

Insert the injector valve -1- all the way into the VAS 6418/1 -2-.

Scheme 278

Adjust the temperature to 50 degrees using the knob -4-.

Set a cleaning time of 30 minutes using the knob -5-.

Turn the ultrasonic device on with the button -3-.

Note. The time begins counting down once the cleaning temperature reaches 50 degrees.

Replace the combustion chamber seal (Teflon® seal) after cleaning each fuel injector. Refer to TEFLON® COMBUSTION CHAMBER SEAL .

Install the fuel injectors. Refer to FUEL INJECTORS .

THROTTLE VALVE CONTROL MODULE -J338-, CLEANING

Note. If a new Engine Control Module (ECM) -J623- is installed, then it must be adapted to the throttle valve control module. The throttle valve connections must not be damaged when cleaning.

Remove the throttle valve control module. Refer to Throttle Valve Control Module -J338 .

Open the throttle valve by hand and hold it in the open position with a suitable object (for example, a plastic or wood wedge) -arrow-.

Scheme 279

Clean the throttle valve connections, especially in the area -arrows- of the closed throttle valve, with standard acetone and a brush.

Scheme 280

Wipe throttle valve connections with a lint-free cloth.

Allow acetone to dry completely and reinstall cleaned throttle valve control module.

Erase the adaptation values and adapt the ECM to the throttle valve control module. Use vehicle diagnostic tester for this.

RELEASING PRESSURE IN HIGH PRESSURE AREA

Special tools and workshop equipment required

1. Trim Removal Wedge 3409

High Fuel Pressure, Reducing

Connect a vehicle diagnosis tester.

Start the engine and run at idle speed.

Select "Engine electronics" in On Board Diagnostics (OBD).

Select "Measured values".

Select "Fuel pressure" from the list.

Pry the cover -1- on the left and right of the instrument panel off, for example using the 3409 -arrow-.

Scheme 281

Remove the fuse from the Fuel Pump (FP) control module -J538- with the engine idling. Refer to appropriate SYSTEMS WIRING DIAGRAM.

Note. By removing the fuse, the voltage supply to >>terminal 30<< for the FP control module is interrupted.

Check the fuel pressure on the diagnostic system.

1. The fuel pressure decreases rapidly because the mechanical high pressure pump is no longer supplied with fuel from the transfer fuel pump -G6-.

Turn the ignition off as soon as the fuel pressure drops to approximately 8 bar.

Note. The fuel pressure must not drop below 6 bar, because otherwise the engine will shut off (risk of catalytic converter damage).

After reducing the fuel pressure, place a clean cloth around the connection and open the high pressure system >>immediately<<. Escaping fuel must be absorbed.

Note. If the high pressure system is not opened immediately, the pressure will increase because of post-heating.

Final Procedures

Install the fuse.

Erase the Diagnostic Trouble Code (DTC) memory and generate the readiness code in the Engine Control Module (ECM) in "Guided Functions".

COMPONENT LOCATIONS OVERVIEW

Components A through I are not depicted in the exploded view illustration.

Scheme 282

1. 1 - Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19- Component location (Scheme 302)Removing and installing, refer to «Heated Oxygen Sensor -G39- AND Oxygen Sensor Heater -Z19»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__heated-oxygen-sensor-g39-and-oxygen)
2. 2 - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor (O2S) 1 after Catalytic Converter -Z29- Component location (Scheme 302)Removing and installing, refer to «Oxygen Sensor after Three Way Catalytic Converter -G130- AND Heater for Oxygen Sensor 1 after Catalytic Converter -Z29»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__oxygen-sensor-after-three-way-catalytic)
3. 3 - Fuel Pressure Regulator Valve -N276- Component location (Scheme 297)
4. 4 - High Pressure Pump Removing and installing (Scheme 297)
5. 5 - Channel Separating Plate Vacuum Diaphragm (intake manifold flaps) Component location (Scheme 293)
6. 6 - Intake Manifold Runner Control (IMRC) Valve -N316- Component location (Scheme 293)
7. 7 - Engine Speed (RPM) Sensor -G28- 4.5 Nm Component location (Scheme 298)
8. 8 - Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80
9. 9 - 6-Pin Connectors For Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19- (black) Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor (O2S) 1 after Catalytic Converter -Z29- (brown connector) Component location see scheme 35
10. 10 - Connectors For Knock Sensor (KS) 1 -G61-, IMRC valve, fuel pressure sensor -G247-, intake manifold runner position sensor -G336-, Engine Coolant Temperature (ECT) sensor -G62-, Camshaft Position (CMP) sensor -G40- and fuel injectors N30...N33 Component location (Scheme 296)
11. 11 - Engine Control Module (ECM) -J623- Component location (Scheme 284)Removing and installing, refer to «Engine Control Module -J623»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__engine-control-module-j623)
12. 12 - Charge Air Pressure Sensor -G31- Component location see scheme 34Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/blowers-superchargers-turbochargers/#20l-turbocharger-supercharger-engine-codes-caeb-avant)
13. 13 - Throttle Valve Control Module -J338-, Electronic Power Control (EPC) throttle drive -G186- EPC throttle drive angle sensor 1 -G187- and EPC throttle drive angle sensor 2 -G188- Each time the throttle valve control module is removed and installed or replaced, it must be adapted to the ECM. Component location (Scheme 300)
14. 14 - Intake Air Temperature (IAT) Sensor -G42- Component location (Scheme 300)
15. 15 - Knock Sensor (KS) 1 -G61- 20 Nm In order to remove, the coolant pump and coolant thermostat must be removed Removing and installing, refer to «Knock Sensor 1 -G61»(/audi/a4/b8-2007-2012/remont/ignition-system/#20l-ignitionglow-plug-system-engine-codes-caeb-avant)
16. 16 - Engine Coolant Temperature (ECT) Sensor -G62- Component location (Scheme 301)Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/cooling-fan/#20l-cooling-system-engine-codes-caeb-avant)
17. 17 - Fuel Pressure Sensor -G247- Component location (Scheme 292)Removing and installing, refer to «Fuel Pressure Sensor -G247»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__fuel-pressure-sensor-g247)
18. 18 - Oil Pressure Regulation Valve -N428- Component location (Scheme 290)Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/lubrication-system/#20l-lubrication-engine-codes-caeb-avant)
19. 19 - Reduced Oil Pressure Switch -F378- Component location (Scheme 289)Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/lubrication-system/#20l-lubrication-engine-codes-caeb-avant)
20. 20 - Oil Pressure Switch -F22- Component location (Scheme 289)Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/lubrication-system/#20l-lubrication-engine-codes-caeb-avant)
21. 21 - Intake Manifold Runner Position Sensor -G336- Component location (Scheme 294)
22. 22 - Camshaft Position (CMP) Sensor -G40- Component location (Scheme 295)
23. 23 - Camshaft Adjustment Valve 1 -N205- Component location (Scheme 299)Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant)
24. 24 - Ignition Coils with Power Output Stages Component location (Scheme 291)The ignition coils must be pulled out of the cylinder head using the ignition coil puller T40039 Removing and installing, refer to «IGNITION COILS WITH POWER OUTPUT STAGES»(/audi/a4/b8-2007-2012/remont/ignition-system/#20l-ignitionglow-plug-system-engine-codes-caeb-avant__ignition-coils-with-power-output-stages)
25. 25 - Turbocharger Recirculating Valve -N249- Installed directly on turbocharger (Scheme 303)Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/blowers-superchargers-turbochargers/#20l-turbocharger-supercharger-engine-codes-caeb-avant)
26. 26 - Cam Adjustment Actuator Cam adjustment actuator 1 -F366- Cam adjustment actuator 2 -F367- Cam adjustment actuator 3 -F368- Cam adjustment actuator 4 -F369- Cam adjustment actuator 5 -F370- Cam adjustment actuator 6 -F371- Cam adjustment actuator 7 -F372- Cam adjustment actuator 8 -F373- Component location (Scheme 291)Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant)
27. 27 - Wastegate Bypass Regulator Valve -N75- Installed directly on turbocharger (Scheme 303)Removing and installing, refer to «Description and Operation»(/audi/a4/b8-2007-2012/remont/blowers-superchargers-turbochargers/#20l-turbocharger-supercharger-engine-codes-caeb-avant)
28. 28 - Mass Airflow (MAF) Sensor -G70- Removing and installing, refer to «Mass Airflow Sensor -G70»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)
29. A - Data Link Connector (DLC) In knee bolster on driver's side
30. B - Fuel Pump (FP) Control Module -J538- Component location (Scheme 285)Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-fuel-supply-system-engine-codes-caeb-avant)
31. C - Brake Lamp Switch -F- and Brake Pedal Switch -F47- Component location (Scheme 287)In footwell at brake pedal Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/anti-locktraction-control/#anti-lock-brake-system-avant)
32. D - Clutch Position Sensor -G476- Only on vehicles with a manual transmission Component location (Scheme 287)
33. E - Accelerator Pedal Position Sensor -G79- and Accelerator Pedal Position Sensor 2 -G185- Component location (Scheme 286)On accelerator pedal (both sensors are stored in one housing Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-fuel-supply-system-engine-codes-caeb-avant)
34. F - Coolant Fan Control Module -J293- Installed inside the coolant fan
35. G - Fuel Injectors Cylinder 1 fuel Injector -N30- Cylinder 2 fuel Injector -N31- Cylinder 3 fuel Injector -N32- Cylinder 4 fuel Injector -N33- Removing and installing, refer to «FUEL INJECTORS»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__fuel-injectors)
36. H - After-Run Coolant Pump -V51- Not installed on all vehicles (only extreme hot climate countries) Component location (Scheme 288)Removing and installing, refer to «Description and Operation»(/audi/a4/b8-2007-2012/remont/blowers-superchargers-turbochargers/#20l-turbocharger-supercharger-engine-codes-caeb-avant)
37. I - Left Electrohydraulic Engine Mount Solenoid Valve -N144- Not installed in all vehicles (depends on the transmission)

Scheme 283

1. Inside the left E-box in the engine compartment.

Scheme 284

Removing and installing, refer to Removal and Installation .

