3.2l - General, Technical Data - Engine Mechanical - Engine Code(s): Cala (coupe) (as of 12.2008) Audi A5 I

SAFETY PRECAUTIONS

Note the following when working on the fuel system

Procedures before opening high pressure fuel injection system. Refer to 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 and the engine was started, then malfunctions have been stored in the Engine Control Module (ECM). "Generate readiness code" in "Guided Functions" Vehicle diagnostic tester.

Disconnect battery. Refer to 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

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 (for example in tool boxes etc.).
6. When the 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.

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 remove, the fuel pressure must be definitely reduced to a residual pressure of approximately 6 bar, as described in the following.

Special tools and workshop equipment required

1. Trim Removal Wedge 3409
2. Vehicle Diagnostic Tester

Procedure

With the ignition off, connect the vehicle diagnostic tester to the Data Link Connector using the diagnostic lead.

Scheme 9

Start the engine and let it run at idle.

Display on vehicle diagnostic tester

Scheme 10

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

Display on vehicle diagnostic tester

Scheme 11

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

Display on vehicle diagnostic tester

Scheme 12

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

Display on vehicle diagnostic tester

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

Display on vehicle diagnostic tester

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

Display on vehicle diagnostic tester

Scheme 13

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

1. With the 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.

1. Control module identifications

Pry the cover -1- on the left of the instrument panel off, for example using the Trim Removal Wedge 3409 -arrow-.

Scheme 14

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

Scheme 15

Display on VAS 5051B

With the engine still running, checking display -2- for the fuel pressure in the 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 the ignition off as soon as the 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 the 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 the top) in the driver side instrument panel fuse holder -ST2- (brown).

If electrical connectors were disconnected and the engine was started, then malfunctions have been stored in the engine control module. "Generate readiness code" in "Guided Functions".

ENGINE NUMBER

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

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 the 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. For locations of the type plate and vehicle data label.

FUEL SYSTEM, CHECKING FOR LEAKS

Let the engine run a few minutes at a moderate speed.

Switch off ignition.

Check the entire fuel system for leaks.

If there are leaks in spite of correct tightening specifications, the corresponding component must be replaced.

Then perform a road test and depress the accelerator pedal all the way at least one time.

Then check the high pressure area again for leaks.

ENGINE CONTAMINANTS

1. To prevent foreign objects from entering when working on the engine, seal open intake and exhaust channels with suitable plugs, for example from the Engine Bung Set VAS 6122.
2. If mechanical damage to a cylinder bank is found, check the intake and exhaust tract and the combustion chambers in the opposite cylinder back for foreign objects to prevent further damage.

CONTACT CORROSION

Contact corrosion can occur if incorrect fasteners (bolts, nuts, washers, etc.) are used.

For this reason, only install connecting elements that are treated with a special coating.

Also, rubber or plastic parts and adhesive consist of non-conductive materials.

If there are doubts about the suitability of parts, generally use new parts.

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

LINES, ROUTING AND SECURING

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.

COOLERS AND CONDENSERS

When assembled correctly, radiator and condenser can show slight impressions on fins. This is not damage. Radiators or condensers should not be replaced because of slight impressions like these.

ENGINE DATA

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 and leakage

Check the vacuum line leading to and from the solenoid valve.

If there is a fault, check the vacuum lines for the named component, but also all the vacuum lines.

If using the Hand Vacuum Pump 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.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 16

Scheme 17

1. Hand Vacuum Pump VAS 6213
2. Trim Removal Wedge 3409
3. Vehicle Diagnostic Tester

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