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
- Before loosening, connections and the surrounding areas must be cleaned thoroughly with engine or brake cleaner, and then cleaned area must be dried completely.
- Seal the open lines and connections immediately with clean plugs, for example, from the engine bung set VAS 6122.
- Place removed parts on a clean surface and cover them with lint-free cloths.
- Carefully cover over opened components or seal them, if repairs are not 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 out of their original packaging (for example in tool boxes etc.).
- If the system is open, do not work with compressed air and do not move the vehicle.
- Make sure no fuel gets onto the fuel hoses. If necessary, wipe off the fuel hoses immediately. Replace any corroded fuel hoses.
- Protect the disconnected connectors from dirt and moisture and only connect them when they are dry.
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.
COOLERS AND CONDENSERS
The radiator and condenser may have small indentations on the fins even when installed correctly. It is not damage. Radiators or condensers should not be replaced because of slight impressions like these.
ENGINE CONTAMINANTS
- To prevent foreign objects from entering when working on the engine, seal open the intake and exhaust channels with suitable plugs, for example from the engine bung set VAS 6122.
- 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.
ENGINE NUMBER
Note. The engine number is only visible if the front engine cover is removed.
Scheme 36
- The engine number ("engine code" and "serial number") is located at front on cylinder block at top -arrow 1-.
- Engine codes beginning with "C" are four-digit.
- 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.
- 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. Refer to the Maintenance Procedures.
LINES, ROUTING AND SECURING
- Mark the individual fuel, hydraulic and vacuum lines for the Evaporative Emission (EVAP) canister system as well as the electrical wires before disconnecting and/or removing them. This will prevent a mix-up when reconnecting them. If necessary, draw sketches or take pictures.
- Due to the limited space inside the engine compartment, be especially careful when working near moving or hot parts. This will also prevent damaging the lines.
BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM
| WARNING | The injection system is separated into a high-pressure section (maximum approximately 120 bar (1740 psi)) and a low-pressure section (approximately 6 bar (87 psi)). Before opening the high pressure area, the fuel pressure must be reduced to a residual pressure of approximately 6 bar (87 psi). Refer to General Information . |
COOLING SYSTEM
Note the following when working on the cooling system
| WARNING | Risk of scalding due to hot steam and hot coolant. The coolant system is under pressure when the engine is warm. Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system. |
| CAUTION | The vehicle could overheat if the cap is installed incorrectly. The cap must engage noticeably when sealing. |
EXHAUST SYSTEM
Note the following when working on the exhaust system
| CAUTION | Danger of damaging the decoupling element. Decoupling element must not be bent more than 10°. Do not load decoupling element on cable. Do not damage wire mesh at decoupling element. |
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. |
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 a clean cloth around the connector and carefully loosen the connector. |
Procedures before opening high pressure fuel injection system. Refer to General Information .
To prevent personal injury and damage to the injection and ignition system, observe the following
- Turn off the ignition before disconnecting and connecting the wiring for the injection and ignition system. This includes tester cables as well.
- Only clean the engine with the ignition switched off.
- If electrical connectors were disconnected and the engine was started, then malfunctions have been stored in the engine control modules. "Generate readiness code" in "Guided Functions" using a vehicle diagnosis tester.
| CAUTION | Risk of destroying electronic components when disconnecting the battery. Observe the measures for disconnecting battery. Only disconnect the battery with ignition switched off. |
Disconnect the battery. Refer to Removal and Installation .
SUBFRAME
Note the following whenever working on the subframe
| CAUTION | The suspension components could be damaged. Do not rest the vehicle on its wheels if the subframe mount, the steering gear or the subframe crossbrace are not installed correctly. Do not support the vehicle on the subframe or the subframe crossbrace, for example, by a floor jack or similar device. |
ENGINE DATA
| Identification Codes | CALB | |
|---|---|---|
| Displacement | Liter | 3.197 |
| Output | KW at RPM | 199/5000 |
| Torque | Nm at RPM | 330/3000 |
| Bore | Diameter mm | 85.5 |
| Stroke | Mm | 92.8 |
| Compression ratio | 12.5 | |
| RON | At least | 95 1) |
| Fuel injection and ignition system | Simos | |
| Ignition sequence | 1-4-3-6-2-5 | |
| Turbocharger | No | |
| Knock control | 2 sensors | |
| Oxygen sensor regulation | 4 heated oxygen sensors | |
| Variable valve timing | Intake and exhaust | |
| Variable intake manifold | Yes | |
| Secondary Air Injection (AIR) System | Yes | |
| Valve per cylinder | 4 | |
| 1) Unleaded RON 91 is also permitted, but performance is reduced. | ||
FUEL SYSTEM, CHECKING FOR LEAKS
Let the engine run a few minutes at a moderate speed.
Turn off the 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.
VACUUM SYSTEM, CHECKING
Special tools and workshop equipment required
- Hand Vacuum Pump VAS 6213
Procedure
Check all vacuum lines in the vacuum system for
- Cracks
- Damage caused by animals
- Crimps
- 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.
If using the VAS 6213 does not produce any vacuum or if the vacuum 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 37
- Hand Vacuum Pump VAS 6213
See also:
• General Information
• Removal and Installation