Scheme 285

2 - Connector

Scheme 286

Integrated functions: clutch pedal starter interlock switch -F194- and clutch pedal switch -F36- (manual transmission only)

1 - Brake lamp switch and brake pedal switch

Scheme 287

1 - After-run coolant pump connector

Scheme 288

1 - Oil pressure switch connector

2 - Oil pressure switch

3 - Reduced oil pressure switch

4 - Reduced oil pressure switch connector

Scheme 289

Scheme 290

1 - Ignition coil 1 with power output stage -N70

2 - Ignition coil 2 with power output stage -N127

3 - Ignition coil 3 with power output stage -N291

4 - Ignition coil 4 with power output stage -N292

5 - Cam adjustment actuator 2 -F367- (for cylinder 1)

6 - Cam adjustment actuator 1 -F366- (for cylinder 1)

7 - Cam adjustment actuator 3 -F368- (for cylinder 2)

8 - Cam adjustment actuator 4 -F369- (for cylinder 2)

9 - Cam adjustment actuator 6 -F371- (for cylinder 3)

10 - Cam adjustment actuator 5 -F370- (for cylinder 3)

11 - Cam adjustment actuator 7 -F372- (for cylinder 4)

12 - Cam adjustment actuator 8 -F373- (for cylinder 4)

Scheme 291

Scheme 292

1 - Intake manifold flap vacuum diaphragm

Scheme 293

Scheme 294

Scheme 295

1 - From EVAP canister purge regulator valve 1

2 - From the KS 1

3 - (14-pin) intake manifold runner control valve, fuel pressure sensor, intake manifold runner position sensor, ECT Sensor and CMP Sensor

4 - (8-pin) from fuel injectors N30 to N33

5 - From the throttle valve control module

6 - IAT sensor

Scheme 296

1 - Fuel pressure regulator valve

2 - High pressure pump

3 - -arrows- bolts

Scheme 297

Scheme 298

Scheme 299

1 - IAT sensor

2 - Throttle valve control module

Scheme 300

Installed below from the intake manifold inside the coolant pump.

Scheme 301

Removing and installing, refer to Removal and Installation

1 - EVAP canister purge regulator valve 1 -N80

2 - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor (O2S) 1 after Catalytic Converter -Z29

3 - Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19

1 - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor (O2S) 1 after Catalytic Converter -Z29

2 - Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19

Scheme 302

1 - Turbocharger

2 - Turbocharger vacuum diaphragm, checking, adjusting, removing and installing, refer to Diagnosis and Testing

3 - Wastegate bypass regulator valve

4 - Turbocharger recalculating valve (note the installation position, next illustration)

Removing and installing turbocharger components, refer to Removal and Installation

Scheme 303

Scheme 304

1. 1 - Intake Air Temperature (IAT) Sensor -G42- Bolt 9 Nm
2. 2 - Intake Air Temperature Sensor -G42
3. 3 - Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80- With double check-valve, checking refer to «DOUBLE CHECK-VALVE, CHECKING»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__double-check-valve-checking)
4. 4 - Intake Manifold 9 Nm. Removing and installing, refer to «INTAKE MANIFOLD»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__intake-manifold)
5. 5 - Channel Separating Plate Vacuum Diaphragm (intake manifold flaps)
6. 6 - Intake Manifold Runner Control Valve -N316
7. 7 - Fuel Injectors Replace the O-ring and Teflon® ring Note correct installation position Removing and installing, refer to «FUEL INJECTORS»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__fuel-injectors)
8. 8 - Intake Manifold Support
9. 9 - Intake Manifold Support Bolt 23 Nm
10. 10 - Intake Manifold Support Nut 10 Nm
11. 11 - Throttle Valve Control Module -J338- Bolts 10 Nm
12. 12 - Throttle Valve Control Module -J338-, Electronic Power Control (EPC) Throttle Drive -G186- EPC throttle drive angle sensor 1 -G187- and EPC throttle drive angle sensor 2 -G188- After replacing the throttle valve control module, it must be adapted to the Engine Control Module (ECM) -J623-. Use a vehicle diagnosis tester.
13. 13 - Seal Replace

Scheme 305

1. 1 - Fuel Injector With combustion chamber seal (Teflon® seal), always replace Replace O-rings Note correct installation position Removing and installing, refer to «FUEL INJECTORS»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__fuel-injectors)
2. 2 - Support Ring
3. 3 - Fuel Rail Removing and installing, refer to «FUEL RAIL»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__fuel-rail)
4. 4 - High Pressure Pump With fuel pressure regulator valve -N276- There is an electric fuel pump located in the tank that supplies the fuel to the mechanical high pressure pump. When installing, make sure that no dirt enters the fuel system. The fuel system must be without pressure to install the high-pressure pump, releasing fuel pressure, refer to «RELEASING PRESSURE IN HIGH PRESSURE AREA»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__releasing-pressure-in-high-pressure-area) Install the fuel lines free of tension Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__high-pressure-pump)
5. 5 - Roller Tappet
6. 6 - Fuel Pressure Regulator Valve -N276
7. 7 - High Pressure Pump Bolts First tighten the bolts diagonally hand-tight, then to 5 Nm and then to 20 Nm.
8. 8 - Connections for the Fuel Supply Line on the Fuel Rail 40 Nm Replace
9. 9 - Fuel Supply Line Union Nut 20 Nm
10. 10 - Channel Separating Plates (intake manifold flaps)
11. 11 - Gasket Replace
12. 12 - Intake Manifold Removing and installing, refer to «INTAKE MANIFOLD»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__intake-manifold)
13. 13 - Vacuum Diaphragm for the Charge-Motion Valves
14. 14 - Throttle Valve Control Module -J338-, Electronic Power Control (EPC) Throttle Drive -G186- 7 Nm EPC throttle drive angle sensor 1 -G187- and EPC throttle drive angle sensor 2 -G188- It is necessary to adapt the throttle valve control module to the Engine Control Module (ECM) -J623- whenever it is removed and installed or replaced. Use a vehicle diagnosis tester.
15. 15 - Intake Manifold Bolts 9 Nm
16. 16 - Intake Manifold Runner Position Sensor -G336- Adapt the intake manifold runner position sensor to the ECM after removing, installing or replacing the intake manifold runner position sensor or the intake manifold. Use a vehicle diagnostic tester in "Guided Functions".
17. 17 - Fuel Pressure Sensor -G247- 27 Nm Coat the threads with clean engine oil. Always replace the connections and tighten them to 40 Nm. Removing and installing, refer to «Fuel Pressure Sensor -G247»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__fuel-pressure-sensor-g247)

Scheme 306

1. 1 - Mass Airflow (MAF) Sensor -G70- Removing and installing, refer to «Mass Airflow Sensor -G70»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)
2. 2 - Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19- Component location see scheme 62Removing and installing, refer to «Heated Oxygen Sensor -G39- AND Oxygen Sensor Heater -Z19»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__heated-oxygen-sensor-g39-and-oxygen)
3. 3 - Heated Oxygen Sensor (HO2S) -G39- Connector Component location see scheme 48
4. 4 - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor (O2S) 1 after Catalytic Converter -Z29- Component location see scheme 62Removing and installing, refer to «Oxygen Sensor after Three Way Catalytic Converter -G130- AND Heater for Oxygen Sensor 1 after Catalytic Converter -Z29»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__oxygen-sensor-after-three-way-catalytic)
5. 5 - Fuel Pressure Regulator Valve -N276- Component location (Scheme 307)
6. 6 - High Pressure Pump Removing and installing (Scheme 297)
7. 7 - Low Fuel Pressure Sensor -G410- Component location see scheme 55
8. 8 - Channel Separating Plate Vacuum Diaphragm (intake manifold flaps) Component location see scheme 50
9. 9 - Intake Manifold Runner Control (IMRC) Valve -N316- Component location see scheme 50
10. 10 - Engine Speed (RPM) Sensor -G28- 4.5 Nm Component location see scheme 56
11. 11 - Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80- Component location see scheme 61
12. 12 - 6-Pin Connector Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor (O2S) 1 after Catalytic Converter -Z29- Component location see scheme 61
13. 13 - Connectors For Knock Sensor (KS) 1 -G61-, IMRC, fuel pressure sensor, intake manifold runner position sensor, Engine Coolant Temperature (ECT) sensor -G62-, Camshaft Position (CMP) sensor -G40- and fuel injectors N30...N33 Component location see scheme 53
14. 14 - Throttle Valve Control Module -J338-, Electronic Power Control (EPC) Throttle Drive -G186- EPC throttle drive angle sensor 1 -G187- and EPC throttle drive angle sensor 2 -G188- Each time the throttle valve control module is removed and installed or replaced, it must be adapted to the Engine Control Module (ECM) -J623
15. 15 - Engine Control Module (ECM) -J623- Component location see scheme 42Removing and installing, refer to «Engine Control Module -J623»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__engine-control-module-j623)
16. 16 - Charge Air Pressure Sensor -G31- Component location (Scheme 308)Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/blowers-superchargers-turbochargers/#20l-turbocharger-supercharger-engine-codes-caeb-avant)
17. 17 - Intake Manifold Vacuum Connection
18. 18 - Cold Start Injector -N17- Component location see scheme 60
19. 19 - Knock Sensor (KS) 1 -G61- 20 Nm In order to remove, the coolant pump and coolant thermostat must be removed Removing and installing, refer to «Knock Sensor 1 -G61»(/audi/a4/b8-2007-2012/remont/ignition-system/#20l-ignitionglow-plug-system-engine-codes-caeb-avant)
20. 20 - Intake Air Temperature (IAT) Sensor -G42
21. 21 - Engine Coolant Temperature (ECT) Sensor -G62- Component location see scheme 58Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/cooling-fan/#20l-cooling-system-engine-codes-caeb-avant)
22. 22 - Oil Pressure Regulation Valve -N428- Component location see scheme 47Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/lubrication-system/#20l-lubrication-engine-codes-caeb-avant)
23. 23 - Reduced Oil Pressure Switch -F378- Component location see scheme 46Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/lubrication-system/#20l-lubrication-engine-codes-caeb-avant)
24. 24 - Fuel Pressure Sensor -G247- Component location see scheme 49Removing and installing, refer to «Fuel Pressure Sensor -G247»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__fuel-pressure-sensor-g247)
25. 25 - Oil Pressure Switch -F22- Component location see scheme 46Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/lubrication-system/#20l-lubrication-engine-codes-caeb-avant)
26. 26 - Intake Manifold Runner Position Sensor -G336- Component location see scheme 51If the intake manifold is replaced, the intake manifold runner position sensor must be adapted to the ECM.
27. 27 - Camshaft Adjustment Valve 1 -N205- Component location see scheme 57Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant)
28. 28 - Camshaft Position (CMP) Sensor -G40- Component location see scheme 52
29. 29 - Ignition Coils with Power Output Stages Component location see scheme 48The ignition coils must be pulled out of the cylinder head using the ignition coil puller T40039 Removing and installing, refer to «IGNITION COILS WITH POWER OUTPUT STAGES»(/audi/a4/b8-2007-2012/remont/ignition-system/#20l-ignitionglow-plug-system-engine-codes-caeb-avant__ignition-coils-with-power-output-stages)
30. 30 - Turbocharger Recirculating Valve -N249- Installed directly on the turbocharger Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/blowers-superchargers-turbochargers/#20l-turbocharger-supercharger-engine-codes-caeb-avant)
31. 31 - Cam Adjustment Actuator Cam adjustment actuator 1 -F366- Cam adjustment actuator 2 -F367- Cam adjustment actuator 3 -F368- Cam adjustment actuator 4 -F369- Cam adjustment actuator 5 -F370- Cam adjustment actuator 6 -F371- Cam adjustment actuator 7 -F372- Cam adjustment actuator 8 -F373- Component location see scheme 48Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant)
32. 32 - Wastegate Bypass Regulator Valve -N75- Installed directly on the turbocharger Removing and installing, refer to «Description and Operation»(/audi/a4/b8-2007-2012/remont/blowers-superchargers-turbochargers/#20l-turbocharger-supercharger-engine-codes-caeb-avant)
33. A - Fuel Pump Control Module -J538- Component location see scheme 43Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-fuel-supply-system-engine-codes-caeb-avant)
34. B - Brake Lamp Switch - F- and Brake Pedal Switch -F47- Component location see scheme 45In footwell at brake pedal Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/anti-locktraction-control/#anti-lock-brake-system-avant)
35. C - Clutch Position Sensor -G476- Only on vehicles with a manual transmission Component location see scheme 45
36. D - Accelerator Pedal Position Sensor -G79- and Accelerator Pedal Position Sensor 2 -G185- Component location see scheme 44On accelerator pedal (both sensors are stored in one housing) Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-fuel-supply-system-engine-codes-caeb-avant)
37. E - Coolant Fan Control Module -J293- Installed inside the coolant fan
38. F - Fuel Injectors Cylinder 1 fuel Injector -N30- Cylinder 2 fuel Injector -N31- Cylinder 3 fuel Injector -N32- Cylinder 4 fuel Injector -N33- Removing and installing, refer to «FUEL INJECTORS»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__fuel-injectors) Fuel injectors referred to here are high pressure fuel injectors. They inject fuel directly into the cylinder under high pressure (max. approximately 120 bar).
39. G - After-Run Coolant Pump -V51- Not installed on all vehicles (extreme hot climate countries) Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/cooling-fan/#20l-cooling-system-engine-codes-caeb-avant)
40. H - Left Electrohydraulic Engine Mount Solenoid Valve -N144- Not installed in all vehicles (depends on the transmission)
41. I - Fuel Quality Sensor -G446- Component location (Scheme 310)

Removing and installing, refer to Removal and Installation .

Integrated functions: clutch pedal starter interlock switch -F194- and clutch pedal switch -F36- (manual transmission only)

1 - Brake lamp switch and brake pedal switch

1 - Oil pressure switch connector

2 - Oil pressure switch

3 - Reduced oil pressure switch

4 - Reduced oil pressure switch connector

1 - Low fuel pressure sensor -G410

2 - Ignition coil 1 with power output stage -N70

3 - Ignition coil 2 with power output stage -N127

4 - Ignition coil 3 with power output stage -N291

5 - Ignition coil 4 with power output stage -N292

6 - Oxygen sensor -G39- connector

7 - Cam adjustment actuator 2 -F367- (for cylinder 1)

8 - Cam adjustment actuator 1 -F366- (for cylinder 1)

9 - Cam adjustment actuator 3 -F368- (for cylinder 2)

10 - Cam adjustment actuator 4 -F369- (for cylinder 2)

11 - Cam adjustment actuator 6 -F371- (for cylinder 3)

12 - Cam adjustment actuator 5 -F370- (for cylinder 3)

13 - Cam adjustment actuator 7 -F372- (for cylinder 4)

14 - Cam adjustment actuator 8 -F373- (for cylinder 4)

1 - Intake manifold flap vacuum diaphragm

1 - From EVAP canister purge regulator valve 1 -N80

2 - From the KS 1

3 - (14-pin) IMRC valve, fuel pressure sensor, intake manifold runner position sensor, ECT sensor and CMP sensor

4 - (8-pin) from fuel injectors N30 to N33

5 - from the throttle valve control module

6 - IAT sensor

1 - Fuel pressure regulator valve

2 - Fuel high pressure pump

3 - -arrows- bolts

Scheme 307

It is installed under the intake manifold inside the coolant pump.

Removing and installing, refer to Removal and Installation .

Scheme 308

1 - EVAP canister purge regulator valve 1

2 - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor (O2S) 1 after Catalytic Converter -Z29

1 - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor (O2S) 1 after Catalytic Converter -Z29

2 - Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19

1 - Turbocharger

2 - Turbocharger vacuum diaphragm, checking, adjusting, removing and installing, refer to Removal and Installation

3 - Wastegate bypass regulator valve

4 - Turbocharger recalculating valve (note the installation position, next illustration)

Removing and installing turbocharger components, refer to Removal and Installation

Scheme 309

The fuel quality sensor is installed on the underbody on the right side (-arrow- pointing in the direction of travel).

