4.2l v8 5v Fuel Injection and Ignition, Engine Code(s): Bhf Audi S4 B7

Safety precautions

Note the following points if testers and measuring instruments have to be used in the course of 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 ignition before disconnecting or connecting injection, ignition system wiring, or tester cables.
2. To run engine at starting speed without actually starting it (for example, in order to test compression), disconnect connector from the output stages of the ignition coils and also the connectors on the injectors.
3. In the case of some tests, a malfunction may be recognized and stored by the control module. At the end of all tests and repairs, the Diagnostic Trouble Code (DTC) memory should be checked and, if necessary, erased.
4. Always switch ignition off before washing engine.

1. Always switch ignition off before disconnecting and connecting battery so as not to damage engine control module.

Rules for cleanliness

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

1. Thoroughly clean all connections and adjacent areas before disconnecting.
2. Place removed parts on a clean surface and cover. Use lint-free cloths.
3. Carefully cover or seal opened components if repairs cannot be done immediately.
4. Only install clean components: Only remove replacement parts from packaging immediately prior to installation. Do not use parts that have been stored loose (e.g. in tool boxes).

1. When system is open: Do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely necessary.
2. Separated electrical connectors: Protect from dirt and moisture. Make sure connections are dry when attaching.

Technical data

1) Current values

Refer to

1. «01 - MAINTENANCE»(/audi/s4/b7-2004-2008/remont/procedures/#maintenance-procedures)
2. «01 - MAINTENANCE»(/audi/s4/b7-2004-2008/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET

2) With warm engine, injector resistance increases by approx. 4 to 6 ohms.

Scheme 529

Components A to I are not shown in exploded view.

A - "MIL" exhaust emissions warning lamp

1. In instrument cluster (Function of lamp)
2. (Scheme 530)

B - "EPC" warning lamp

1. In instrument cluster (Function of lamp
2. See 2: see scheme 4

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

1. In footwell at accelerator pedal (integrated into accelerator pedal module)
2. (Scheme 532)

D - Fuel Pump (FP) Relay -J17

1. In 9-position relay carrier behind driver's storage compartment, relay position 1
2. (Scheme 534)

E - Brake light switch -F- and Brake Pedal Switch (cruise control/Diesel Direct Fuel Injection) -F47

1. In footwell at pedal bracket next to brake pedal
2. (Scheme 533)

F - Clutch Vacuum Vent Valve Switch -F36

1. (Scheme 533)

G - Motronic Engine Control Module -J220- and relays in plenum chamber electronics box

1. Installation locations. (Scheme 535)and (Scheme 536)

H - Diagnostic connector

1. In driver's knee restraint

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

1. (Scheme 531)

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

3 - Connector console

1. Pin assignment
2. (Scheme 537)

4 - Valve -1- for camshaft adjustment -N205

1. (Scheme 539)

5 - Camshaft Position (CMP) sensor -G40

1. Cylinder bank 1
2. (Scheme 539)

6 - Engine coolant temperature (ECT) sensor -G62

1. At coolant pipe behind cylinder head, bank 1
2. (Scheme 539)

7 - Fuel supply line

8 - Throttle valve control module -J338

1. With Throttle drive (power accelerator actuation) -G186-, Angle sensor -1- for throttle drive (power accelerator actuation) -G187- and Angle sensor -2- for throttle drive (power accelerator actuation) -G188
2. (Scheme 539)

9 - Oil pressure switch -F1

1. (Scheme 539)

10 - Camshaft Position (CMP) Sensor 2 -G163

1. Cylinder bank 2
2. (Scheme 539)

11 - Connector console

1. Pin assignment
2. (Scheme 538)

12 - Valve -2- for camshaft adjustment -N208

1. (Scheme 539)

13 - Engine Speed (RPM) Sensor -G28

1. In transmission housing above ring gear

14 - Ignition coils with output stages

1. Cylinder bank 2

15 - 3-pin connector

1. For knock sensor 3 -G198
2. For knock sensor 4 -G199
3. (Scheme 540)

16 - Secondary Air Injection (AIR) Solenoid Valve -N112

1. (Scheme 540)

17 - Intake Manifold Change-Over Valve -N156

1. (Scheme 540)

18 - 3-pin connector

1. For Knock Sensor (KS) 1 -G61
2. For Knock Sensor (KS) 2 -G66
3. (Scheme 540)

19 - Ignition coils with output stages

1. Cylinder bank 1

20 - Secondary Air Injection (AIR) Pump Motor -V101

1. Beneath right longitudinal member
2. (Scheme 541)

Scheme 530

Emission-specific malfunctions recognized by the engine control module are indicated by activating the exhaust emissions warning lamp.

