3.2l - Fuel Injection System - Engine Code(s): Calb Audi Q5 I

SAFETY PRECAUTIONS

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

To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following

Scheme 70

1. For safety reasons, if the battery is not disconnected, Fuel Pump (FP) Control Module -J538- fuse must be removed before opening fuel system. Otherwise, the fuel pump will be activated by the driver's door contact switch.
2. Individuals with a pacemaker must not stay in the danger area of high voltage systems, for example ignition systems, xenon light.
3. Fuel lines must not be opened when engine is running.
4. Only disconnect and reconnect wires for injection and ignition system, including test leads, when ignition is switched off.
5. If engine is to be cranked at starting RPM without starting (for example for compression testing), disconnect connectors from ignition coils and remove fuse for electric fuel pump.
6. It is possible that the control module will recognize a malfunction and store a Diagnostic Trouble Code (DTC) during some tests. Therefore after completing all checks and repairs the DTC memory must be checked and if necessary erased.
7. Cleaning the engine should only be performed with ignition switched off.
8. The battery must only be disconnected and connected with the ignition switched off, since the ECM can otherwise be damaged.

CLEAN WORKING CONDITIONS

Even minor contamination can lead to malfunctions in the fuel injection system. Therefore when working on the fuel supply/injection system, pay careful attention to the following rules of cleanliness

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. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored unpacked (for example in tool boxes etc.).
5. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.

ON BOARD DIAGNOSTICS

1. The engine control module is equipped with On Board Diagnostics (OBD). Before repairs such as fault finding, check the Diagnostic Trouble Code (DTC) memory first. Also the vacuum hoses and connections must be checked (unmetered air).
2. Fuel hoses in engine compartment must only be secured with spring-type clips. The use of clamp or screw type clips is not permissible.
3. For the electric components to work properly, a voltage of at least 11.5 Volts is required.
4. Do not use sealants containing silicone. Particles of silicone drawn into the engine, will not be burnt in the engine and damage the oxygen sensor.
5. The vehicles have a crash fuel shut-off. It reduces the risk of fire in an accident because the fuel pump relay switches the fuel pump off.
6. At the same time, with this set-up, an improvement in the comfort of engine startability is also attained. When the driver-side door is opened, the Fuel Pump (FP) is activated for 2 seconds so that pressure builds in the fuel system, observe safety measures. Refer to «SAFETY PRECAUTIONS»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__safety-precautions) .

BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM

Note. hp is the same as mbar 1bar is 1000 mbar or 1000 hp or 100000 Pa If you have 36000hp on the tester you have 36000 mbar or 36 bar system-pressure.

High Fuel Pressure, Reducing

Connect vehicle diagnostic tester.

Scheme 71

Start engine and run at idle speed.

Select "engine electronics" in OBD.

Then select "Measured values".

Select "Fuel pressure" from the list.

When the engine is at idle, fuel pressure between 30 and 40 bar (435.11 to 580.15 psi) is displayed.

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

Scheme 72

While the engine is idling, remove the fuse in the fuse holder inside the instrument panel on the driver side from the Fuel Pump (FP) control module -J538-. Refer to appropriate SYSTEM WIRING DIAGRAM.

Check fuel pressure.

1. The fuel pressure decreases rapidly because the mechanical high pressure pump is no longer supplied with fuel from the transfer fuel pump -G6-.

Switch ignition off as soon as the fuel pressure drops to approximately 8 bar (116 psi).

Note. The fuel pressure must not drop below 6 bar (87 psi), because otherwise the engine will shut off (risk of catalytic converter damage).

After reducing fuel pressure, place a clean cloth around the connection and open the high pressure system immediately. Escaping fuel must be absorbed.

Perform the following steps are completing all work

Install fuse.

Erase Diagnostic Trouble Code (DTC) memory and, using "Guided Fault Finding", generate the readiness code in the Engine Control Module (ECM) vehicle diagnostic tester.

COMPONENT LOCATIONS OVERVIEW

Right Side of Engine Compartment

Scheme 73

1. Heated Oxygen Sensor (HO2S) -G39- Component location (Scheme 93)Location of electrical connector (Scheme 92)Removing and installing, refer to «Heated Oxygen Sensor -G39»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__heated-oxygen-sensor-g39) 55 Nm
2. Camshaft Adjustment Valve 1 (exhaust) -N318- Component location (Scheme 79)Replace O-rings 2.5 Nm
3. Camshaft Adjustment Valve 1 -N205- Component location (Scheme 79)Replace O-rings 2.5 Nm
4. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- Component location (Scheme 93) Connector location (Scheme 92)Removing and installing, refer to «Oxygen Sensor after Three Way Catalytic Converter -G130»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__oxygen-sensor-after-three-way-catalytic) 55 Nm
5. Connectors For fuel injectors, cylinder bank 1 For throttle valve control module -J338- For Knock Sensor (KS) 1 -G61- For Heated Oxygen Sensor (HO) -G39- For Oxygen Sensor (O) Behind Three Way Catalytic Converter (TWO) -G130- Connector locations (Scheme 92)
6. Throttle valve control module -J338- With Throttle Drive (for Electronic Power Control (EPC)) -G186-, Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) -G187- and Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) -G188- After replacement, adapt in "Guided Functions" operating mode under "Adapting throttle valve control module" Component location (Scheme 90)
7. Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80- Component location (Scheme 90)
8. Intake Air Temperature (IAT) Sensor -G42- /Manifold Absolute Pressure (MAP) Sensor -G71- Component location (Scheme 90)
9. Secondary air injection (AIR) solenoid valve -N112- Installed on vehicles with Ultra Low Emission Vehicles 2 (ULEV 2) emissions standard Component location (Scheme 91)
10. Secondary Air Injection (AIR) Solenoid Valve 2 -N320- Installed on vehicles with ULEV 2 emissions standard Component location (Scheme 91)
11. Climatronic refrigerant shut-off valve -N422- Installed only on vehicles with an auxiliary heater Component location (Scheme 90)
12. Fuel injector, Cylinder bank 1 Cylinder 3 Fuel Injector -N32- Component location (Scheme 81)Removing and installing, refer to «FUEL INJECTORS»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__fuel-injectors)
13. Knock Sensor (KS) 1 -G61- Component location (Scheme 81) Location of electrical connector (Scheme 92)Removing and installing, refer to «KNOCK SENSORS»(ref-515429-S31294765092012120300000)
14. Fuel injectors, Cylinder bank 1 Cylinder 1 Fuel Injector -N30- Cylinder 2 Fuel Injector -N31- Component location (Scheme 81)Removing and installing, refer to «FUEL INJECTORS»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__fuel-injectors)
15. Intake Manifold Tuning (IMT) Valve Position Sensor -G513- Component location (Scheme 86)
16. Intake Manifold Tuning (IMT) Valve -N156- Component location (Scheme 86)
17. Actuator for intake manifold change-over Vacuum diaphragm
18. Engine Coolant Temperature (ECT) Sensor -G62- Component location (Scheme 86)
19. Camshaft Position (CMP) sensor -G40- Component location (Scheme 79)Replace O-rings 9 Nm Removing and installing, refer to «CAMSHAFT POSITION SENSOR»(ref-515429-S41441591332012120300000)
20. Camshaft adjuster actuators Cam adjustment actuator 1 -F366- Cam adjustment actuator 2 -F367- Cam adjustment actuator 3 -F368- Cam adjustment actuator 4 -F369- Cam adjustment actuator 5 -F370- Cam adjustment actuator 6 -F371- Component location (Scheme 79)
21. High pressure pump With Low Fuel Pressure Sensor -G410- and Fuel Metering Valve -N290- Component location (Scheme 87)Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__high-pressure-pump)
22. Ignition coils, Cylinder bank 1 Ignition Coil 1 with Power Output Stage -N70- Ignition Coil 2 with Power Output Stage -N127- Ignition Coil 3 with Power Output Stage -N291- Removing and installing, refer to «IGNITION COILS»(ref-515429-S26718985242012120300000)
23. Camshaft position (CMP) sensor 3 -G300- Component location (Scheme 79)Replace O-rings 9 Nm Removing and installing, refer to «CAMSHAFT POSITION SENSOR»(ref-515429-S41441591332012120300000)
24. Secondary Air Injection (AIR) Pump Motor -V101- Not installed on vehicles with EU 2 emission standard Removing and installing, refer to «Removal and Installation»(/audi/q5/i-2008-2012/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-calb)