Scheme 310

1. 1 - Intake Air Temperature Sensor -G42- Bolt 9 Nm
2. 2 - Intake Air Temperature (IAT) Sensor -G42
3. 3 - Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80
4. 4 - Intake Manifold Tighten to 9 Nm. Removing and installing, refer to «INTAKE MANIFOLD UPPER SECTION»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__intake-manifold-upper-section)
5. 5 - Channel Separating Plate Vacuum Diaphragm (intake manifold flaps)
6. 6 - High Pressure Pump Bolts First tighten the bolts diagonally hand-tight, then to 5 Nm and then to 20 Nm.
7. 7 - Fuel Supply Line Connectors Coming from the tank
8. 8 - Fuel Pressure Regulator Valve -N276
9. 9 - High Pressure Pump With fuel pressure regulator valve There is an electric fuel pump located in the tank that supplies the fuel to the mechanical high pressure pump. When installing, make sure that no dirt enters the fuel system. The fuel system must be without pressure to install the high-pressure pump, releasing fuel pressure, refer to «RELEASING PRESSURE IN HIGH PRESSURE AREA»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__releasing-pressure-in-high-pressure-area) Install the fuel lines free of tension Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__high-pressure-pump)
10. 10 - Roller Tappet Can remain in the vacuum pump after removing the high pressure pump, removable
11. 11 - Fuel Supply Line Connectors 40 Nm No replacement part, it is part of the high pressure pump Do not loosen There is an adapter between the connection and the fuel supply line, depending on the date of manufacture. If the adapter is there, replace it.
12. 12 - Fuel Supply Line Union Nut Install the fuel lines free of tension 20 Nm
13. 13 - Intake Manifold Runner Control Valve -N316
14. 14 - Fuel Injectors Replace the O-ring and Teflon® ring Note correct installation position Removing and installing, refer to «FUEL INJECTORS»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__fuel-injectors)
15. 15 - Intake Manifold Support Nut 10 Nm
16. 16 - Intake Manifold Support
17. 17 - Intake Manifold Support Bolt 23 Nm
18. 18 - Throttle Valve Control Module -J338- Bolts 10 Nm
19. 19 - Throttle Valve Control Module, Electronic Power Control (EPC) Throttle Drive -G186- EPC throttle drive angle sensor 1 -G187- and EPC throttle drive angle sensor 2 -G188- After replacing the throttle valve control module, it must be adapted to the Engine Control Module (ECM) -J623-. Use a vehicle diagnosis tester.
20. 20 - Gasket Replace

Scheme 311

1. Tightening Specifications: 10 Nm

Scheme 312

1. Tightening Specifications: 10 Nm

Scheme 313

1. 1 - Fuel Injector With combustion chamber seal (Teflon® seal), always replace Replace O-rings Note correct installation position Removing and installing, refer to «FUEL INJECTORS»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__fuel-injectors)
2. 2 - Support Ring
3. 3 - Fuel Rail 10 Nm Removing and installing, refer to «INTAKE MANIFOLD LOWER SECTION»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__intake-manifold-lower-section)
4. 4 - High Pressure Pump With fuel pressure regulator valve -N276- There is an electric fuel pump located in the tank that supplies the fuel to the mechanical high pressure pump. When installing, make sure that no dirt enters the fuel system. The fuel system must be without pressure to install the high-pressure pump, releasing fuel pressure, refer to «RELEASING PRESSURE IN HIGH PRESSURE AREA»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__releasing-pressure-in-high-pressure-area) . Install the fuel lines free of tension Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__high-pressure-pump)
5. 5 - Roller Tappet
6. 6 - Fuel Pressure Regulator Valve -N276
7. 7 - High Pressure Pump Bolts First tighten the bolts diagonally hand-tight, then to 5 Nm and then to 20 Nm.
8. 8 - Connections for the Fuel Supply Line on the Fuel Rail 40 Nm Replace
9. 9 - Fuel Supply Line Union Nut 20 Nm
10. 10 - Channel Separating Plates (intake manifold flaps)
11. 11 - Gasket Replace
12. 12 - Intake Manifold Removing and installing, refer to «INTAKE MANIFOLD UPPER SECTION»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__intake-manifold-upper-section)
13. 13 - Vacuum Diaphragm for the Charge-Motion Valves
14. 14 - Throttle Valve Control Module -J338-, Electronic Power Control (EPC) Throttle Drive -G186- 7 Nm EPC throttle drive angle sensor 1 -G187- and EPC throttle drive angle sensor 2 -G188- It is necessary to adapt the throttle valve control module to the Engine Control Module (ECM) -J623- whenever it is removed and installed or replaced. Refer to "Guided Functions"
15. 15 - Intake Manifold Bolts 9 Nm
16. 16 - Intake Manifold Runner Position Sensor -G336- If the intake manifold runner position sensor is replaced, then the new intake manifold runner position sensor must be adapted to the ECM. Refer to "Guided Functions". Adapt the intake manifold runner position sensor to the ECM every time the intake manifold runner position sensor or intake manifold are removed and replaced. Use a vehicle diagnosis tester.
17. 17 - Fuel Pressure Sensor -G247- 27 Nm Coat the threads with clean engine oil. Always replace the connections and tighten them to 40 Nm.

Scheme 314

Removing and installing, refer to Cold Start Injector -N17 .

FASTENER TIGHTENING SPECIFICATIONS

TECHNICAL DATA

DOUBLE CHECK-VALVE, CHECKING

Special tools and workshop equipment required

1. Hand Vacuum Pump VAS 6213
2. Connector Test Set V.A.G 1594C

Test Conditions

1. The Evaporative Emission (EVAP) canister purge regulator valve 1 -N80- was tested with the vehicle diagnostic tester and is OK.

Remove the engine cover.

Disconnect the connector -1- and the ventilation hose -arrow- from the EVAP canister purge regulator valve.

Set the slide ring -1- on the VAS 6213 to the -A- position for "vacuum."

Scheme 315

Connect the VAS 6213 to the EVAP canister purge regulator valve 1.

Scheme 316

Using the lines, connect the contacts on the EVAP canister purge regulator valve 1 -1- to the battery. This opens the EVAP canister purge regulator valve 1.

Then activate the VAS 6213 several times.

1. Vacuum must build up.

Disconnect the battery again (interrupt the power supply).

No vacuum

Replace the double check-valve -1-.

The double check-valve, the EVAP canister purge regulator valve 1 and the plastic hoses are a single component and can only be replaced together.

FUEL HOLDING PRESSURE, CHECKING WITH HIGH PRESSURE PUMP

Special tools and workshop equipment required

1. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
2. Adapter V.A.G 1318/11
3. Adapter V.A.G 1318/17-1
4. Fuel Line Feed Adapter V.A.G 1318/23
5. Measuring Container, Fuel-Resistant
6. Protective Gloves

Test Conditions

1. Battery voltage at least 12.5 V.
2. Fuel filter OK.
3. Fuel tank minimum 1 / 4 full.
4. Fuel Pump (FP) control module -J538- OK.
5. The ignition is off.

Checking the Fuel Pressure

Pull the release ring -1- and disconnect the fuel line -2-.

Scheme 317

Attach V.A.G 1318/23 and V.A.G 1318/17-1 to V.A.G 1318.

Scheme 318

Install the V.A.G 1318/17-1 on the disconnected fuel supply line.

Attach V.A.G 1318/11 to V.A.G 1318.

Connect assisting hose -arrow- on pressure gauge and hold it in a container.

Close shut-off valve on V.A.G 1318. Lever stands perpendicular to direction of flow -arrow-.

Scheme 319

Connect a vehicle diagnosis tester.

Select "Engine electronics" in OBD.

Select "Output diagnostic test mode".

Select "Fuel pump electronics" and press "start".

Note. This function controls the fuel pump.

Read the fuel pressure on the V.A.G 1318.

1. Specified value: Approximately 5 bar (3 to 6 bar) pressure.

If the specification is not obtained

Check fuel pump delivery rate. Refer to Diagnosis and Testing .

Checking Holding Pressure

Check for leaks and residual pressure by watching for the pressure on the V.A.G 1318 to decrease.

1. After 10 minutes there must be a residual pressure of at least 3 bar.

If the residual pressure drops below 3 bar

1. Check connection between V.A.G 1318 and fuel supply line for leaks.
2. Check the V.A.G 1318 for leaks.
3. Check fuel lines and their connections for leaks.
4. Check the fuel pump delivery quantity. Refer to «Diagnosis and Testing»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-fuel-supply-system-engine-codes-caeb-avant) .
5. Replace fuel filter with integrated fuel pressure regulator «Removal and Installation»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-fuel-supply-system-engine-codes-caeb-avant) . Then repeat test.
6. If the fuel filter is OK, replace fuel pump. Refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-fuel-supply-system-engine-codes-caeb-avant) .

Install in reverse order of removal. Note the following

The ignition must be off.

Note. Before removing the pressure gauge, release fuel pressure by opening the shut-off valve. Hold a container under the connection.

Connect the fuel supply line -arrow- (make sure it is clean).

Note. Check fuel system for leaks.