Exhaust emissions warning lamp (CHECK)

Note. Exhaust emissions warning lamp may flash or be constantly lit. DTC memory is always to be checked.

Flashing of exhaust emissions warning lamp

1. A malfunction has been detected which will cause the catalytic converter damage in this driving status. In such cases, the vehicle is only to be driven at reduced power (until MIL goes out or lights constantly) and malfunction is to be repaired as quickly as possible.

Constant lighting of exhaust emissions warning lamp

1. A malfunction detrimental to emissions has occurred. Check engine control module or automatic transmission DTC memory.
2. In the event of engine running problems or a customer complaint without lighting of the exhaust emissions warning lamp, check operation of warning lamp and then check DTC memory, as malfunctions may also have been stored which do not immediately activate the exhaust emissions warning lamp.

EPC warning lamp

"EPC" is the abbreviation for Electronic Power Control, in other words electronic engine output control (electronic throttle).

When the ignition is turned on, the engine control module switches on the EPC lamp.

After the engine is started the engine control module checks all components relevant to the operation of electronic throttle system.

During the component check, the EPC lamp lights up for approx. 3 seconds. The lamp lights continuously if a malfunction is already established in the course of this check.

If malfunctions in the electronic throttle system are detected during engine operation, the engine control module activates the EPC lamp. At the same time, an entry is made in the engine control module DTC memory.

Scheme 531

Scheme 532

1. Integrated into accelerator pedal module (arrow)

Scheme 533

1 - Clutch vacuum vent valve switch -F36

2 - Brake light switch -F-, Brake Pedal Switch (cruise control/Diesel Direct Fuel Injection) -F47

Note. Switches are only to be installed once, as to ensure a firm fit.

Switch adjustment

Refer to

1. 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
2. 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
3. 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
4. «30 CLUTCH»(ref-278902-S08645519692008020700000) for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
5. «30 CLUTCH»(ref-278903-S21941806522008020700000) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
6. «30 CLUTCH»(/audi/s4/b7-2004-2008/remont/differentials-drive-axles/#6-speed-manual-transmission-0a3-all-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL

Refer to 46 - BRAKES - MECHANICAL COMPONENTS

Scheme 534

1. Position 1 (arrow) on 9-position relay carrier on left of driver's footwell.

Scheme 535

1.1 - Coolant Circulation Pump Relay -J151- (hot countries only)

1.2 - Not used

2 - Secondary Air Injection (AIR) Pump Relay -J299

3 - Motronic Engine Control Module (ECM) Power Supply Relay -J271

4 - Relay for automatic transmission

A - Engine electronics fuse S282

B - Secondary air pump fuse S130

C - Not used

Scheme 536

Scheme 537

1 - 6-pin connector for Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19- before catalytic converter, bank 1

2 - Connector for starter (terminal 50) and generator

3 - 2-pin connector for camshaft timing control, bank 1

4 - 4-pin connector for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) -Z29-, bank 1

Scheme 538

1 - 4-pin connector for Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- and Oxygen Sensor (O2S) Heater 2 (behind Three Way Catalytic Converter (TWC)) -Z30-, bank 2

2 - 3-pin grey connector for Engine Speed (RPM) Sensor -G28

3 - 2-pin connector for camshaft timing control, bank 2

4 - 6-pin connector for Heated Oxygen Sensor (HO2S) 2 (-G108) and Oxygen Sensor (O2S) Heater 2 -Z28- before catalytic converter, bank 2

Scheme 539

1 - Valve -2- for camshaft adjustment -N208

2 - Camshaft Position (CMP) Sensor 2 -G163-, cylinder bank 2

3 - Oil pressure switch -F1

4 - Throttle Valve Control Module -J338

5 - Engine Coolant Temperature (ECT) Sensor -G62

6 - Camshaft Position (CMP) Sensor -G40-, cylinder bank 1

7 - Valve -1- for camshaft adjustment -N205

Scheme 540

1 - Vacuum unit for intake manifold changeover

2 - Knock Sensor (KS) 1 -G61

3 - Knock Sensor (KS) 2 -G66

4 - Intake Manifold Change-Over Valve -N156

5 - Secondary Air Injection (AIR) Solenoid Valve -N112

6 - Knock sensor 3 -G198

7 - Knock sensor 4 -G199

Scheme 541

Beneath right longitudinal member

Scheme 542

Behind wheel housing liner in left rear wheel housing

Fuel pressure regulator and holding pressure, checking

Note. The fuel pressure regulator is found in the fuel filter under the tank.