Left Side of Engine Compartment

Scheme 74

1. 1 - Left Holder for Connectors For Knock Sensor (KS) 2 -G66- For fuel injectors, cylinder bank 2 For fuel pressure sensor -G247- For Oxygen Sensor (O) 2 Behind Three Way Catalytic Converter (TWO) -G131- For Heated Oxygen Sensor (HO) 2 -G108- Connector locations (Scheme 89)
2. 2 - Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- Component location (Scheme 95) Location of electrical connector (Scheme 94) Removing and installing, refer to «Oxygen Sensor 2 after Catalytic Converter -G131»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__oxygen-sensor-2-after-catalytic-converter) 55 Nm
3. 3 - Camshaft Adjustment Valve 2 -N208- Component location (Scheme 80) Replace O-rings 2.5 Nm
4. 4 - Camshaft Adjustment Valve 2 (exhaust) -N319- Component location (Scheme 80) Replace O-rings 2.5 Nm
5. 5 - Engine Control Module -J623- Component location (Scheme 75) Removing and installing, refer to «ENGINE CONTROL MODULE»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__engine-control-module)
6. 6 - Heated Oxygen Sensor (HO2S) 2 -G108- Component location (Scheme 95) Location of electrical connector (Scheme 94) Removing and installing, refer to «Heated Oxygen Sensor 2 -G108»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__heated-oxygen-sensor-2-g108) 55 Nm
7. 7 - Camshaft Position (CMP) Sensor 4 -G301- Component location (Scheme 80) Replace O-rings 9 Nm Removing and installing, refer to «CAMSHAFT POSITION SENSOR»(ref-515429-S41441591332012120300000)
8. 8 - Oil Pressure Regulation Valve -N428- Component location (Scheme 83) Removing and installing, refer to «Removal and Installation»(ref-515405-S23853514112012120300000)
9. 9 - Ignition Coils, Cylinder Bank 2 Ignition Coil 4 with Power Output Stage -N292- Ignition Coil 5 with Power Output Stage -N323- Ignition Coil 6 with Power Output Stage -N324- Removing and installing, refer to «IGNITION COILS»(ref-515429-S26718985242012120300000)
10. 10 - Camshaft Adjuster Actuators Cam adjustment actuator 7 -F372- Cam adjustment actuator 8 -F373- Cam adjustment actuator 9 -F374- Cam adjustment actuator 10 -F375- Cam adjustment actuator 11 -F376- Cam adjustment actuator 12 -F377- Component location (Scheme 80)
11. 11 - Camshaft Position (CMP) Sensor 2 -G163- Component location (Scheme 80) Replace O-rings 9 Nm Removing and installing, refer to «CAMSHAFT POSITION SENSOR»(ref-515429-S41441591332012120300000)
12. 12 - Intake Manifold Tuning (IMT) Valve Position Sensor -G513- Component location (Scheme 86)
13. 13 - Intake Manifold Tuning (IMT) Valve -N156- Component location (Scheme 86)
14. 14 - Fuel Injector, Cylinder Bank 2 Cylinder 4 Fuel Injector -N33
15. 15 - Fuel Pressure Sensor -G247- Component location (Scheme 82)
16. 16 - Knock Sensor (KS) 2 -G66- Component location (Scheme 82) Connector location (Scheme 89) Removing and installing, refer to «KNOCK SENSORS»(ref-515429-S31294765092012120300000)
17. 17 - Fuel injectors, Cylinder bank 2 Cylinder 5 Fuel Injector -N83- Cylinder 6 Fuel Injector -N84- Component location (Scheme 82) Removing and installing, refer to «FUEL INJECTORS»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__fuel-injectors)
18. 18 - Reduced Oil Pressure Switch -F378- Component location (Scheme 84) Removing and installing, refer to «Removal and Installation»(ref-515405-S23853514112012120300000)
19. 19 - Oil Pressure Switch -F22- Component location (Scheme 85) Removing and installing, refer to «Removal and Installation»(ref-515405-S23853514112012120300000)
20. A - Engine Speed (RPM) Sensor -G28- Component location (Scheme 88) Removing and installing, refer to «Engine Speed Sensor -G28»(ref-515429-S42829290842012120300000) 9 Nm
21. B - Fuel Pump (FP) Control Module -J538- Component location (Scheme 76) Installed under right rear seat Removing and installing, refer to «Removal and Installation»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system)
22. C - Throttle Position (TP) Sensor -G79- /Accelerator Pedal Position Sensor 2 -G185- In footwell on accelerator pedal (both sensors are integrated into one housing) Component location (Scheme 77) Removing and installing, refer to «Removal and Installation»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system)
23. D - Brake Lamp Switch -F- /Brake Pedal Switch -F47- In footwell at brake pedal Removing and installing, refer to «Removal and Installation»(/audi/q5/i-2008-2012/remont/anti-locktraction-control/#anti-lock-brake-system) Component location (Scheme 78)
24. E - Clutch Position Sensor -G476- Only for vehicles with manual transmission Component location (Scheme 78)
25. G - Relay and Fuse Carrier in Left E-Box Plenum Chamber Refer to appropriate SYSTEM WIRING DIAGRAM.

