FUEL SYSTEM
Note the following when working on the fuel system
| WARNING | There is a risk of injury because the fuel is under very high pressure. Reduce the fuel pressure down to residual pressure before opening the high pressure area of the fuel injection system. To reduce remaining residual pressure, place clean cloth around the connector and carefully loosen connector. |
Procedures before opening high pressure fuel injection system. Refer to [For engine(s) CALA] General Information .
To prevent personal injury and damage to the injection and ignition system, observe the following
- The ignition must be turned off before connecting or disconnecting injection and ignition system wiring or tester cables.
- Wash the engine only when the ignition is turned off.
- If the electrical connectors were disconnected and the engine was started, then malfunctions have been stored in the Engine Control Modules (ECM). Generate Readiness Code in Guided Functions vehicle diagnosis tester.
| CAUTION | Danger of causing damage to other electronic components when disconnecting the battery. Complete the steps for disconnecting the battery. Always turn off the ignition before disconnecting the battery. |
Disconnect the battery. Refer to Removal and Installation .
Carry out the following measures before starting work on the fuel supply
| WARNING | Danger of explosion due to cell phones. Keep cell phones out of reach in the work space area. |
| CAUTION | Danger of causing damage to electronic components. Complete the steps for disconnecting the battery. |
- Disconnect the battery. Refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/charging-system/#battery-starter-generator-cruise-control-coupe) .
- Open the fuel filler flap briefly and then close it again.
Note the following when removing and installing components from a filled or partially filled fuel tank
- The fuel tank may only be partially full. How much fuel can remain in the fuel tank may be read in the respective work description. Empty the fuel tank, if necessary, refer to «FUEL TANK, DRAINING»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-tank-draining) .
- Before starting work, turn on the exhaust extraction system and place an extraction hose close to the installation opening of fuel tank to extract escaping fuel fumes. If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displacement greater than 15 m 3 /h can be used.
- Prevent fuel from contacting skin! Wear fuel-resistant gloves!
Note the following when removing and installing the fuel tank
- Fuel tank must be empty for weight reasons. Empty the fuel tank, if necessary, refer to «FUEL TANK, DRAINING»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-tank-draining) .
TEST DRIVES WITH THE USE OF TEST AND MEASURING DEVICES
If testing equipment must be used during a road test, observe the following
| WARNING | Distraction and testing equipment that is not secured properly can cause accidents. The passenger airbag could pose a risk if it deploys in a collision. Operating testing equipment while driving causes it to shift position. There is an increased risk of injury due to unsecured testing equipment. Always secure testing equipment on the rear seat using a strap and have a second person in the rear seat operate it. |
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
- Before loosening, connections and surrounding areas must be cleaned thoroughly with engine or brake cleaner, and then cleaned area must be dried completely.
- Immediately seal off lines and connections with clean plugs or protective caps.
- Place removed parts on a clean surface and cover them. Use lint-free cloths.
- Carefully cover or plug unpacked components if repairs cannot be performed immediately.
- Only install clean components: Remove the replacement parts from their packaging just prior to installing them. Do not use parts that have been stored outside of their original packaging (for example in tool boxes etc.).
- When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.
- Protect the disconnected connectors from dirt and moisture and only connect when they are dry.
TEST CONDITIONS
- Battery voltage at least 12.5 V.
- Fuse for fuel pump OK, refer to Wiring Diagram.
- Fuel Pump (FP) control module -J538- OK; checking, refer to «Fuel Pump Control Module -J538-, CHECKING»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-pump-control-module-j538-checking) .
- FP relay -J17- OK, refer to Wiring Diagram.
- Fuel tank minimum 1 / 4 full.
- Fuel filter OK.
- Fuel lines OK (not plugged, not kinked).
- The ignition is off.
CONTACT CORROSION
Contact corrosion can occur if incorrect fasteners (bolts, nuts, washers, etc.) are used.
For this reason, only connecting elements with a special surface coating are installed.
In addition, rubber or plastic parts and adhesive are made of materials that do not conduct electricity.
If you are not sure about the suitability of parts, install new parts.
Note. Only original replacement parts are recommended, they are checked and compatible with aluminum. It is recommended to use Audi accessories. Damage resulting from contact corrosion is not covered by the warranty.