FUEL PRESSURE SENSOR -G247-, CHECKING

Special tools and workshop equipment required

1. Pressure Sensor Tester VAS 6394
2. Pressure Sensor Tester VAS 6394/1
3. Adapter VAS 6394/2
4. Test Instrument Adapter/DSO (3-pin) VAS 5570
5. Torque Wrench 5-50 Nm V.A.G 1331
6. Vehicle Diagnostic Tester

Procedure

Remove the engine cover.

Remove the fuel pressure sensor. Refer to Fuel Pressure Sensor -G247 .

In place of the fuel pressure sensor install the VAS 6394/2 and tighten it using the tightening specification for the fuel pressure sensor.

Scheme 320

1. Tightening specifications: Fuel rail assembly overview, refer to «FUEL RAIL OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)

Remove the plug -2- on the VAS 6394, install the fuel pressure sensor and tighten the sensor to the tightening specification.

Scheme 321

Use the VAS 5570 in order to establish the electrical connection between the vehicle and the fuel pressure sensor.

Scheme 322

Connect the vehicle diagnosis tester.

Turn the ignition on.

Select "Engine electronics" in OBD.

Select "Measured values".

Select "Fuel pressure" from the list.

The current value is displayed in field, which the fuel pressure sensor reports to the Engine Control Module (ECM).

Turn the VAS 6394 on by pressing the button -A- briefly.

Scheme 323

Note. Holding the button -A- for 2 seconds switches on the illumination for 20 seconds.

The VAS 6394/1 should display 0 bar; if this is not the case, then press button -C- one time quickly to set it back to zero.

Connect the VAS 6394 pressure line to the VAS 6394/2.

Start the engine.

Compare the pressure displayed on the VAS 6394/1 with the actual value displayed on the vehicle diagnostic tester.

1. The pressures may have a maximum difference of 5 bar.

If the difference is greater than 5 bar, test a new fuel pressure sensor.

Install a new fuel pressure sensor in the VAS 6394/1.

Repeat the test with the new fuel pressure sensor and compare both measured values.

If the measured values do not now match again

Check the electrical connection between the fuel pressure sensor and the ECM. Refer to appropriate SYSTEMS WIRING DIAGRAM.

If the measured values now match

Install the new fuel pressure sensor.

VACUUM SYSTEM, CHECKING

Special tools and workshop equipment required

1. Hand Vacuum Pump VAS 6213

Procedure

Check all vacuum lines in the vacuum system for

1. Cracks
2. Damage caused by animals
3. Crimps
4. Leaks

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 to the other components.

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.

VARIABLE INTAKE MANIFOLD, CHECKING

Only perform the test if there is a loss of torque. That means there is a reduction in the engine acceleration.

Special tools and workshop equipment required

1. Hand Vacuum Pump VAS 6213

Test Conditions

1. The intake manifold runner control valve -N316- was checked with a vehicle diagnosis tester.

If the intake manifold runner control valve is OK, perform the following tests

Remove the engine cover.

Start the engine and let it run at idle.

Have a second person increase engine speed abruptly (press accelerator pedal). Observe the variable intake manifold vacuum actuator.

Scheme 324

1. The actuator must activate -arrow-.

If the change-over does not function as specified

Check the vacuum system for leaks.

Check whether the change-over mechanism moves easily. Do this by actuating the linkage by hand.

Check whether the vacuum lines are correctly connected.

Check that vacuum hoses are not porous.

Remove the adjusting element vacuum hose -1- for the intake manifold runner control valve from the control valve actuator -- -2-.

Set the slide ring -1- on the VAS 6213 to the -A- position for "vacuum."

Connect the VAS 6213 to the intake manifold runner control valve actuator.

Scheme 325

Operate the VAS 6213 several times.

The vacuum actuator must move -arrows-.

Replace the vacuum actuator if it does not move.

WIRING AND COMPONENTS, CHECKING WITH TEST BOX 105 PIN V.A.G 1598/42

Special tools and workshop equipment required

1. Adapter Cable -V.A.G 1598/39-1
2. Adapter Cable -V.A.G 1598/39-2
3. Test Box 105 Pin -V.A.G 1598/42

Note. The test box has 105 terminals. The connection cable can be separated from the test box. This means that as new Engine Control Module (ECM) connectors are introduced in the future, only a new cable must be designed and no longer the entire test box. The smaller of the two connectors on the ECM is assigned with terminals 1 to 60. The larger of the two connectors is assigned with terminals 1 to 94. For testing at the 60-pin harness connection, the -V.A.G 1598/39-1- is connected to the test box with connector "A". Components of the 60-pin harness connection, refer to appropriate SYSTEMS WIRING DIAGRAM. For testing at the 94-pin harness connection, the -V.A.G 1598/39-2- is connected to the test box with connectors "A" and "B". Components of the 94-pin harness connection, refer to appropriate SYSTEMS WIRING DIAGRAM. The V.A.G 1598/42 is designed so that it can be connected simultaneously to the ECM harness and the ECM itself. This is advantageous because the electronic engine control remains fully functional (for example measurement of signals with engine running) when the test box is attached. The procedures will indicate whether the ECM is to remain connected to the test box or not.

The ECM must be removed to disconnect the ECM multi-pin connectors. Refer to Engine Control Module -J623 .

Connect -V.A.G 1598/42- to wiring harness with -V.A.G 1598/39-1- or -V.A.G 1598/39-2-. Clamp the test box Ground (GND) clip to battery negative terminal. The procedure will indicate whether the ECM is to be connected to the test box or not.

Perform test as described in the relevant repair sequences.

Installing the ECM

Install in reverse order of removal.

Thereafter, the ECM must be equipped with the protective housing.

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

Always use new shear bolts.

The procedures to follow after connecting the new ECM are described in Guided Fault Finding and Guided Functions.

Note. When ending Guided Fault Finding, the tester attempts to erase the Diagnostic Trouble Code (DTC) memory of all control modules. If this is not successful, the remaining DTCs stored in memory must be corrected until all DTCs can be erased.

REMOVING

Carefully remove the engine cover from retaining pins. Do not remove the engine cover on one side or in a jerking manner.

Scheme 326

INSTALLING

In order to prevent causing damage, do not hit the engine cover with your fist or tool.

Position the engine cover (observe oil filler tube and oil dipstick) on the engine.

Using both hands, press the engine cover into the rubber sleeves.

Disconnect the connector -1- from the Mass Airflow (MAF) sensor -G70-.

Open the hose clamp -2- on the air duct hose to the turbocharger and pull it off at the MAF sensor.

Scheme 327

Remove all screws -arrows- from the air filter upper section and remove it.

Remove the old filter element.

For problem-free operation of the MAF sensor it is very important to observe the following notes and procedures.

Note. If the air filter is very dirty or soaked, dirt particles or moisture may have contaminated the MAF sensor and may be causing false mass airflow values. This results in a reduction of power, since a lower injection quantity is calculated. Always use an original air filter. Hose connections and charge air system hoses must be free of oil and grease before installing. When installing, do not use any lubricants containing silicone. The air filter housings must be absolutely clean. Secure all hose connections using hose clamps appropriate for the model type: Note the following when blowing out the air filter housing with pressurized air: To prevent malfunctions, cover the critical airflow components, such as the MAF sensor, air intake tubes, etc., with a clean cloth. Observe disposal regulations!

Clear the water drain -arrow- in the air filter housing lower section with compressed air.

Scheme 328

Note. Ignore items 1, 2 and 3.

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

Check the MAF sensor and air duct hose (intake air side) for salt residue, dirt, and leaves.

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

If equipped, reconnect the vacuum hose to the intake air switch-over valve -N335-.

Make sure that air filter is properly centered when placed in the mounting of the air filter housing lower section.

Set the upper section of the air filter housing onto lower section of the air filter housing, without using much force. When doing this, make sure that the upper section of the air filter housing is not placed crooked onto the air filter (observe sealing lip of air filter).

Make sure the air duct hose is securely seated on the MAF sensor.

Install in reverse order of removal.

Disconnect the connector -1- from the Mass Airflow (MAF) sensor -G70-.

Open the hose clamp -2- on air duct hose to the turbocharger and pull it off at the MAF sensor.

Remove the air duct -3-.

Remove the vacuum hose -arrow- (if installed).

Scheme 329

Unlock the release -4- on the air filter housing lower section (push in the left and right rubber pieces and pull up).

Note. The components (bypass door with intake air switch-over valve -N335- -1-) are not installed in all equipment packages and/or in all country versions. Do not use any lubricant when installing the fastener.

Disconnect the connector on the intake air switch-over valve (if equipped).

Remove the complete air filter housing carefully.

Observe the following to ensure the MAF sensor functions correctly.

Note. Use a lubricant (silicone-free) for installing the intake hose. Secure all hose connections using hose clamps appropriate for the model type

If a warm air intake is installed (only for countries with warm climates), make sure the air intake connectors are engaged correctly -arrows- (check markings).