Scheme 75

1. In left E-box in the engine compartment.

Scheme 76

Removing and installing. Refer to Removal and Installation .

Scheme 77

2 - Electrical harness connector

Scheme 78

Integrated functionalities: clutch pedal starter interlock switch -F194- and clutch pedal switch -F36

1 - Brake lamp switch -F- and brake pedal switch -F47

Only for vehicles with manual transmission

Scheme 79

1. Camshaft Position (CMP) sensor 3 -G300
2. Camshaft adjustment valve 1 (exhaust) -N318
3. Camshaft Adjustment Valve 1 -N205
4. Cam adjustment actuator 6 -F371
5. Cam adjustment actuator 5 -F370
6. Cam adjustment actuator 4 -F369
7. Cam adjustment actuator 3 -F368
8. Cam adjustment actuator 2 -F367
9. Cam adjustment actuator 1 -F366
10. CMP sensor -G40

Scheme 80

1. Camshaft Position (CMP) sensor 2 -G163
2. Cam adjustment actuator 7 -F372
3. Cam adjustment actuator 8 -F373
4. Cam adjustment actuator 9 -F374
5. Cam adjustment actuator 10 -F375
6. Cam adjustment actuator 11 -F376
7. Cam adjustment actuator 12 -F377
8. Camshaft adjustment valve 2 -N208
9. Camshaft adjustment valve 2 (exhaust) -N319
10. CMP sensor 4 -G301

Scheme 81

1. Cylinder 1 fuel injector -N30
2. Cylinder 2 fuel injector -N31
3. Cylinder 3 fuel injector -N32
4. Knock Sensor (KS) 1 -G61

Scheme 82

1. Cylinder 6 fuel injector -N84
2. Cylinder 5 fuel injector -N83
3. Cylinder 4 fuel injector -N33
4. Fuel pressure sensor -G247
5. Knock Sensor (KS) 2 -G66

Scheme 83

Scheme 84

Scheme 85

Scheme 86

1. Engine Coolant Temperature (ECT) sensor -G62
2. Intake Manifold Tuning (IMT) valve -N156
3. Intake Manifold Tuning (IMT) valve position sensor -G513

Scheme 87

1. Low fuel pressure sensor -G410
2. Fuel metering valve -N290

Scheme 88

1. Bolted in the transmission from below.

Scheme 89

1 - Knock Sensor (KS) 2 -G66

2 - Fuel injectors, cylinder bank 2 and from the fuel pressure sensor -G247

Scheme 90

1 - Throttle valve control module -J338

2 - Evaporative Emission (EVAP) canister purge regulator valve 1 -N80

3 - Auxiliary heater exhaust gas sensor -N422- (installed only on vehicles without an auxiliary heater)

4 - Intake Air Temperature (IAT) sensor -G42- /Manifold Absolute Pressure (MAP) Sensor -G71

Scheme 91

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

2 - Secondary air injection (AIR) solenoid valve -N112

3 - Intake Air Temperature (IAT) sensor -G42- /Manifold Absolute Pressure (MAP) sensor -G71

4 - Auxiliary heater exhaust gas sensor -N422- (installed only on vehicles without an auxiliary heater)

5 - Secondary Air Injection (AIR) solenoid valve 2 -N320

6 - Throttle valve control module -J338

Scheme 92

1 - Fuel injectors, Cylinder bank 1

2 - Throttle valve control module -J338

3 - Knock Sensor (KS) 1 -G61

4 - Heated Oxygen Sensor (HO2S) -G39

5 - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130

Scheme 93

1 - Oxygen sensor -G39

2 - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130

Scheme 94

1 - Oxygen Sensor (O2S) 2 after catalytic converter -G131

2 - Heated Oxygen Sensor (HO2S) 2 -G108

3 - Fuel injectors, cylinder bank 2 and from the fuel pressure sensor -G247

4 - Knock Sensor (KS) 2 -G66

Scheme 95

1 - Heated Oxygen Sensor (HO2S) 2 -G108

2 - Oxygen Sensor (O2S) 2 after catalytic converter -G131

Scheme 96

1. Hose Clamp
2. Air Guide Hose To Throttle Valve Control Module -J338- Pay attention to the marking when installing (the arrow faces toward the throttle valve control module -J338- bolt)
3. Air Filter Element Always use a genuine air filter element Maintenance intervals 817 Service Procedures Removing and installing, refer to «AIR FILTER ELEMENT»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__air-filter-element) Clean snow screen also (if present)
4. Air Duct Clipped into upper part of air filter housing Clean air duct of dirt and leaves
5. Air Duct Clean air duct of dirt and leaves
6. Air Duct To lock carrier Clean air duct of dirt and leaves
7. Rubber Grommet
8. Water Drain Hose Clean water drain hose of dirt and leaves (important)
9. Water Drain Hose Guide
10. Warm Air Intake (only installed in countries with hot climates) Slide the warm air intake into the air filter as far as the stop and then turn it clockwise until it engages.
11. Lower Air Filter Housing Clean air filter housing-lower section of salt residue, dirt and leaves Check water drain for dirt, clean if necessary (important)
12. Fastener for the Lower Air Filter Housing
13. Secondary Air Injection (AIR) pump intake hose Not equipped on all vehicles
14. Intake Air Switch-Over Valve -N335- Not equipped on all vehicles The valve is installed but is not functional
15. Bolt For intake air switch-over valve -N335
16. Bolt
17. Upper Air Filter Housing Clean air filter housing upper section of salt residue, dirt and leaves
18. Bolt For securing air filter element

Scheme 97

1. Vacuum Hose
2. Intake Manifold Tuning (IMT) Valve -N156
3. Bolt 2.5 Nm For Intake Manifold Tuning (IMT) Valve Position Sensor -G513
4. Bolt 2.5 Nm
5. Actuator for Intake Manifold Change-Over Installed location of tooth segments for variable intake manifold (Scheme 98)As replacement part together with -26
6. Seal Replace if damaged Lift out with screwdriver to replace Press in by hand
7. Ball Pin 2.5 Nm
8. Upper Intake Manifold Removing and installing, refer to «UPPER INTAKE MANIFOLD»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__upper-intake-manifold)
9. Seal Replace
10. Throttle Valve Control Module -J338
11. Bracket
12. Bolt 6 Nm
13. Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80
14. Hose
15. Bolt 3 Nm
16. Intake Air Temperature (IAT) Sensor -G42- /Manifold Absolute Pressure (MAP) Sensor -G71
17. O-ring Replace
18. Bolt 2.5 Nm
19. Hose for Crankcase Ventilation
20. O-ring Replace
21. Bolt 8 Nm
22. Washer
23. Sleeve
24. Seals Replace
25. Seal Replace if damaged Lift out with screwdriver to replace Press in by hand
26. Lever with Tooth Segment For variable intake manifold Installed location of tooth segments (Scheme 98)As replacement part together with -5
27. Seal Replace if damaged Lift out with screwdriver to replace Press in by hand
28. Vacuum Hose

