3.2l - General, Technical Data - Engine Mechanical - Engine Code(s): Cala (coupe) (as of 11.2007) Audi A5 I

SAFETY PRECAUTIONS

Note the Following When Working on the Fuel System

Procedures before opening high pressure fuel injection system BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

To Prevent Personal Injury and Damage to the Injection and Ignition System, Observe the Following

1. The ignition must be switched off before connecting or disconnecting the injection and ignition system wiring or tester cables.
2. Only clean engine with ignition switched off.
3. If electrical connectors were disconnected, faults are saved in ECM

Connect vehicle diagnosis, testing and information system VAS 5051B.

Start "Guided Functions" operating mode.

Generate readiness code in ECM.

Disconnect battery Removal and Installation .

Note the Following When Working on the Cooling System

Note the Following When Working on the Subframe

If it is Necessary to Use Testing and Measuring Devices on Road Tests, Observe the Following

BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM

1. The fuel injection system is separated into a high-pressure section (maximum approximately 120 bar) and a low-pressure section (approximately 6 bar).
2. Before a component in the fuel injection system high pressure area is removed, the fuel pressure must be reduced to a residual pressure of approximately 6 bar, as described in the following.

Special tools and workshop equipment required

1. Vehicle diagnostic, testing, and information system VAS 5051B

Procedure

Proceed as follows

With ignition off, connect vehicle diagnosis, testing and information system VAS 5051B to the Data Link Connector (DLC) using diagnostic lead.

Scheme 1

Start engine and let it run at idle.

Display on VAS 5051B

Scheme 2

Press the Vehicle Self-Diagnosis button -1- in selection.

Display on VAS 5051B

Scheme 3

In selection -1-, press "On Board Diagnostic (OBD)" and continue by pressing --> button.

Display on VAS 5051B

Scheme 4

In selection -1-, press "Engine electronics" vehicle system and continue by pressing --> button.

Display on VAS 5051B

In selection -1-, press "Measured values" function and continue by pressing --> button.

Display on VAS 5051B

In selection -1-, press "Fuel pressure" measured value and continue by pressing --> button.

Display on VAS 5051B

Scheme 5

Check display -2- for fuel pressure in fuel rail.

1. With engine at idle, a value of approximately 35 kPa is displayed. This is the actual pressure in the fuel system generated by the high pressure pump.

Note. The unit "kPa" is also used instead of "bar" : 1 bar = 1 kPA.

Pry cover -1- on left of instrument panel off, for example using trim removal wedge 3409 -arrow-.

Scheme 6

Remove fuse 3 -SC3- (third from top) in driver side instrument panel fuse holder -ST2- (brown).

Scheme 7

Display on VAS 5051B

With engine still running, checking display -2- for fuel pressure in fuel rail

1. The fuel pressure decreases rapidly because the mechanical high pressure pump is no longer supplied with fuel by the electrical fuel pump.

Switch ignition off as soon as fuel pressure drops just below 8 kPa.

Note. The fuel pressure must not drop below 6 bar or the engine will shut off (the catalytic converter could be damaged).

The fuel rail will continue to be filled with fuel, but it will no longer be under high pressure.

Loosen wire at a connection immediately.

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

Final Procedures

Insert fuse 3 -SC3- (third from top) in driver side instrument panel fuse holder -ST2- (brown).

Connect vehicle diagnosis, testing and information system VAS 5051B while ignition is switched off.

Start "Guided Functions" operating mode.

Generate readiness code in engine control module .

CLEAN WORKING CONDITIONS

Even a little contamination can lead to faults. When working on the fuel supply and 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 parts that have been removed on a clean surface and cover them. Use lint-free cloths.
4. Carefully cover over opened components or seal, if repairs are not performed immediately.
5. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored outside of their original packaging (e.g. in tool boxes etc.).
6. When system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.
7. Protect disconnected electrical connectors from dirt and moisture and only connect if dry.

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

1. Only original replacement parts are recommended, they are checked and compatible with aluminum.
2. Audi accessories are recommended.
3. Damage due to contact corrosion is not covered by warranty.

FUEL SYSTEM, CHECKING FOR LEAKS

Proceed as follows

Let engine run a few minutes at a moderate speed.

Switch off ignition.

Check 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 high pressure area again for leaks.

LINES, ROUTING AND SECURING

To prevent mistakes and ensure the original installation location is kept, mark the hydraulic lines, vacuum lines or electrical lines before removing them. If necessary, draw sketches or take pictures.

ENGINE NUMBER

Note. The engine number is only visible if the front engine cover is removed.

Scheme 8

1. The engine number ("engine code" and "serial number") is located at front on cylinder block at top -arrow 1-.
2. Engine codes beginning with "C" are four-digit.
3. The first 3 digits of the engine code stand for displacement and mechanical structure of the engine. They are stamped in the cylinder block, including the serial number.
4. The fourth digit describes the engine output and torque and depends on the engine control module.

Note. Ignore -arrow 2-. The 4 digit engine code is on the type plate, vehicle data label and engine control module. Locations of the type plate and vehicle data label .

ENGINE DATA

See also:
• Removal and Installation
• BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM