4.2l v8 5v Fuel Injection & Ignition, Engine Code(s): Bfm Audi A8 D3 рестайлинг

Safety precautions

Observe the following precautions if test and measuring instruments are required during a test drive

To prevent injuries to persons and/or damage to the fuel injection and ignition system, the following must be noted

1. Always switch off the ignition before connecting or disconnecting injection or ignition system wiring or tester cables.
2. To operate the engine at starting speed without actually starting it (for example, in order to test compression), disconnect the connectors from the output stages for the ignition coils and also the connectors on the injectors.
3. During some of the tests the control module may identify and record faults. The Diagnostic Trouble Code (DTC) memory should therefore be checked and (if necessary) erased after completing the tests and any repair work that may be required.

1. Always switch off the ignition before cleaning the engine.
2. Always switch off the ignition before connecting or disconnecting the battery, otherwise the engine control module may be damaged.

Rules for cleanliness

When working on the fuel supply/injection system, pay careful attention to the following 6 rules for cleanliness

1. Thoroughly clean all unions and the adjacent areas before disconnecting fuel lines.
2. Place parts that have been removed on a clean surface and place a cover on them. Do not use fluffy cloths.
3. Carefully cover or seal opened components if the repair cannot be performed immediately.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (e.g. in tool boxes etc.).

1. When the system is open: Do not work with compressed air in the area if this can be avoided. Do not move vehicle unless absolutely necessary.
2. Keep disconnected electrical connectors clean and dry. Connect only when dry.

Technical data

1) When the engine is at operating temperature the resistance is increased by approx. 4...6 ohms.

Scheme 654

Components A to N are not shown in the exploded drawing.

A - MIL exhaust emissions warning lamp

1. In instrument cluster
2. Notes on warning lamp. See «MIL exhaust emissions warning lamp»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

B - EPC warning lamp

1. In instrument cluster
2. Notes on warning lamp. See «EPC warning lamp»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

C - Throttle Position (TP) sensor -G79- and Sender 2 for accelerator pedal position -G185

1. In footwell on accelerator pedal (both senders are located in one housing)

D - Fuel Pump (FP) relay -J17

1. 5-way relay carrier in passenger's footwell, relay socket 4. See «Relay carrier in passenger's footwell»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

E - Fuel Pump (FP) 2 relay -J49

1. Relay and fuse carrier at right of luggage compartment, relay socket 3. See «Relay and fuse carrier at right of rear compartment»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

F - Secondary Air Injection (AIR) pump relay -J299

1. 3-way relay carrier in electronics box in plenum chamber, relay socket 3. See «Relay carrier in electronics box in plenum chamber»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

G - Motronic Engine Control Module (ECM) power supply relay -J271

1. 3-way relay carrier in electronics box in plenum chamber. See «Relay carrier in electronics box in plenum chamber»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

H - Starter relay 1

1. See «Relay carrier in passenger's footwell»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

I - Starter relay 2

1. See «Relay carrier in passenger's footwell»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

J - 3-pin connector for Engine speed (RPM) sensor -G28

1. See «Connector console (underside of transmission)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

K - 4-pin connector for Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) heater -Z19

1. Bank 1
2. See «Connector assignment»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

L - 4-pin connector for Heated Oxygen Sensor (HO2S) 2 -G108- and Oxygen Sensor (O2S) 2 heater -Z28

1. Bank 2
2. See «Connector assignment»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

M - 4-pin connector for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- and Oxygen Sensor (O2S) heater 1 -Z29

1. Bank 1
2. See «Connector console (underside of transmission)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

N - 4-pin connector for Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- and Oxygen Sensor (O2S) heater 2 -Z30

1. Bank 2
2. See «Connector console (underside of transmission)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

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

1. See «Connector assignment»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

2 - Motronic Engine Control Module (ECM) -J623

1. In plenum chamber
2. See «Electronics box in plenum chamber»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

3 - Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42

4 - Valve 1 for camshaft adjustment -N205

5 - Throttle valve control module -J338

1. With Throttle drive (power accelerator actuation) -G186-, Angle sensor 1 for throttle drive -G187- and Angle sensor 2 for throttle drive -G188

6 - Secondary Air Injection (AIR) solenoid valve -N112

1. See «Secondary air injection valve»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

7 - Camshaft Position (CMP) sensor 2 -G163

1. Cylinder bank 2

8 - Fuel pressure regulator

9 - Ignition coils with output stages

1. Cylinder bank 2

10 - Valve 2 for camshaft adjustment -N208

11 - 3-pin connector

1. For Knock Sensor (KS) 1 -G61
2. For Knock Sensor (KS) 2 -G66
3. See «Knock sensor connectors»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

12 - Intake Manifold Change-Over valve -N156

1. See «Front view»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

13 - Intake Manifold Tuning (IMT) valve 2 -N261

1. Intake Air Switch-over valve -N335-. See «Front view»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

14 - Camshaft Position (CMP) sensor -G40

1. Cylinder bank 1

15 - Ignition coils with output stages

1. Cylinder bank 1

16 - Secondary Air Injection (AIR) pump motor -V101

1. Below longitudinal member, right side
2. See «Secondary air injection pump motor (below right longitudinal member)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm)

Scheme 655

2 - Starter relay 1

3 - Starter relay 2

4 - Fuel Pump (FP) relay -J17

Scheme 656

3 - Fuel Pump (FP) 2 relay -J49

Scheme 657

1 - Secondary Air Injection (AIR) pump relay -J299-, relay socket 1

2 - Motronic Engine Control Module (ECM) supply relay -J271-, relay socket 3

3 - Fuse -S130- for secondary air injection pump

Scheme 658

If the engine control module detects faults affecting the emission control system, this is indicated by the exhaust emissions warning lamp.

Location of exhaust emissions warning lamp

Note. The emissions warning lamp indicates a fault with either a flashing light or continuous light. In both cases the Diagnostic Trouble Code (DTC) memory should be checked.

Flashing light

1. This indicates a fault which will cause damage to the catalytic converter if the vehicle is driven further under the current conditions. If the warning lamp is flashing, the vehicle should only be driven with reduced power (until the MIL goes out or remains on continuously); the fault should be corrected as soon as possible.

Continuous light

1. This indicates a fault that causes an increase in exhaust emissions. Check DTC memories of engine control module and automatic transmission control module (if equipped).
2. If the vehicle does not run properly, or the customer reports driveability problems, and the exhaust emissions warning lamp does not light up, check the function of the warning lamp and then check the DTC memory. The DTC memory may have stored faults which are not indicated immediately by the exhaust emissions warning lamp.

Scheme 659

"EPC" stands for Electronic Power Control and refers to the electronic throttle control system.

Location of EPC warning lamp

The engine control module switches the EPC warning lamp on when the ignition is switched on.

After the engine has been started, the engine control module tests all parts for faults relating to the EPC system.

During the test sequence the EPC warning lamp lights up for about 3 seconds. If a fault is detected during this test phase the warning lamp will remain lit.

If a fault is detected in the EPC system while the engine is running, the engine control module will activate the EPC warning lamp. At the same time a code is stored in the DTC memory of the engine control module.

Scheme 660

1 - Evaporative Emissions canister purge regulator valve -N80

2 - 4-pin connector for Heated Oxygen Sensor (HO2S) 2 -G108- and Oxygen Sensor (O2S) 2 heater -Z28

3 - 4-pin connector for Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) heater -Z19

Scheme 661

1 - Engine Control Module (ECM) -J623

Scheme 662

1 - 3-pin connector for Engine speed (RPM) sensor -G28

2 - 4-pin connector for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- and Oxygen Sensor (O2S) heater 1 -Z29

3 - 4-pin connector for Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter -G131- and Oxygen Sensor (O2S) heater 2 -Z30