Scheme 330

Check the MAF sensor and air duct hose (intake air side) for salt residue, dirt, and leaves.

Check the intake channels up to the air filter for dirt.

Reconnect the electrical connector on the intake air switch-over valve -N335- (if applicable).

Install the air filter housing.

Note. Route the water drain hose straight down, do not bend it.

Install the vacuum hose -arrow- (if equipped).

Make sure the air guide hose is securely attached to the MAF sensor.

Reconnect the connector on the MAF sensor.

Install the air guide.

Further installation is in the reverse sequence to removal.

HIGH PRESSURE PUMP

Note. Remove the high pressure pump only when the engine is cold. When installing, make sure that no dirt enters the fuel system. Catch escaping fuel with a cloth. Always replace the O-ring. Install the fuel high-pressure lines free of tension.

Remove the engine cover.

Disconnect the connector -1- from the fuel pressure regulator valve -N276-.

Open both fuel lines -arrows-.

Scheme 331

Remove the 2 bolts -arrows-.

Carefully pull out the high-pressure fuel pump. The roller tappet may remain in the vacuum pump.

Replace the O-ring for the high-pressure pump.

Insert the roller tappet in the vacuum pump after checking the tappet for damage.

Note. To insert the high pressure pump, the roller tappet must be at its lowest point. If the same or a used high pressure pump is installed, replace the fuel supply line connections (high pressure side). See the high pressure pump assembly overview, item 11, refer to HIGH PRESSURE PUMP OVERVIEW .

Rotate the crankshaft until the roller tappet is at the lowest point.

Install the high pressure pump into the vacuum pump and tighten it.

Tighten the bolts by hand.

Replace the connections on the high pressure pump.

1. Tightening specifications: High pressure pump assembly overview, refer to «HIGH PRESSURE PUMP OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__high-pressure-pump-overview)

Tighten the bolts in a diagonal sequence to the specification. See the high pressure pump, assembly overview, refer to HIGH PRESSURE PUMP OVERVIEW .

Tighten the fuel supply line union nut by hand. Align so it is free of stress.

1. Fuel supply line union nut tightening specification: Intake manifold assembly overview, refer to «INTAKE MANIFOLD OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant) .

Connect the electrical connector -1- from the fuel pressure regulator valve -N276-.

If the fuse was pulled, insert it again.

Note. Check fuel system for leaks.

FUEL INJECTORS

Special tools and workshop equipment required

1. Tool Set T10133 with puller
2. Removal Tool T10133/16

Note. Puller T10133/2 was changed and is now called puller T10133/2-A. If the new tool is not available, the old one can be modified.

Modify the T10133/2 to create the T10133/2-A.

File the semicircle as shown in the illustration. The semicircle allows the tool to slide farther onto the fuel injector, thus providing the tool with a larger contact surface.

Mark the modified tool with an "A" at the end of the tool number.

Scheme 332

Special tools and workshop equipment required

1. Round file approximately 6 mm

Remove the engine cover.

Remove the intake manifold and the fuel rail (engine code CAEB). Refer to INTAKE MANIFOLD .

Remove the intake manifold and the fuel rail (engine code CMPA). Refer to INTAKE MANIFOLD UPPER SECTION .

Removing the fuel injectors, in the event that they are stuck in the fuel rail

Carefully pull the fuel injectors out of the fuel rail.

Removing the fuel injectors, in the event that they are stuck in the cylinder head

Scheme 333

1 - Combustion chamber sealing ring (Teflon® sealing ring), replace, the ring must not be greased or handled with any other lubricants when installing.

2 - The support ring is being replaced by an intermediate ring. See next illustration (Scheme 336)

3 - Fuel injector

4 - Spacer ring, replace if damaged

5 - O-ring (replace, coat lightly with clean engine oil when installing)

6 - Support ring (via this support ring, fuel rail utilizes the force to hold the fuel injector in place in the cylinder head).

Scheme 334

1 - Intermediate ring, replacing

2 - Mount

3 - Combustion chamber sealing ring (Teflon® sealing ring), replace, the ring must not be greased or handled with any other lubricants when installing.

4 - Fuel injector

5 - Spacer ring, replace if damaged

6 - O-ring (replace, coat lightly with clean engine oil when installing)

7 - Support ring (via this support ring, fuel rail utilizes the force to hold the fuel injector in place in the cylinder head).

Cover open intake channels with a clean cloth.

Disconnect electrical harness connector at fuel injector that is to be removed.

Guide the T10133/2A in the groove on the fuel injector.

Scheme 335

Then position the T10133/16 and remove the fuel injector by loosening the bolt -1-.

Note. The combustion chamber seal must always be replaced before installing the fuel injector. Refer to TEFLON® COMBUSTION CHAMBER SEAL .

TEFLON® COMBUSTION CHAMBER SEAL

Special tools and workshop equipment required

1. Puller T10133/2A
2. Hammer T10133/3
3. Nylon Brush T10133/4
4. Assembly Cone T10133/5
5. Guide Sleeve T10133/6
6. Calibration Sleeve T10133/7
7. Calibration Sleeve T10133/8

Note. Always replace the combustion chamber seal before installing a fuel injector.

Replacing

Remove the fuel injector. Refer to FUEL INJECTORS .

Carefully remove the old combustion chamber seal with the appropriate tool (for example cut the seal open with a razor blade, spread it outward with a small screwdriver and remove it forward). When doing this, make sure not to damage the groove and circumferential rib in the groove base.

Note. If the groove is damage, the fuel injector must be replaced.

Clean off any combustion residue on the seal groove and on the shaft of the fuel injector with a clean cloth before installing the new combustion chamber seal.

Place the T10133/5 with the new combustion chamber seal -1- onto the fuel injector -2-.

Scheme 336

Slide the combustion chamber seal further onto the T10133/5 using T10133/6 until the combustion chamber seal locks into the groove in the seal. When doing this, do not use any lubricants.

Scheme 337

Note. When pushing the combustion chamber seal onto the fuel injector, the combustion chamber seal spreads open. Therefore after pushing it on, it must be tightened again in 2 steps, as follows.

Press the T10133/7 with a gentle turning movement (approximately 180°) all the way onto the fuel injector.

Scheme 338

Turn the T10133/7 in the opposite direction and remove it.

Press the T10133/8 with a gentle turning movement (approximately 180°) all the way onto the fuel injector.

Scheme 339

Turn the T10133/8 in the opposite direction and remove it.

Replace the O-ring on the fuel injector. Coat the O-ring with clean engine oil before installing it.

Note. When installing the injector valve, make sure there is no cleaning product or oil in the holes in the cylinder head.

Using the included T10133/4 thoroughly clean the high-pressure fuel injector bores in the cylinder head before installing the fuel injectors.

Scheme 340

Press the fuel injector by hand into the bore in the cylinder head (free of oil and grease) until it stops. Make sure the fuel injectors are positioned correctly in cylinder head.

Note. The fuel injector must not be difficult to install. If necessary, wait as the combustion chamber seal continues to pull itself together. Check fuel injectors for correct seating and installation position in cylinder head. If it is difficult to install the fuel injector by hand using the T10133/2A -2- with the T10133/3.

Further installation is in the reverse sequence to removal.

Important: Always observe the following points.

1. Coat the O-rings for the fuel injectors with clean engine oil so they are easier to guide into the fuel rail.
2. Replace all seals.
3. The fuel rail should be placed on the fuel injectors and pressed on evenly.
4. Install intake manifold with fuel rail. Refer to «INTAKE MANIFOLD»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant__intake-manifold) .

Disconnect the connector -1- from the Mass Airflow (MAF) sensor -G70-.

Open the hose clamp -2- on air duct hose to the turbocharger and pull it off at the MAF sensor.

Remove both bolts from the MAF sensor.

Carefully pull the MAF sensor out of the guide from air filter housing.

For problem-free operation of the MAF sensor it is very important to observe the following notes and procedures.

Note. If the air filter is very dirty or soaked, dirt particles or moisture may have contaminated the MAF sensor and may be causing false mass airflow values. This results in a reduction of power, since a lower injection quantity is calculated. Always use an original air filter. Use a silicone-free lubricant for installing the air guide hose. Secure all hose connections using hose clamps appropriate for the model type

Check the MAF sensor and air duct hose (intake air side) for salt residue, dirt, and leaves.

Check the intake channels up to the air filter for dirt. If any contaminants are discovered, clean the air filter housing (upper and lower sections) of salt residue, dirt and leaves (if necessary, clean by washing or vacuuming). Air filter, removing and installing, refer to AIR FILTER .

Install in reverse order of removal.

FUEL PRESSURE SENSOR -G247

Special tools and workshop equipment required

1. Assembly Tool T10118
2. Socket 27 mm T40218 or a commercially available 27 mm socket

Remove the engine cover.