Scheme 543

Special tools and equipment

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

Test 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 set to P or N

Check pressure system

1. Open the fuel tank lid briefly (pressure should drop).
2. Remove engine cover.

1. Use cloth to cover union (subject to fuel pressure).

Scheme 544

1. Remove fuel hose from fuel rail pipe connection. To do so, counterhold using an open-end wrench at each hex head -1- and -3- and remove union nut -2-.
2. Unscrew pressure gauge V.A.G 1318 with adapters V.A.G 1318/6, 1318/7 between supply line and fuel rail.
3. Open pressure gauge cut-off valve. Lever points in direction of flow.
4. Start engine and run at idling speed.

1. Measure fuel pressure.

Specification: approx. 3.5 bar

1. Switch ignition off.
2. Test for leaks and holding pressure by watching pressure drop on gauge.

1. After 10 minutes the remaining pressure should be at least 2.5 bar.

If holding pressure drops below 2.5 bar

1. Start engine and run at idling speed.

Scheme 545

1. Switch off ignition once pressure has built up. At the same time, close cut-off valve of pressure gauge V.A.G 1318 (lever at right angle to direction of flow).
2. Observe pressure drop on gauge.

Pressure drops again

1. Check pressure gauge for tightness.
2. Check line and O-rings at the fuel rail and injectors for tightness.

Pressure does not drop

1. Check pressure regulator in fuel filter. Refer to «Vehicle with all-wheel drive»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf__vehicle-with-all-wheel-drive)

Vehicle with all-wheel drive

1. Remove rear seat

Refer to

1. «72 - SEAT - FRAMES»(/audi/s4/b7-2004-2008/remont/gauges-instrument-panels/#body-interior)
2. «72 - SEAT - FRAMES»(/audi/s4/b7-2004-2008/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

Scheme 546

1. Remove locking flange cover and screws (arrows).

Scheme 547

1. Remove fuel return line (arrow) from locking flange (left vehicle side).

Scheme 548

1. Attach adapter V.A.G. 1318/17 1 on return line.
2. Use hose clamp 3094 to clamp adapter V.A.G. 1318/17 1.

Note. The hose clamp 3094 may not set directly on the fuel line - danger of damage.

1. Start engine and run at idling speed.

1. Switch ignition off once pressure has built up. At the same time, close cut-off valve of pressure gauge V.A.G 1318 (lever at right angle to direction of flow).
2. Observe pressure drop on gauge.

Pressure drops again

1. If valve is defective, replace fuel pump (check valve defective).

The pressure does not drop

1. Replace fuel filter

Refer to 20 - FUEL SUPPLY SYSTEM

The pressure drops again

1. Check pressure gauge for tightness.

Note. Before removing the pressure gauge, lower fuel pressure by opening the shut-off valve. Hold container at the connection. The assembly of the fuel system is in reverse order of removal.

1. Secure fuel hose to connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head -1- and -3- and tighten union nut -2- to 22 Nm.
2. Bleed air from fuel system. Refer to «Bleed air from fuel system»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf__bleed-air-from-fuel-system)

Bleed air from fuel system

1. Start engine, run it at the middle rpm range for several minutes, and then turn ignition off again.

Note. The engine may run rough at the beginning because of air in the fuel system.

1. Examine fuel system for leakage.
2. Check DTC memory, if necessary delete.

Refer to Vehicle diagnostic, testing and information system VAS 5051

1. Consider the safety precautions.

1. Perform a test drive with at least one full load acceleration, after which the fuel system is to be inspected for leaks again.
2. After the test drive check the DTC memory again. If a DTC is present again, erase the memory and generate a new readiness code.
3. Read readiness code if no DTC is stored. If readiness code is not OK, generate a new one.