Scheme 663

1 - 3-pin connector for Knock Sensor (KS) 1 -G61-, cylinder bank 1

2 - 3-pin connector for Knock Sensor (KS) 2 -G66-, cylinder bank 2

Scheme 664

1 - Intake Manifold Change-Over valve -N156

1. Activation for both vacuum units

2 - Vacuum units for intake manifold change-over function

3 - Intake Air Switch-over valve -N335

1. Activation for control flap in air cleaner

a - T-connection for vacuum supply from intake manifold pressure control valve

b - Vacuum supply from intake manifold

c - Vacuum hose to vacuum reservoir

d - T-connection for vacuum supply from Intake Air Switch-over valve -N335- and vacuum reservoir

e - T-connection for vacuum supply from Intake Manifold Change-Over valve -N156

f - Vacuum hose to control flap in air cleaner

Scheme 665

1 - Secondary Air Injection (AIR) solenoid valve -N112

Scheme 666

1 - Secondary Air Injection (AIR) pump motor -V101

Fuel pressure regulator and holding pressure, checking

Special tools and equipment required

Scheme 667

1. V.A.G 1318 with V.A.G 1318/6 and V.A.G 1318/7

Conditions

1. Fuel pump relay OK
2. Fuel pump OK
3. Fuel filter OK
4. Battery voltage at least 11 V

1. Vehicles with automatic transmission: selector lever in position P or N

Note. The fuel pressure regulator regulates the fuel pressure according to intake manifold pressure.

1. Briefly open fuel tank filler cap (to release pressure).
2. Cover pressurized union with a cloth.

Scheme 668

1. Open union (arrow) and catch escaping fuel with a cloth.

Scheme 669

1. Connect pressure tester V.A.G 1318 with adapters V.A.G 1318/15 (6) and 1318/7 between fuel supply pipe and fuel rail.
2. Open shut-off valve on pressure gauge. Valve handle points in direction of flow.
3. Start engine and run at idling speed.
4. Measure fuel pressure.

Specification: approx. 3.5 bar

Scheme 670

1. Pull vacuum hose (arrow) off fuel pressure regulator.

Fuel pressure should increase to approx. 4.0 bar.

Note. If fuel flows out at the vacuum connection on the fuel pressure regulator during the following pressure test, install a new fuel pressure regulator.

If the specification is not obtained

1. Install a new pressure regulator as a trial measure and repeat pressure test.

If fuel pressure still does not match specification

1. Check fuel pump and supply line for damage (e.g. pinching) and replace if necessary.

If the specification is obtained

1. Reconnect vacuum hose.
2. Switch ignition off.
3. Observe pressure drop on pressure gauge to check leakage and holding pressure.

After 10 minutes pressure should still be at least 3 bar.

If the holding pressure drops below 3.0 bar

1. Start engine and run at idling speed.

Scheme 671

1. Switch ignition off after pressure has built up. At same time close shut-off valve on pressure gauge V.A.G 1318 (valve handle at 90° to direction of flow).
2. Observe pressure drop on gauge.

If the pressure drops again, the following faults are possible

1. Unions on pressure gauge downstream of cut-off valve leaking
2. Fuel pressure regulator faulty
3. Injectors leaking

If the pressure does not drop, the following faults are possible

1. Union between pressure gauge and fuel supply pipe leaking
2. Supply line leaking at fuel tank
3. Non-return valve in fuel pump leaking.

Refer to 20 - FUEL SUPPLY

Injection rate, leakage and spray pattern of injectors, checking

Conditions

1. Fuel pressure OK

Removing fuel rail

1. Remove engine compartment cover.
2. Disconnect vacuum hose from fuel pressure regulator.
3. Disconnect connectors from injectors and remove cable ties where necessary.
4. Unscrew fuel rail from intake manifold and pull fuel rail upward off manifold together with injectors.