Remove the coolant line bolt -arrow- from the intake manifold.

Scheme 341

Disconnect the connector from the fuel pressure sensor -G247- using T10118.

Remove the fuel pressure sensor -G247- using T40218.

Install in reverse order of removal.

Check the connection tightening specification before installing the fuel pressure sensor.

1. Connection tightening specification: Fuel rail assembly overview, refer to «FUEL RAIL OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)
2. Fuel pressure sensor tightening specification: Fuel rail assembly overview, refer to «FUEL RAIL OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)

Remove the engine cover.

Open the clamp on the air guide hose -arrow- and remove it from the throttle valve control module.

Scheme 342

Disconnect the electrical connector -1- from the throttle valve control module.

Remove the four bolts -arrows- on the throttle valve control module and then remove the throttle valve control module.

Scheme 343

Install in reverse order of removal.

Clean the sealing ring surface.

Replace seal.

1. Tightening specifications: Intake manifold assembly overview, refer to «INTAKE MANIFOLD OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant) .

Use a vehicle diagnostic tester to readapt the throttle valve control module to the Engine Control Module (ECM) -J623- after it has been replaced.

HEATED OXYGEN SENSOR -G39- AND OXYGEN SENSOR HEATER -Z19

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Disconnect the connector -3- from the Heated Oxygen Sensor (HO2S) -G39- and the Oxygen Sensor (O2S) heater -Z19-.

Note. HO2S connector component location -6- on vehicles with engine code CPMA.

Remove the HO2S -2- using 3337.

Note the following when installing

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with oxygen sensor slots. Hot bolt paste, Wiring connection of the oxygen sensor must always be secured in the same position when installing so that the contact with the exhaust pipe is avoided.

1. Tightening specifications: Heated oxygen sensors assembly overview, refer to «HEATED OXYGEN SENSORS OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)

OXYGEN SENSOR AFTER THREE WAY CATALYTIC CONVERTER -G130- AND HEATER FOR OXYGEN SENSOR 1 AFTER CATALYTIC CONVERTER -Z29

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Disconnect the connector -2- from the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and heater for Oxygen Sensor (O2S) 1 after catalytic converter -Z29-.

Note. 3- is not on vehicles with engine code CPMA.

Remove the O2S after TWC -1- using a tool from the 3337.

Note the following when installing

Note. New oxygen sensors are coated with assembly paste; the paste must not get into the slots of the oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with the oxygen sensor slots. Hot bolt paste, Wiring connection of the oxygen sensor must always be secured in the same position when installing so that the contact with the exhaust pipe is avoided.

1. Tightening specifications: Heated oxygen sensors assembly overview, refer to «HEATED OXYGEN SENSORS OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)

ENGINE CONTROL MODULE -J623

Note. Some Engine Control Modules (ECM) are not equipped with a protective housing. The removal and installation of the protective housing depends on the engine and transmission combination.

Special tools and workshop equipment required

1. Hot Air Blower VAS 1978/14A with nozzle attachment from the Wiring Harness Repair Set VAS 1978 B
2. Small Commercially Available Locking Pliers

Note. The ECM -1- is bolted to a protective housing -5-. To make removing the shear bolts -4- for the retaining tabs -2- more difficult, the threads are coated with locking compound. To disconnect the connectors from the ECM (for example to connect the test box or to replace the ECM), the metal housing must be removed.

If the ECM was replaced, select diagnostic object "Replacing engine control module " in "Guided Functions".

Turn off the ignition and remove the key.

Pull the plenum chamber cover rubber seal in front of the nut -1- slightly.

Scheme 344

Disengage the wiring harness -2- at the mounts -A-.

Remove nut -1-.

Remove the filler neck -3- with the filler tube from the washer fluid reservoir and the opening in the body.

Remove the bolts -arrows- and the cover from the E-box.

Scheme 345

Release the retainers -A arrows- and remove the ECM -arrow B-.

Additional steps if there is a protective housing installed

The ECM -1- is secured in a metal housing -5- with retaining tabs -2- and shear bolts -3 and 4- to make it harder to access it.

Scheme 346

The threads of the shear bolts -4- (that are not screwed into the ECM) are coated with a locking compound. For this reason, the threads must be heated with the heat gun to remove both bolts.

The threads of both shear bolts -3-, that are screwed into the ECM, are not coated with a locking compound. The threads in the ECM housing must not be heated and do not require to be heated (unintentional heating of the ECM).

Set the adjustment on the heat gun as shown in the illustration, with the temperature potentiometer -2- set to maximum heat and the two-stage airflow switch -3- set to level 3.

Scheme 347

Warm threads on connector-side shear bolts for approximately 25 to 30 seconds.

Scheme 348

Remove shear bolts with locking pliers (see direction of -arrow-).

Scheme 349

The shear bolts installed in the ECM do not need to be heated for removal. They can be removed without heat.

Disconnect metal retainers from the ECM connectors.

Disengage the connectors from the ECM and disconnect the connector.

Remove the old ECM and install the ECM.

Install in reverse order of removal.

The ECM must be installed with a housing.

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

Always use new shear bolts.

1. Tightening Specifications: E-box cover bolts: 3.5 Nm

Perform the following step after installing a new ECM

Activate the ECM in "Guided Functions" under "replace engine control module". Use a vehicle diagnosis tester for this.

INTAKE MANIFOLD

If the fuel rail is removed or replaced, the intake manifold runner position sensor -G336- must be adapted to the Engine Control Module (ECM) -J623-. Use a vehicle diagnosis tester.

Special tools and workshop equipment required

1. Assembly Tool T10118
2. Hose Clip Pliers V.A.G 1921
3. Socket Torx® T30 T10347
4. Hazet Oil Filter Wrench 2171-1 or an Oil Filter Wrench 3417

Note. It is necessary to remove the intake manifold and fuel rail in order to be able to get to the fuel injectors. The combustion chamber seal (Teflon®) and the O-ring must always be replaced. Intake manifold assembly overview, refer to INTAKE MANIFOLD OVERVIEW Fuel rail assembly overview, refer to FUEL RAIL OVERVIEW

Disconnect the battery Ground (GND) cable.

Remove the engine cover.

Disconnect the vacuum line -arrow- to the Evaporative Emission (EVAP) canister.

Disconnect the following electrical connectors.

1 - EVAP canister purge regulator valve 1 -N80

2 - From the Knock Sensor (KS) 1 -G61

3 - From the Intake Manifold Runner Control (IMRC) valve -N316-, Fuel Pressure Sensor -G247- and the Camshaft Position (CMP) sensor -G40

4 - From the fuel injectors

5 - Throttle valve control module -J338

6 - Intake Air Temperature (IAT) sensor -G42

Disconnect the connector -1- from the CMP sensor.

Open the air guide hose clamp -arrow- and remove the hose from the throttle valve control module.

Disconnect the vacuum line -1- at the separating point -2-.

Scheme 350

Remove the crankcase ventilation hose -3-.

Open the spring clamp -upper arrow- and remove the fuel supply line from the high pressure pump.

Open the high pressure fuel line union nut -lower arrow- on the high pressure pump.

Note. The fuel system must have no pressure. Use a clean cloth to absorb exiting fuel. Seal the open connections with clean caps and make sure no dirt has entered the fuel system.

Remove the vacuum line -arrow- from the IMRC valve.

Scheme 351

Remove the coolant line bolt -arrow- from the intake manifold.

Disconnect the connector from the fuel pressure sensor -1-.

Loosen the mounting nut -1- slightly and remove the bolt -2- completely.

Scheme 352

Remove the oil filter with a 2171-1 or an 3417.

Scheme 353

Remove the intake manifold bolts using T10347.

Note. The throttle valve control module must be removed in order to remove any bolts that are not accessible and not using the T10347.

Carefully pull the intake manifold with fuel rail away from the cylinder head slightly.

Disconnect the connector -1- from the intake manifold runner position sensor and remove the intake manifold.

Note. The fuel injectors could remain stuck in the fuel rail. Seal the intake channels with a clean cloth.

Separate the intake manifold from the fuel rail. Refer to FUEL RAIL .

Note. Make sure the fuel injectors are installed correctly.

Mount the intake manifold onto the cylinder head on the stud bolts (lower left and right).

Install in reverse order of removal.

1. Tightening specifications: Intake manifold assembly overview, refer to «INTAKE MANIFOLD OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)
2. Tightening specifications: Fuel rail assembly overview, refer to «FUEL RAIL OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)

FUEL RAIL

If the fuel rail is removed or replaced, the intake manifold runner position sensor -G336- must be adapted to the Engine Control Module (ECM) -J623-. Refer to "Guided Functions".

Note. Intake manifold must be removed, removing, refer to INTAKE MANIFOLD .

Open the hose clamp -1-.

Remove hoses from the Evaporative Emission (EVAP) canister.