Scheme 98

1. The lower edges of the toothed segments must align with one another -arrow-.

Scheme 99

1. Lower Intake Manifold Left and right, removing and installing, refer to «LOWER INTAKE MANIFOLD WITH FUEL RAIL»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__lower-intake-manifold-with-fuel-rail)
2. Sleeve
3. Fuel Pressure Sensor -G247- 20 Nm
4. Bracket
5. Bolt 9 Nm
6. High-Pressure Line WARNING: There is a risk of injury because the fuel is under very high pressure. Before opening high pressure area of the fuel injection system, fuel pressure must be relieved to residual pressure. Reduce fuel pressure in the high pressure area, refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__before-opening-high-pressure-fuel-injection). Do not change bent shape Never bend bracket from the fuel line. If bracket is bent, or if the fuel line is being replaced, then the bracket must be replaced. Tightening (Scheme 100)
7. Bolt 9 Nm
8. Threaded Support 40 Nm
9. Stud bolt
10. Nut 9 Nm
11. Retaining Bracket for Fuel Rail
12. Bolt 2.5 Nm
13. Bolt 9 Nm
14. Sleeve
15. Fuel Rail
16. Seals Replace
17. Support Ring Make sure it is seated properly The fuel rail wields force via the support ring to hold the fuel injector tightly in the cylinder head.
18. O-ring Replace Coat with clean engine oil
19. Spacer ring Replace if damaged
20. Combustion Chamber Seal Replacing, refer to «FUEL INJECTORS»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__fuel-injectors).
21. Radial Adjustment Replace if damaged Clip with support ring -17
22. Fuel Injector Removing and installing, refer to «FUEL INJECTORS»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__fuel-injectors)

Scheme 100

First tighten the high pressure line union nut by hand.

Make sure the high pressure line does not have tension.

Use torque wrench 5-50 Nm V.A.G 1331 with the ring spanner insert V.A.G 1331/2 to tighten the high pressure line on the fuel rail.

1. Tightening Specifications High pressure line union nut: 27 Nm

Scheme 101

1. Fuel Metering Valve -N290- Cannot be separated from the high pressure pump
2. Low Fuel Pressure Sensor -G410- 15 Nm
3. Seal Replace
4. Bolt 20 Nm
5. High Pressure Pump With fuel metering valve -N290- (cannot be separated) Tighten fuel line connecting pieces before installing fuel lines Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__high-pressure-pump) Do not disassemble
6. Threaded Support 27 Nm
7. Hose Clamp Replace; must be appropriate for the model type
8. Fuel Supply Hose Low pressure side
9. High Pressure Fuel Line WARNING: There is a risk of injury because the fuel is under very high pressure. Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure. Reduce fuel pressure in the high pressure area, refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__before-opening-high-pressure-fuel-injection). Counter hold to loosen and tighten union nut on high pressure pump connecting pieces Tighten connecting pieces on high pressure pump before installing Installing (Scheme 103)
10. Gasket Replace
11. Bolt 9 Nm
12. Camshaft Position (CMP) Sensor -G40
13. Bolt 9 Nm
14. O-ring Replace Lubricate O-rings with clean engine oil before installing
15. Housing
16. Roller Tappet Lubricate O-rings with clean engine oil before installing
17. O-ring Replace Lubricate O-rings with clean engine oil before installing

Scheme 102

Tighten bolts -arrows- on the protective plate -1-.

1. Tightening Specifications: 9 Nm

Scheme 103

First tighten the high pressure line union nut by hand.

Make sure the high pressure line does not have any tension.

To tighten the high pressure line on the high pressure pump, use the torque wrench 5-50 Nm V.A.G 1331 with the ratchet V.A.G 1331/1 and socket 14 mm 3150.

1. Tightening Specifications High pressure line union nut: 25 Nm

OXYGEN SENSORS OVERVIEW

1 - Fuel injectors, Cylinder bank 1

2 - Knock Sensor (KS) 1 -G61

4 - Heated Oxygen Sensor (HO2S) -G39

5 - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130

1 - Oxygen Sensor (O2S) 2 after catalytic converter -G131

2 - Heated Oxygen Sensor (HO2S) 2 -G108

3 - Fuel injectors, cylinder bank 2 and from the fuel pressure sensor -G247

4 - Knock Sensor (KS) 2 -G66

1 - HO2S -G39

2 - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130

HO2S -G39-, removing and installing. Refer to Heated Oxygen Sensor -G39

Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130-, removing and installing. Refer to Oxygen Sensor after Three Way Catalytic Converter -G130

1. Tightening Specifications 55 Nm

1 - Heated Oxygen Sensor (HO2S) 2 -G108

2 - Oxygen Sensor (O2S) 2 after catalytic converter -G131

Heated Oxygen Sensor (HO2S) 2 -G108-, removing and installing. Refer to Heated Oxygen Sensor 2 -G108 .

Oxygen Sensor (O2S) 2 after Catalytic Converter -G131-, removing and installing. Refer to Oxygen Sensor 2 after Catalytic Converter -G131 .

1. Tightening Specifications: 55 Nm

FASTENER TIGHTENING SPECIFICATIONS

TECHNICAL DATA

FUEL PRESSURE AND RESIDUAL PRESSURE BEFORE HIGH PRESSURE PUMP, CHECKING

Special tools and workshop equipment required

1. Pressure Gauge K-Jetronic V.A.G 1318
2. Pressure Gauge Adapter V.A.G 1318/10-12
3. Connector Test Set V.A.G 1594C
4. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-3
5. Measuring container, fuel-resistant
6. Protective gloves

Fuel Pressure, Checking

1. Battery voltage at least 12.5 Volts.
2. Fuel filter OK.
3. Fuel tank at least 1 / 4 filled.
4. Fuel Pump (FP) control module -J538- OK.
5. Ignition turned off.

Fuel Pressure, Checking

Remove rear seat bench. Refer to Removal and Installation .

Remove locking flange cover -arrows-.

Scheme 104

Disconnect electrical harness connector -1- at locking flange.

Scheme 105

Note. Ignore -2-.

Connect V.A.G 1348/3A with V.A.G 1348/3-3 with an adapter cable from the V.A.G 1594C at terminal -1-.

Using insulating tape, tape over the second terminal on the V.A.G 1348/3-3 -arrow- to prevent a short circuit.

Scheme 106

Connect terminal -5- to the vehicle ground using a jumper cable from the V.A.G 1594C.

Connect V.A.G 1348/3A to item -A- in the terminal box in the plenum chamber (battery +). For safety reasons, install a fuse (10 A) in the wiring connection.

Route V.A.G 1348/3A switch forward in engine compartment.