Checking injectors for leaks

Scheme 672

1. Place injector which is to be tested into a measuring glass from injection quantity tester V.A.G 1602.
2. Connect test box V.A.G 1598/31 to wiring harness for engine control module. Do not connect to engine control module itself. Refer to «Wiring and component check with test box V.A.G 1598/31»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm__wiring-and-component-check-with-test) .
3. Bridge contacts 1 and 65 on test box using test leads from adapter set V.A.G 1594 A. (This creates a Ground connection to one side of fuel pump relay coil.)
4. Switch ignition on.

Note. Once the ignition has been switched on the fuel pump runs continuously, even if the engine is not running. This is because when the ignition is switched on the fuel pump relay receives a positive voltage supply via the central electrics. The Ground connection for the fuel pump relay is made via the cable bridge on the test box.

1. Check injectors for leaks (visual check).

When fuel pump is running, only 1 or 2 drops should escape per minute from each injector.

If the fuel loss is greater

1. Switch off fuel pump (turn off ignition) and replace faulty injector.

Checking injection quantity

1. Place injector which is to be tested into a measuring glass from injection quantity tester V.A.G 1602.

Scheme 673

1. Connect one injector contact to engine Ground using test lead and alligator clamp from V.A.G 1594 A.
2. Connect second injector contact to positive using remote control V.A.G 1348/3 A, adapter cable V.A.G 1348/3-2 and auxiliary cable.
3. Bridge contacts 1 and 65 on test box using test leads from adapter set V.A.G 1594 A.
4. Switch ignition on.

Fuel pump should run.

1. Activate remote control V.A.G 1348/3A for 30 seconds.
2. Perform measurement on all injectors.
3. Once all four injectors (bank 1 or bank 2) have been actuated, place measuring glasses on a level surface.

Specification at each injector

If none of the injectors delivers the specified quantity

1. Check fuel pressure. Refer to «Fuel pressure regulator and holding pressure, checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm__fuel-pressure-regulator-and-holding-pressure) .

If only one injector fails to deliver the specified quantity

1. Replace affected injector.

Note. When checking the injection quantity, also check the spray pattern. The spray pattern should be the same for all the injectors.

Installation of the fuel rail together with injectors is performed in the reverse sequence. The following points should be noted when installing

1. Replace the O-rings at all opened connections. (When replacing the front O-ring, make sure not to remove the plastic cap from the injector head. The O-ring must be pulled off over the plastic cap.)
2. Moisten the O-rings with clean engine oil.
3. Check to make sure that the retainer clamps are properly seated.
4. Tighten fuel rail to intake manifold to 10 Nm.

Wiring and component check with test box V.A.G 1598/31

Note. The test box V.A.G. 1598/31 is designed so it can be simultaneously connected to the control module wiring harness and to the control module itself. This has the advantage of enabling the engine management system to remain fully operational even with the test box connected (for example, when checking signals while the engine is running). The instructions for performing the individual tests indicate whether or not the engine control module itself also needs to be connected to the test box. Use multimeter Fluke 83 or equivalent and the diode test lamp V.A.G 1527 for the checks. To connect the testers to test box 1598/31, always use the adapter leads from adapter set V.A.G 1594.

Connecting test box V.A.G 1598/31

1. Switch ignition off.
2. Remove cover of plenum chamber, right side.

Scheme 674

1. Loosen both screws (arrows) and pull engine control module in direction of travel and out.

Scheme 675

As a deterrent against unauthorized access to the connectors on the engine control module, the control module -1- is bolted to a metal casing -4- by means of a locking plate -2- and shear bolts -3-.

The threads of the shear bolts are additionally coated with a thread-locking compound to make them more difficult to remove.

In order to disconnect the connectors from the engine control module (for instance when connecting the test box or replacing the control module), the control module must be separated from the protective casing. The required procedure is described below

Required tools and equipment

Scheme 676

1. Hot air blower -1- (from wiring repair set VAS 1978)
2. Nozzle attachment -2- (also included in wiring repair set VAS 1978)
3. A normal (commercially available) vise-grip wrench

Work sequence

1. Pivot engine control module with protective casing towards engine compartment so that locking plate (item -2- in illustration) is visible. Place a clean cloth under engine control module with protective casing.