Open the fuel line on the fuel rail.

Loosen both bolts -arrows- from the fuel rail.

Scheme 354

Remove the fuel rail from the intake manifold.

Always replace both fuel supply line connections.

Tighten the fuel line.

Connect the electrical connector.

Install intake manifold. Refer to INTAKE MANIFOLD .

1. Tightening specifications: Intake manifold assembly overview, refer to «INTAKE MANIFOLD OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)
2. Tightening specifications: Fuel rail assembly overview, refer to «FUEL RAIL OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)

Install in reverse order of removal.

Remove the intake manifold. Refer to INTAKE MANIFOLD UPPER SECTION .

Remove the bolt -1- on the clamp -2- on the intake manifold.

Remove the bolt -1- from the cold start injector.

Remove the cold start injector and bracket through the opening.

Remove the clamp -1-.

Scheme 355

Remove the cold start injector from the mount.

Install in reverse order of removal.

Install intake manifold, refer to INTAKE MANIFOLD UPPER SECTION .

Remove the upper section of the intake manifold. Refer to INTAKE MANIFOLD UPPER SECTION .

Remove the intake manifold lower section. Refer to INTAKE MANIFOLD LOWER SECTION .

Disconnect the connector from the fuel pressure sensor -G247- -1-.

Remove both bolts -2- from the fuel rail.

Scheme 356

Remove the fuel rail.

Note. The fuel injectors could remain stuck in the fuel rail.

Note. Make sure the fuel injectors are installed correctly.

1. Tightening specifications: Fuel rail - assembly overview, refer to «FUEL RAIL OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)

Install in reverse order of removal.

Install intake manifold. Refer to INTAKE MANIFOLD .

INTAKE MANIFOLD UPPER SECTION

Special tools and workshop equipment required

1. Assembly Tool T10118
2. Hose Clip Pliers V.A.G 1921
3. Socket Torx® T30 T10347

Note. It is necessary to remove the intake manifold and fuel rail in order to be able to get to the fuel injectors. The combustion chamber seal (Teflon®) and the O-ring must be replaced.

Disconnect the battery Ground (GND) cable.

Remove the engine cover.

Disconnect the vacuum line -arrow- to the Evaporative Emission (EVAP) canister.

Disconnect the following electrical connectors.

1 - EVAP canister purge regulator valve 1 -N80

2 - From the Knock Sensor (KS) 1 -G61

3 - From the Intake Manifold Runner Control (IMRC) valve -N316-, fuel pressure sensor -G247- and the Camshaft Position (CMP) sensor -G40

4 - From the fuel injectors

5 - Throttle valve control module -J338

6 - Intake Air Temperature (IAT) sensor -G42

Note. The fuel system must have no pressure. Use a clean cloth to absorb exiting fuel. Seal the open connections with clean caps and make sure no dirt has entered the fuel system.

Remove the bolts -1 and 2- and the bracket for the connectors.

Scheme 357

Disconnect the connector -2- from the low fuel pressure sensor -G410-.

Scheme 358

Disconnect the connector -4- from the CMP sensor.

Open the hose clamps -1- and remove both fuel hoses.

Open hose clamp -3-.

Remove the EVAP line from the intake manifold upper section and from the separating point -arrows-.

Remove the EVAP canister purge regulator valve 1 -1- down from the bracket.

Guide the EVAP line under the fuel lines and move it to the side.

Open the air guide hose clamp -arrow- and remove the hose from the throttle valve control module.

Open the high pressure fuel line union nut -lower arrow- on the high pressure pump.

Open the union nut and remove the fuel high pressure line from the intake manifold upper section.

Open the union nut on the fuel rail for the fuel high pressure line.

Remove the coolant line bolt -arrow- from the intake manifold upper section.

Remove bolt -2-.

Remove the intake manifold upper section bolts using T10347.

Remove the intake manifold upper section from the intake manifold lower section.

Disconnect the connector from the cold start injector -N17-.

Note. Seal the intake channels with a clean cloth.

Remove the intake manifold lower section. Refer to INTAKE MANIFOLD LOWER SECTION .

Replace the connections for the fuel high pressure line on the high pressure pump and on the fuel rail.

Mount the intake manifold onto the cylinder head on the stud bolts (lower left and right).

Tighten the union nuts for the fuel high pressure line hand-tight.

Tighten the intake manifold to the tightening specification (tighten the bolt starting from the inside toward the outside).

Tighten the fuel high pressure line to the tightening specification.

Install in reverse order of removal.

1. Tightening specifications: Intake manifold assembly overview, refer to «INTAKE MANIFOLD OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)
2. Tightening specifications: Fuel rail assembly overview, refer to «FUEL RAIL OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)

INTAKE MANIFOLD LOWER SECTION

Special tools and workshop equipment required

1. Oil Filter Wrench 3417

If the intake manifold lower section is removed or replaced, the intake manifold runner position sensor -G336- must be adapted to the Engine Control Module (ECM) -J623-.

Remove the upper section of the intake manifold. Refer to INTAKE MANIFOLD UPPER SECTION .

Remove the vacuum line -arrow- from the Intake Manifold Runner Control (IMRC) valve -N316-.

Remove the IMRC valve from the bracket.

Remove the oil filter -arrow- using the 3417.

Open the crankcase ventilation bolts -arrows- a few turns.

Scheme 359

Disconnect crankcase ventilation hose -1-.

Remove the connection -3-.

Remove the intake manifold lower section.

Disconnect the connector -1- from the intake manifold runner position sensor.

Note. Make sure the fuel injectors are installed correctly.

Always replace both fuel supply line connections.

Connect the connector to the intake manifold runner position sensor.

Install intake manifold. Refer to INTAKE MANIFOLD .

1. Tightening specifications: Intake manifold assembly overview, refer to «INTAKE MANIFOLD OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)
2. Tightening specifications: Fuel rail - assembly overview, refer to «FUEL RAIL OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-caeb-avant)

Install in reverse order of removal.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 360

Scheme 361

Scheme 362

Scheme 363

Scheme 364

Scheme 365

Scheme 366

Scheme 367

Scheme 368

1. Hazet Oil Filter Wrench 2171-1 or an Oil Filter Wrench 3417
2. Ring Spanner 7-Piece Set 3337
3. Assembly Tool T10118
4. Tool Set T10133 with puller
5. Socket Torx® T30 T10347
6. Release Tool f/ Rev. Light Switch Conn. T40138
7. Socket 27 mm T40218
8. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
9. Adapter Cable -V.A.G 1598/39-1
10. Adapter Cable -V.A.G 1598/39-2
11. Test Box 105 Pin -V.A.G 1598/42
12. Hose Clip Pliers V.A.G 1921
13. Hot Air Blower VAS 1978/14A -item 1- with nozzle attachment -2- from the Wiring Harness Repair Set VAS 1978 B
14. Small Commercially Available Locking Pliers -3
15. Hand Vacuum Pump VAS 6213
16. Not illustrated
17. Trim Removal Wedge 3409
18. Puller T10133/2A
19. Hammer T10133/3
20. Nylon Brush T10133/4
21. Assembly Cone T10133/5
22. Guide Sleeve T10133/6
23. Calibration Sleeve T10133/7
24. Calibration Sleeve T10133/8
25. Removal Tool T10133/16
26. Adapter V.A.G 1318/11
27. Adapter V.A.G 1318/17-1
28. Fuel Line Feed Adapter V.A.G 1318/23
29. Torque Wrench 5-50 Nm V.A.G 1331
30. Connector Test Set V.A.G 1594C
31. Pressure Sensor Tester VAS 6394
32. Pressure Sensor Tester VAS 6394/1
33. Adapter VAS 6394/2
34. Test Instrument Adapter/DSO (3-pin) VAS 5570
35. Ultrasonic Cleaning Unit VAS 6418
36. Injection Module Mounting Plate VAS 6418/1

See also:
• IGNITION COILS WITH POWER OUTPUT STAGES
• Removal and Installation
• Knock Sensor 1 -G61
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• RELEASING PRESSURE IN HIGH PRESSURE AREA
• TEST AND MEASURING INSTRUMENTS DURING TEST DRIVE
• AIR FILTER
• HIGH PRESSURE PUMP
• FUEL RAIL
• Heated Oxygen Sensor -G39- AND Oxygen Sensor Heater -Z19
• Oxygen Sensor after Three Way Catalytic Converter -G130- AND Heater for Oxygen Sensor 1 after Catalytic Converter -Z29
• FUEL INJECTORS
• TEFLON® COMBUSTION CHAMBER SEAL
• Engine Control Module -J623
• Fuel Pressure Sensor -G247
• DOUBLE CHECK-VALVE, CHECKING
• INTAKE MANIFOLD
• INTAKE MANIFOLD UPPER SECTION
• INTAKE MANIFOLD LOWER SECTION
• HIGH PRESSURE PUMP OVERVIEW