Remove seal -arrow-.

Scheme 107

Unclip plenum chamber cover -2- and remove it.

Note. Ignore -1 and 3-.

Release retainer -arrow A- and open cover -arrow B-.

Scheme 108

Connect alligator clip to the battery jump start terminal -U6- -A- in the terminal 30 wire junction 2 -TV22- in plenum chamber.

Remove fuel filler cap from fuel filler tube.

Remove front engine cover.

Remove fuel supply line -arrow- from the high pressure pump.

Scheme 109

Connect V.A.G 1318 to the fuel supply line using an adapter.

Scheme 110

Connect an assisting hose -arrow- to pressure gauge and hold it in a measuring container.

Open shut-off valve of pressure gauge.

1. The lever points in the direction of flow.

Bleed fuel system by pressing remote control briefly.

Close shut-off valve of pressure gauge.

Scheme 111

1. Lever stands perpendicular to direction of flow -arrow-.

Hold the switch of the remote control until no more pressure increase is observed on the fuel pressure gauge.

1. Specified value: Approximately 5.5 bar (4.5 to 6.5 bar) positive pressure.

If specification is not obtained

Check delivery quantity of Fuel Pump (FP). Refer to Diagnosis and Testing .

Residual Pressure, Checking

Check for leaks and residual pressure by observing pressure drop on pressure gauge.

1. After 10 minutes there must be a residual pressure of at least 3 bar.

If residual pressure drops below 3 bar

1. Check connection between fuel pressure gauge and fuel line for leaks.
2. Check pressure gauge for leaks.
3. Check fuel lines and their connections for leaks.
4. Check delivery quantity of Fuel Pump (FP). Refer to «Diagnosis and Testing»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system) .
5. Replace fuel filter with integrated fuel pressure regulator. Refer to «Removal and Installation»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system) .
6. Fuel pump check-valve is faulty. Refer to «Diagnosis and Testing»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system) .

Assembly is in the reverse order of removal, note the following

Switch off ignition.

Note. Before removing pressure gauge, release fuel pressure by opening shut-off valve. Hold a container under the connection.

Connect fuel supply line -arrow- to the high pressure pump.

Note. Check fuel system for leaks.

FUEL SYSTEM, PERFORMING LEAK TEST

Proceed as follows

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.

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 to other components.

If using the 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.

WIRING AND COMPONENTS, CHECKING WITH TEST BOX VAG 1598/42

Special tools and workshop equipment required

1. Adapter cable -V.A.G 1598/39-1
2. Adapter cable -V.A.G 1598/39-2
3. Test box -V.A.G 1598/42

Note. The test box is designed with 105 pins. The connection cable can be separated from the test box. This means that as new Engine Control Module (ECM) connectors are introduced in the future, only a new cable must be designed and no longer the entire test box. The smaller of the two connectors on the ECM is assigned with terminals 1 to 60. The larger of the two connectors is assigned with terminals 1 to 94. If a wiring connection to the ECM is to be tested, use the wiring diagrams to determine through which connector the electrical wiring connection leads to the ECM. Lead the electrical wiring connector to the 60-pin connected, then connect the smaller of the two connectors V.A.G 1598/39-1 to the input "A" on the Test Box V.A.G 1598/42. If an electrical wiring connection leads to the 94-pin connector according to wiring diagram, connect the larger of the two connectors V.A.G 1598/39-2 as follows. The connector designated with an "A" must be connected to input "A" of the V.A.G 1598/42 and the connector "B" must be connected to input "B" of the V.A.G 1598/42. The V.A.G 1598/42 is designed so that it can be connected simultaneously to the engine control module harness and the engine control module itself. This is advantageous because electronic engine control remains fully functional (for example measurement of signals with engine running) when the test box is attached. The procedures will indicate whether the engine control module is to remain connected to the test box or not. Always use V.A.G 1594 C to connect measuring equipment (for example V.A.G 1527 B, V.A.G 1526 C, etc.)

Remove Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE .

Connect test box V.A.G 1598/42 to wiring harness connector. Ground (GND) clip at test box must be clipped to battery minus. The procedures will indicate whether the Engine Control Module (ECM) -J623- is to be connected to the test box.

Perform test as described in relevant repair sequences.

Installing ECM

Install in reverse order of removal.

The ECM -- must be equipped with the metal retainer again.

New shear bolts must always be used.

Clean the threaded holes of residue and locking compound for the new shear bolts. Cleaning can be performed with a thread cutter (tap).

Check the DTC memory and, if necessary, erase it. After DTC memory is erased, a readiness code must be generated for the engine control module using the "Guided Functions" operating mode, see vehicle diagnostic tester.

Note. When ending Guided Fault-Finding, the tester attempts to erase the Diagnostic Trouble Code (DTC) memory of all control modules. If this is not successful, the remaining DTCs stored in memory must be corrected until all DTCs can be erased.

AIR FILTER ELEMENT

Removing

Remove air guide hose from the air filter housing by opening clips -arrows-.

Scheme 112

Remove bolts -arrows- from the upper air filter housing and remove the upper section of the housing upward.

Scheme 113

Note. Always use an original equipment air filter element. Use a lubricant (silicone-free) for installing the air duct hose. Secure all hose connections using hose clamps appropriate for the model type.

Check the water drain hose -arrow- in the lower section of the air filter for dirt and contamination (clean if necessary).

Scheme 114

Clean air filter housing (upper and lower sections) of salt residue, dirt or leaves (use vacuum cleaner if necessary).

Check intake ducting up to the air filter element for dirt.

When installing the air filter element, make sure it is centered in the mount in the lower section of the air filter housing.

Assemble the new air filter element with the upper section of the air filter housing.

Scheme 115

The tab on the air filter element -1- must align with the tab on the air filter housing -2-.

Scheme 116

Place upper section of air filter housing on to lower section or air filter housing carefully and without using excessive force.

Note. Check again before tightening if the upper section of the air filter housing is in the groove on the lower section (leaks).

Then bolt the upper air filter housing to the lower section.

Make sure the air guide hoses are secure.

Further installation is performed in reverse order.

LOWER AIR FILTER HOUSING

Removing

Remove air guide hose from the air filter housing by opening the clips -arrows-.

Remove bolts -arrows- from the upper section of the air filter housing and remove the upper section of the housing upward.

Disconnect the vacuum hose -1- on the Intake Manifold Runner Control (IMRC) valve -N335- -2-.

Release fastener from the lower section of the air filter housing (press the rubber in at the left and right pull upward).

Note. Do not use any lubricant when installing the fastener.

Disconnect air guide hose -1- to the secondary air injection pump.

Scheme 117

Note. Item 1 is not installed on all vehicles (EU 5 only). The electrical connector on the intake air switch-over valve -N335- is not installed on all vehicles.