Scheme 677

1. Set controls on hot air blower as shown in illustration: temperature control -2- to maximum heat and two-stage air delivery switch -3- to setting 3.

Note. In the next step the blower is used to heat the threads for the shear bolts in the locking plate. This reduces the effect of the thread locking compound so the bolts can then be more easily removed.

Scheme 678

1. Apply nozzle -1- of hot air blower to thread in locking plate so that nozzle surrounds thread. Nozzle may rest against top of metal casing.
2. Switch blower on and apply heat to thread for about 20 to 25 seconds.

Scheme 679

1. Apply vise-grip wrench -1- to bolt head -2- and unscrew shear bolt in direction indicated (arrows).
2. Repeat procedure for second shear bolt.

Note. Be particularly careful at the second shear bolt location because the control module connectors are very close to the bolt.

Scheme 680

1. Apply nozzle -1- of hot air blower to thread in locking plate so that nozzle surrounds thread. Nozzle may rest against top of metal casing.
2. Switch blower on and apply heat to thread for about 20 to 25 seconds.

Scheme 681

1. Apply vise-grip wrench -1- to bolt head -2- and unscrew shear bolt in direction indicated (arrows).

The engine control module can now be separated from the metal casing.

1. Release connectors on engine control module and disconnect connectors.

Scheme 682

1. Connect test box V.A.G 1598/31 to connector on wiring harness. Also connect Ground clamp (arrow) to Ground. Instructions for individual tests indicate whether or not engine control module itself also needs to be connected to test box.
2. Perform test as described in relevant repair instructions.

Installing engine control module

Installation is performed in the reverse sequence. Make sure to install the protective casing to the engine control module. Use new shear bolts when installing the protective case.

Engine Control Module (ECM) -J623-, replacing

Note. When the engine control module is disconnected the learned values are erased but the contents of the Diagnostic Trouble Code (DTC) memory remain intact.

Removing

1. Connect vehicle diagnostic, testing and information system VAS 5051 and select vehicle system "01 - Engine electronics" from menu. Ignition must be on.

Scheme 683

The display on the vehicle diagnostic, test and information system VAS 5051 will show the control module identification and the coding -2-.

1. Call up and print out control module identification.
2. Switch ignition off.
3. Remove cover of plenum chamber, right side.

1. Loosen both screws (arrows) and pull engine control module in direction of travel and out.

As a deterrent against unauthorized access to the connectors on the engine control module, the control module -1- is bolted to a metal casing -4- by means of a locking plate -2- and shear bolts -3-.

The threads of the shear bolts are additionally coated with a thread-locking compound to make them more difficult to remove.

In order to disconnect the connectors from the engine control module (for instance when connecting the test box or replacing the control module), the control module must be separated from the protective casing. The required procedure is described below

Required tools and equipment

1. Hot air blower -1- (from wiring repair set VAS 1978)
2. Nozzle attachment -2- (also included in wiring repair set VAS 1978)
3. A normal (commercially available) vise-grip wrench

Work sequence

1. Pivot engine control module with protective casing toward engine compartment so that locking plate (Item -2- in illustration) is visible. Place a clean cloth under engine control module with protective casing.

1. Set controls on hot air blower as shown in illustration: temperature control -2- to maximum heat and two-stage air delivery switch -3- to setting 3.

Note. In the next step the blower is used to heat the threads for the shear bolts in the locking plate. This reduces the effect of the thread locking compound so the bolts can then be more easily removed.

1. Apply nozzle -1- of hot air blower to thread in locking plate so that nozzle surrounds thread. Nozzle may rest against top of metal casing.
2. Switch blower on and apply heat to thread for about 20 to 25 seconds.