Remove lower section of the air filter housing.

Installing

Note. Always use an original equipment air filter element. Use a lubricant (silicone-free) for installing the intake hose. Secure all hose connections using hose clamps appropriate for the model type.

If a warm air intake is installed (only for countries with warm climates), make sure the air intake connectors are engaged correctly -arrows- (check markings).

Scheme 118

Check the water drain hose -arrow- in the lower section of the air filter for dirt and contamination (clean if necessary).

Clean air filter housing (upper and lower sections) of salt residue, dirt or leaves (use vacuum cleaner if necessary).

Check intake ducting up to the air filter element for dirt.

Connect electrical connector on the intake air switch-over valve -- (if applicable).

Connect air guide hose -1- (if applicable).

Install lower section of the air filter housing.

Note. Route the water drain hose straight down, do not bend it.

Slide vacuum hose -1- onto the intake air switch-over valve -- connection.

The tab on the air filter element -1- must align with the tab on the air filter housing -2-.

Place upper section of air filter housing on to lower section or air filter housing carefully and without using excessive force.

Note. Check again before tightening if the upper air filter housing is in the groove on the lower section (leaks).

Then bolt the upper section of the air filter housing to the lower section.

Make sure the air guide hoses are secure.

Further installation is performed in reverse order.

UPPER INTAKE MANIFOLD

Removing

Note. During installation, all cable ties must be re-installed at the same location.

Remove front and rear engine covers.

Free up hose connection -1- to the Evaporative Emission (EVAP) canister.

Remove vacuum hose -2- from the air guide hose connection.

Remove air guide hose by loosening the hose clamp -3- and opening the clips -arrows-.

Note. Ignore -4-.

Disconnect vacuum hose -2-.

Scheme 119

Note. Disregard -arrow-.

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

2 - Secondary air injection (AIR) solenoid valve -N112- (installed only on vehicles with emissions standard ULEV 2)

3 - Intake Air Temperature (IAT) sensor -G42- /Manifold Absolute Pressure (MAP) sensor -G71

4 - Auxiliary heater exhaust gas sensor -N422- (installed only on vehicles without an auxiliary heater)

5 - Secondary air injection (AIR) solenoid valve 2 -N320- (installed only on vehicles with emissions standard ULEV 2)

6 - Throttle valve control module -J338

Remove EVAP canister purge regulator valve 1 -N80- from the bracket and lay it aside with the hose connected.

Disconnect front connectors on the intake manifold.

Scheme 120

1. Intake Manifold Tuning (IMT) valve -N156
2. IMT valve position sensor -G513

Remove vacuum hose -arrow-.

Disconnect vacuum hose -arrow- at leak detection pump.

Scheme 121

Free up vacuum hose -arrow-.

Scheme 122

Free up wiring harness.

Remove bolt -3-.

Press retaining tab -2- up slightly and disconnect the crankcase ventilation hose from the intake manifold.

Remove bolts -arrows- and upper section of the intake manifold.

Scheme 123

Note. Plug the intake ports of the cylinder head with clean rags.

Installing

Installation is in reverse order of removal, note the following

1. Tightening Specifications. Refer to «UPPER INTAKE MANIFOLD OVERVIEW»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb) .

Note. Replace seals and O-rings. During installation, all cable ties must be re-installed at the same location. Secure all hose connections using hose clamps appropriate for the model type.

LOWER INTAKE MANIFOLD WITH FUEL RAIL

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1331
2. Ring Spanner Insert V.A.G 1331/2

Removing

Note. The following removal and installation procedure is for the left lower section of the intake manifold. The procedure for the other side is identical.

Remove upper section of the intake manifold. Refer to UPPER INTAKE MANIFOLD .

Disconnect electrical connector on the fuel pressure sensor -G247- -2-.

Scheme 124

Remove union nut -1-.

Remove bolts and nuts -arrows- and remove lower section of the intake manifold with the fuel rail.

Note. Plug intake ports of the cylinder head with clean rags.

Installing

Installation is in reverse order of removal, note the following

Note. Replace seals and O-rings. Lubricate the fuel injector O-rings lightly with clean engine oil.

Press lower section of the intake manifold with the fuel rail evenly onto the fuel injectors.

Tighten bolts and nut -arrows- on the lower section of the intake manifold diagonally in stages.

1. Tightening specification. Refer to «LOWER INTAKE MANIFOLD WITH FUEL RAIL OVERVIEW»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb) .

Disconnect electrical connector -2- on the fuel pressure sensor -G247-.

Install high pressure line -1- on the fuel rail. Refer to HIGH PRESSURE LINES .

Note. Check fuel system for leaks.

FUEL PRESSURE SENSOR

Removing

Remove upper section of the intake manifold. Refer to UPPER INTAKE MANIFOLD .

Disconnect electronic connector from the fuel pressure sensor -G247- -4-.

Remove fuel pressure sensor -G247- -4-.

Installing

Installation is in reverse order of removal.

1. Tightening Specifications. Refer to «LOWER INTAKE MANIFOLD WITH FUEL RAIL OVERVIEW»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb)

Install upper section of the intake manifold. Refer to UPPER INTAKE MANIFOLD .

HIGH PRESSURE PUMP

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Ratchet, Reversible V.A.G 1331/1
3. Socket 14 mm 3150

Removing

Note. The removal and installation of the high-pressure fuel pump can only be performed on a cold engine. When installing the high-pressure fuel pump, make sure that no dirt enters the fuel system. Catch escaping fuel with a rag. The O-ring must always be replaced. High-pressure fuel lines must always be fastened free of tension.

Remove lower section of the air filter housing. Refer to LOWER AIR FILTER HOUSING .

Remove bolts -arrows- and protective plate -1-.

Disconnect electrical connectors -1 and 6-.

Scheme 125

Disconnect fuel supply line -2- and remove the threaded connection -5-.

Remove bolts -3 and 4- on the retaining clamps.

Remove bolts -arrows- and pry the end cover up carefully.

Note. Do not change the angles of the fuel lines. Never bend any of the fuel line mounting clamps. If a mounting clamp was bent, or if the fuel line is being replaced, then the mounting clamps must also be replaced.

Carefully remove high pressure pump.

Remove roller tappet -1- from the housing.

Scheme 126

Installing

Installation is in reverse order of removal, note the following

Note. High pressure line connections must not show any signs of damage. Do not change the angles of the fuel lines. Never bend any of the fuel line mounting clamps. If a mounting clamp was bent, or if the fuel line is being replaced, then the mounting clamps must also be replaced.

Replace O-ring for the high-pressure pump.

Check plunger -1- for damage and replace it if necessary.

Coat plunger with oil and insert it with the tab -arrow A- in the guide -arrow B-.

Note. To insert the high pressure pump, the roller tappet must be at its lowest point.

Rotate crankshaft in the direction of engine rotation at the vibration damper bolt while pressing the roller tappet into the cylinder head until it reaches the deepest point.

Only lift the high pressure line slightly to insert the high pressure pump.

Install the high pressure pump into the housing.

Tighten bolts -arrows- by hand up to the flange.

Tighten bolts diagonally to the tightening specification (approximately 1 turn until the bolts contact the high pressure pump).

Note. Tightening on just one side (bending) can damage the pump.

1. Tightening Specifications. Refer to «HIGH PRESSURE PUMP OVERVIEW»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb) .

Tighten fuel supply line union nut -5- by hand. Align so it is free of stress.

Connect fuel supply hose -2-.

Tighten bolts -3 and 4- on the retaining clamps.

Connect connectors -1 and 6-.

Tighten high pressure line to the tightening specifications. (Scheme 103)

Install protective plate -1-.

Install lower section of the air filter housing. Refer to LOWER AIR FILTER HOUSING .

Note. Check fuel system for leaks.

FUEL INJECTORS

Special tools and workshop equipment required

1. Tool Set T10133

Note. The puller T10133/2 was changed and is now called the puller T10133/2-A. If the new tool is not available, the old one can be modified.

Modify puller T10133/2 to create the puller T10133/2-A.

Special tools and workshop equipment required

1. Round file approximately 6 mm

File the semi-circle as shown in the illustration. The semi-circle allows the tool to slide farther onto the fuel injector, thus providing the tool with a larger contact surface.

Mark modified tool with an "A" at the end of the tool number.

Scheme 127

High Pressure Fuel Injector, Assembly Overview

Scheme 128

1. Radial adjustment - Replace if damaged
2. Combustion chamber seal (Teflon seal) - replace, the seal must not be greased or be handled with any other lubricant during installation
3. Groove on fuel injector
4. Spacer ring - Replace if damaged
5. O-ring - replace, lightly coat with clean engine oil during installation
6. Support ring - fuel rail wields force via the support ring to hold the fuel injector tightly in the cylinder head

Removing

Remove upper section of the intake manifold. Refer to UPPER INTAKE MANIFOLD .

Remove affected intake manifold lower section. Refer to LOWER INTAKE MANIFOLD WITH FUEL RAIL .

If the fuel injectors cannot be pulled out of the cylinder head by hand, proceed as follows

Using a screwdriver, bend the retaining tabs -1- of the radial adjustment aside -arrow- and pull the support ring -2- from the fuel injector.

Scheme 129

Guide puller T10133/2A in the groove on the fuel injector.

Scheme 130

Then position the trim removal wedge T10133/16 and remove the fuel injector by loosening bolt -1-.

Note. When setting the puller in place, the radial adjustment can be destroyed, because the retaining tabs break.

Carefully remove the old combustion chamber seal -arrow-, thereby cutting seal open with a knife or spreading seal open with a small screwdriver and pulling it forward and off.

Scheme 131

Make sure that the groove of the fuel injector does not become damaged. If the groove is damage, the fuel injector must be replaced.

Installing

Note. Replace the combustion chamber seals and O-rings. Replace the spacer ring and radial adjuster if damaged. Lightly coat fuel injector O-rings with clean engine oil. Re-insert injector lines at same cylinder.

Clip radial adjustment -1- to the support ring -2-.

Scheme 132

When re-installing a fuel injector, use a clean cloth to clean combustion residue from the groove for combustion chamber seal and the shaft of the fuel injector.

Place assembly cone T10133/5 with new combustion chamber seal -1- on fuel injector -2-.

Scheme 133

Slide combustion chamber seal as far possible onto assembly cone T10133/5 using assembly sleeve T10133/6.

Scheme 134

Turn assembly sleeve T10133/6 around and slide combustion chamber seal into groove.

Note. When pushing the combustion chamber seal onto the fuel injector, the seal spreads open. Therefore after pushing it on, it must be tightened again in 2 steps, as follows.

Press sizing sleeve T10133/7 with a slight turning motion (approximately 180°) onto the fuel injector until it stops.

Scheme 135

Pull sizing sleeve T10133/7 off again, turning it in the opposite direction.

Press sizing sleeve T10133/8 with a slight turning motion (approximately 180°) onto the fuel injector until it stops.

Scheme 136

Pull sizing sleeve T10133/8 off again, turning it in the opposite direction.

Coat the new O-ring with clean engine oil before installing.

Note. The combustion chamber seal must not be oiled.

Fuel Injectors, Installing

Clean bore in cylinder head with nylon cylinder brush T10133/4.

Scheme 137

Slide fuel injector into the bore cylinder head as far as stop using assembly drift T10133/9.

Scheme 138

Note. The fuel injector must not be difficult to install. If necessary, wait as the combustion chamber seal continues to pull itself together.

Make sure fuel injectors are correctly positioned in cylinder head.

1. The electrical connection of the fuel injector must engage in the intended recess of the cylinder head.

The rest of installation is in reverse order of removal, note the following

Install lower section of the intake manifold. Refer to LOWER INTAKE MANIFOLD WITH FUEL RAIL .

Install upper section of the intake manifold. Refer to UPPER INTAKE MANIFOLD .

HIGH PRESSURE LINES

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Ring Spanner Insert V.A.G 1331/2

Note. Tighten union nut on the fuel high pressure pump (Scheme 103)High pressure line connections must not show any signs of damage. Do not bend the high pressure lines to a different angle. Never bend any of the fuel line mounting clamps. If a mounting clamp was bent, or if the fuel line is being replaced, then the mounting clamps must also be replaced.

Coat threads on the union nut with fuel.

Tighten high pressure line union nuts by hand, making sure they are seated without tension.

Use V.A.G 1331 with the open end V.A.G 1331/2 to tighten the high pressure line on the fuel rail.

1. Tightening Specifications High pressure line union nut: 25 Nm

Only install the retaining tabs after tightening the high pressure lines.

Check fuel system for leaks.

HEATED OXYGEN SENSOR -G39

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Pull rear engine cover off -arrows-.

Scheme 139

Free up fuel supply line -4- and hose connection -1- to the Evaporative Emission (EVAP) canister on the air filter housing and on the air guide tube.

Remove vacuum hose -2- from the air guide hose.

Remove air guide hose by loosening the hose clamp -3- and opening the clips -arrows-.

Remove lower section of the air filter housing. Refer to LOWER AIR FILTER HOUSING .

Disconnect electrical connector -4- for the Heated Oxygen Sensor (HO2S) -G39-.

Remove HO2S -- -1- using a tool from the 3337.

Note. The installation location is shown with the engine removed.

Installing

Installation is in the reverse order of removal, note the following

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with sensor slots. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. During installation, all cable ties must be re-installed at the same location.

1. Tightening specifications, refer to «OXYGEN SENSORS OVERVIEW»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__oxygen-sensors-overview) .