1. Apply vise-grip wrench -1- to bolt head -2- and unscrew shear bolt in direction indicated (arrows).
2. Repeat procedure for second shear bolt.

Note. Be particularly careful at second shear bolt location because the control module connectors are very close to the bolt.

1. Apply nozzle -1- of hot air blower to second thread in locking plate so that nozzle surrounds thread. Nozzle may rest against top of metal casing.
2. Switch blower on and apply heat to thread for about 20 to 25 seconds.

1. Apply vise-grip wrench -1- to bolt head -2- and unscrew shear bolt in direction indicated (arrows).

The engine control module can now be separated from the metal casing.

1. Release connectors on engine control module and disconnect connectors.
2. Remove old engine control module and install new part.

Installing

Installation is performed in the reverse sequence. Make sure to install the protective casing to the engine control module. Use new shear bolts when installing the protective case.

After installing a new engine control module, perform the following operations

1. Select function "replacing" of relevant control module in "guided fault finding".

For this step use vehicle diagnostic, testing and information system VAS 5051.

Intake manifold, removing and installing

Removing

Scheme 684

1. Remove engine cover panel.

Scheme 685

1. Remove air intake hose between air cleaner and throttle valve control module.

Scheme 686

1. Open fuel supply and fuel return lines -1- and -2-.

1. Pull vacuum hose (arrow) off fuel pressure regulator.

Scheme 687

1. Disconnect vacuum unit -1- and hose -2- from throttle valve control module.
2. Disconnect connector from secondary air injection valve and from throttle valve control module.

Scheme 688

1. Remove bracket for secondary air injection valve.

Scheme 689

1. Remove connecting hose of crankcase breather system.

Scheme 690

1. Disconnect vacuum supply -1- for intake manifold change-over function from intake manifold.
2. Disconnect vacuum supply at T-connection -2-.
3. Disconnect connectors from intake manifold change-over valves.
4. Disconnect connectors from camshaft position sensor (bank 1) and from valve 2 for camshaft adjustment (bank 2).

1. Disconnect 8 connectors from injectors.
2. Move both connector rails clear.
3. Unscrew all Allen screws from intake manifold.
4. Carefully pull intake manifold up and out. Water pipe at throttle valve control module remains connected.

1. Move intake manifold clear taking notice of water pipe at throttle valve control module.

Note. Cover the intake ports in the cylinder heads with clean cloths.

Installing

The intake manifold is installed in reverse order, noting the following

Note. Replace seals/gaskets Ensure that all cable ties which were opened or cut open during removal are installed at the same position. Locate the hose connections with genuine hose clamps.

Scheme 691

1. To replace all seals/gaskets of intake manifold, unscrew locating bolts -1-.
2. Observe positioning pin -2- when installing intake manifold.

Scheme 692

1. Tighten intake manifold bolts in stages and in diagonal sequence shown.

Tightening torque: 11 Nm

1. Run engine for 5 minutes.
2. Retighten intake manifold bolts in sequence shown.

Tightening torque: 11 Nm

Oxygen sensor before catalytic converter, removing and installing

Bank 1 and Bank 2: Remove intake manifold prior to removing and installing oxygen sensors

1. Remove intake manifold. Refer to «Intake manifold, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#42l-v8-5v-fuel-injection-ignition-engine-codes-bfm__intake-manifold-removing-and-installing) .

1. Disconnect relevant oxygen sensor connector.

2 - 4-pin connector for Heated Oxygen Sensor (HO2S) 2 -G108- and Oxygen Sensor (O2S) 2 heater -Z28

3 - 4-pin connector for Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) heater -Z19

1. Cut open cable ties to move wiring clear.

Scheme 693

1. Unscrew relevant oxygen sensor with special tool 3337 (illustration shows Heated Oxygen Sensor (HO2S) 2.

Installing

The oxygen sensor is installed in reverse order, noting the following points

Note. Ensure that all cable ties which were opened or cut open during removal are installed at the same position. When installing, the oxygen sensor wire must be secured at exactly the same positions as before in order to avoid contact between the wire and the exhaust pipe. The screw thread on the oxygen sensor is coated with a special paste. This paste must not be allowed to penetrate the openings on the sensor. Sensor tightening torque: 55 Nm.

Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131-, removing and installing

Removing

1. Disconnect relevant connector for Oxygen Sensor (O2S) 2 Behind TWC -G131-.

2 - 4-pin connector for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- and Oxygen Sensor (O2S) heater 1 -Z29

3 - 4-pin connector for Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- and Oxygen Sensor (O2S) heater 2 -Z30

1. Cut open all cable ties at transmission for wiring connections of O2S 2 Behind TWC -G131-.

Scheme 694

1. Unscrew oxygen sensor (arrow) using special tool 3337.

Installing

The oxygen sensor is installed in reverse order, noting the following points

Note. When installing, the oxygen sensor wire must be secured at exactly the same positions as before in order to avoid contact between the wire and the exhaust pipe. The screw thread on the oxygen sensor is coated with a special paste. This paste must not be allowed to penetrate the openings on the sensor. Sensor tightening torque: 55 Nm.

Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-, removing and installing

Removing

1. Disconnect connector for Oxygen Sensor (O2S) Behind TWC -G130-.

2 - 4-pin connector for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- and Oxygen Sensor (O2S) heater 1 -Z29

3 - 4-pin connector for Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- and Oxygen Sensor (O2S) heater 2 -Z30

The transmission must be lowered at the rear to remove O2S Behind TWC -G130- and provide access to the sensor wiring.

The lowering procedure for the transmission is described in

Refer to 37 - CONTROLS, HOUSING ; Removing and installing transmission support and mounting

Removing sensor after lowering transmission

1. Cut open all cable ties at transmission locating wiring connections of O2S Behind TWC -G130-.

Scheme 695

1. Unscrew oxygen sensor using special tool 3337.

Installing

The oxygen sensor is installed in reverse order, noting the following points

Note. When installing, the oxygen sensor wire must be secured at exactly the same positions as before in order to avoid contact between the wire and the exhaust pipe. The screw thread on the oxygen sensor is coated with a special paste. This paste must not be allowed to penetrate the openings on the sensor. Sensor tightening torque: 55 Nm. Tightening torques for installation of the automatic transmission

Refer to 37 - CONTROLS, HOUSING

General notes on ignition system

1. The engine control module is equipped with On Board Diagnostic (OBD).
2. For trouble-free operation of the electrical components a voltage of at least 11.5 V is necessary.
3. During some of the tests it is possible that the control module will detect and record a fault. The Diagnostic Trouble Code (DTC) memory must therefore be checked and if necessary erased when all tests and repair work have been completed.
4. After completing fault finding, repairs or component tests, it is possible that the engine will start, run for a short period and then cut out. If this happens it may be that the immobilizer is blocking the engine control module. In such cases the DTC memory must be checked and if necessary the control module must be adapted.

To prevent injuries to persons and/or damage to the fuel injection and ignition system, the following must be noted

1. Do not touch or disconnect ignition wiring when the engine is running or being turned at starter speed.
2. Always switch off the ignition before connecting or disconnecting the battery, otherwise the engine control module may be damaged.
3. The ignition must be switched off before connecting or disconnecting injection or ignition system wiring or tester cables.
4. In order to run the engine at starting speed without actually starting it (e.g. to test compression), unplug the connectors from the output stages of the ignition coils and from all the injectors. After completing the work, check and erase the DTC memory.

1. The ignition must always be switched off when cleaning the engine.

See also:
• 91 - COMMUNICATION
• 20 - FUEL SUPPLY
• 37 - CONTROLS, HOUSING
• MIL exhaust emissions warning lamp
• Wiring and component check with test box V.A.G 1598/31
• Fuel pressure regulator and holding pressure, checking
• Intake manifold, removing and installing