OXYGEN SENSOR AFTER THREE WAY CATALYTIC CONVERTER -G130

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Pull rear engine cover off -arrows-.

Free up the fuel supply line -4- and hose connection -1- to the Evaporative Emission (EVAP) canister on the air filter housing and on the air guide tube.

Remove vacuum hose -2- from the air guide hose.

Remove air guide hose by loosening the hose clamp -3- and opening the clips -arrows-.

Disconnect electrical connector -5- for the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) --.

Remove O2S after TWC -- -2- using a tool from the 3337.

Note. The installation location is shown with the engine removed.

Installing

Installation is in reverse order of removal, note the following

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with sensor slots. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. During installation, all cable ties must be re-installed at the same location.

1. Tightening specifications, refer to «OXYGEN SENSORS OVERVIEW»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__oxygen-sensors-overview) .

OXYGEN SENSOR 2 AFTER CATALYTIC CONVERTER -G131

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Pull rear engine cover off -arrows-.

Remove coolant reservoir -arrows-.

Scheme 140

Disconnect electrical connector to the engine coolant level warning switch -F66- on the bottom of the coolant reservoir and lay the reservoir aside with the coolant hoses -1 and 2- and -3- attached.

Disconnect electrical connector -1- for Oxygen Sensor (O2S) 2 after catalytic converter -G131-.

Remove O2S 2 after catalytic converter -- -2- using a tool from the 3337.

Note. The installation location is shown with the engine removed.

Installing

Installation is in reverse order of removal, note the following

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with sensor slots. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. During installation, all cable ties must be re-installed at the same location.

1. Tightening specifications, refer to «OXYGEN SENSORS OVERVIEW»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__oxygen-sensors-overview) .

HEATED OXYGEN SENSOR 2 -G108

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Pull rear engine cover off -arrows-.

Remove coolant reservoir -arrows-.

Disconnect electrical connector to the engine coolant level warning switch -F66- on the bottom of the coolant reservoir and lay the reservoir aside with the coolant hoses -1 and 2- and -3- attached.

Disconnect electrical connector -2- for the Heated Oxygen Sensor (HO2S) 2 -G108-.

Remove HO2S 2 -- -1- using a tool from the 3337.

Note. The installation location is shown with the engine removed.

Installing

Installation is in reverse order of removal, note the following

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with sensor slots. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. During installation, all cable ties must be re-installed at the same location.

1. Tightening Specifications. Refer to «OXYGEN SENSORS OVERVIEW»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb__oxygen-sensors-overview)

ENGINE CONTROL MODULE

Special tools and workshop equipment required

1. Heat gun 220 V/50 Hz VAS 1978/14 with nozzle attachment from wiring harness repair kit VAS 1978
2. Small, commercially available locking pliers (vise grips)

Note. The Engine Control Module (ECM) -1- is bolted to a protective housing -5-. To make removing the shear bolts -4- for the retaining tabs -2- more difficult, the threads are coated with locking compound. To disconnect the connectors from the ECM (for example to connect the test box or to replace the ECM), the metal housing must be removed.

Removing

If the engine control module is replaced, in "Guided Fault Finding" select "Replace Engine Control Module" to vehicle diagnostic tester.

Turn ignition and remove the ignition key.

Remove nut -3- and bolt -2-.

Scheme 141

Remove filler neck -1- with filler tube from the washer fluid reservoir and opening in the body -arrow-.

Remove bolts -arrows- and the cover from the E-box.

Scheme 142

Release retainers -A arrows- and remove ECM -J623- -arrow B-.

To increase the difficulty with which the ECM connectors can be accessed, the ECM -1- is secured in a metal housing -5- with retaining tabs -2- and shear bolts -3 and 4-.

Scheme 143

The threads of the shear bolts -4- (that are not screwed into the ECM) are coated with a locking compound. For this reason, the threads must be heated with the heat gun to remove both bolts.

The threads of both shear bolts -3-, that are screwed into the ECM, are not coated with a locking compound. The threads in the ECM housing must not be heated and do not require to be heated (unintentional heating of the ECM).

Set the adjustment on the heat gun as shown in the illustration, with the temperature potentiometer -2- set to maximum heat and the two-stage air flow switch -3- set to level 3.

Scheme 144

Warm threads on connector-side shear bolts for approximately 25 to 30 seconds.

Scheme 145

Remove shear bolts with locking pliers (see direction of -arrow-).

Scheme 146

Both shear bolts that are screwed into the ECM do not require heating to be removed. They can be removed without heat.

Disconnect metal retainers from the ECM connectors.

Disengage connectors from ECM and then disconnect the connectors.

Remove old ECM -- and install the ECM --.

Installing

Install in reverse order of removal.

After that, the ECM -- must be equipped with the metal retainer.

Clean threaded holes for shear bolts of locking compound residue. Cleaning can be performed with a thread cutter (tap).

Always use new shear bolts.

1. Tightening Specifications E-box cover bolts: 3.5 Nm

Perform the following step after installing a new engine control module

Activate the engine control module in the "Guided Functions" operating mode under "Replace engine control module" on the vehicle diagnosis and service system VAS 5051B.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

Scheme 156

1. Pressure Gauge K-Jetronic V.A.G 1318
2. Pressure Gauge Adapter V.A.G 1318/10-12
3. Connector Test Set V.A.G 1594C
4. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-3
5. Hand Vacuum Pump VAS 6213
6. Adapter Cable -V.A.G 1598/39-1
7. Adapter Cable -V.A.G 1598/39-2
8. Test Box - V.A.G 1598/42
9. Ring Spanner Insert V.A.G 1331/2
10. Torque Wrench 5-50 Nm V.A.G 1331
11. Ratchet, Reversible V.A.G 1331/1
12. Socket 14 mm 3150
13. Tool set T10133
14. Ring Spanner 7-Piece Set 3337
15. Heat Gun 220 V/50 Hz VAS 1978/14 -1- with nozzle attachment -2- from Wiring Harness Repair Kit VAS 1978
16. Small, commercially available locking pliers -3- (vise grips)

See also:
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM
• SAFETY PRECAUTIONS
• Heated Oxygen Sensor -G39
• Oxygen Sensor after Three Way Catalytic Converter -G130
• FUEL INJECTORS
• HIGH PRESSURE PUMP
• Oxygen Sensor 2 after Catalytic Converter -G131
• ENGINE CONTROL MODULE
• Heated Oxygen Sensor 2 -G108
• AIR FILTER ELEMENT
• UPPER INTAKE MANIFOLD
• LOWER INTAKE MANIFOLD WITH FUEL RAIL
• UPPER INTAKE MANIFOLD OVERVIEW
• HIGH PRESSURE LINES
• LOWER AIR FILTER HOUSING
• OXYGEN SENSORS OVERVIEW