Injection quantity, leakage, and spray pattern of injectors, checking

Test condition

1. Fuel pressure OK

Removing fuel rail

1. Remove engine compartment cover.
2. Remove connecting pipe between air cleaner housing and throttle valve body.
3. Disconnect vacuum hose from fuel pressure regulator.
4. Disconnect connectors from injectors and remove cable ties as necessary.

1. Remove fuel rail from intake manifold and lift off with injectors.

Checking injectors for leaks

Scheme 549

1. Place injector to be tested in a measuring glass from injection quantity tester VAG 1602.
2. Connect test box V.A.G 1598/31 at wiring harness to engine control module. Engine control module is not to be connected. Refer to «Wiring and component check using test box V.A.G 1598/31»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf__wiring-and-component-check-using-test) .
3. Bridge contacts 1 and 65 on test box using test leads from adapter set VAG 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 for the following reason: with the ignition switched on, the fuel pump relay receives its positive voltage supply via the engine electrics. The Ground voltage supply for the fuel pump relay comes via the cable bridge in the test box.

1. Check injectors for leaks (visual check). With fuel pump running, only 1 to 2 drops per minute per injector may emerge.
2. If fuel loss is greater than this, switch off fuel pump (switch ignition off) and replace faulty injector.

Checking injection quantity

1. Place injector which is to be tested into measuring glass of injection quantity tester VAG 1602.

Scheme 550

1. Connect one of injector contacts to engine Ground (GND) using a test cable and alligator clip from VAG 1594 A.
2. Connect second contact of injector with remote control V.A.G 1348/3A, adapter lead VAG 1348/3-2 and auxiliary cable to positive.
3. Use leads from adapter set V.A.G 1594 A to bridge contacts 1 and 65 at test box.
4. Switch ignition on.

1. Fuel pump should run

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

Specification for each injector: 105 to 125 ml

If specified result is not attained for all injectors

1. Check fuel pressure. Refer to «Fuel pressure regulator and holding pressure, checking»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf__fuel-pressure-regulator-and-holding-pressure) .

If specified results are not attained for one injector

1. Replace relevant 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 the plastic cap is not removed from the injector head. The O-ring must be pulled off over the plastic cap).
2. Coat O-rings with clean engine oil.
3. Check to make sure that the retainer clamps are properly seated.
4. When screwing fuel rail to intake manifold, tighten to: 10 Nm

1. Bleed air from fuel system. Refer to «Bleed air from fuel system»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf__bleed-air-from-fuel-system)

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

Note. The test box VAG 1598/31 is designed in such a way that it can be connected simultaneously to the engine control module wiring harness and to the engine control module itself. This has the advantage that the electronic motor control system remains fully functional when the test box is connected (for example, for measuring signals when the engine is running). Whether the engine control module has to be connected to the test box or not is described in the respective test procedures. Always use test leads from adapter set V.A.G 1594 for connection of testers to test box V.A.G 1598/31.

Connecting test box V.A.G 1598/31

1. Switch ignition off.

Scheme 551

1. Remove rubber seal in direction of (arrow).
2. Remove plenum chamber cover -1- to front.

Scheme 552

1. Pry off two caps -3- using screwdriver.
2. Loosen hex nuts -4- by several turns.
3. Loosen wiper arms -2- from wiper shaft by tilting slightly.
4. Remove hex nuts and detach wiper arms.

1. Remove securing clips -1- and detach cowl panel grille -5-.

Scheme 553

1. Remove cover for electronics box in plenum chamber (arrows).

Scheme 554

1. Carefully pry off fastener (arrow) using screwdriver.

Note. Item -1- in illustration shows engine control module with protective enclosure.

Scheme 555

To render access to the connectors on the engine control module more difficult, the engine control module -1- is bolted by the way of a catch -2- and shear bolts -3- to a protective enclosure -4-.

Locking fluid is applied to thread of shear bolts to make bolts more difficult to remove.

Engine control module must be separated from protective enclosure to disconnect connectors from engine control module (e.g. when connecting up test box or replacing engine control module). This procedure is described in the following.

Tools required

Scheme 556

1. Hot-air blower -1- (from wiring-harness repair set VAS 1978)
2. Nozzle attachment -2- (also from wiring-harness repair set VAS 1978)
3. Commercially available locking pliers

Procedure

1. Tilt engine control module with protective enclosure toward engine compartment so the catch (item -2-) becomes visible, and place a clean cloth beneath engine control module with protective enclosure.

Scheme 557

1. Make settings on hot-air blower as shown in illustration, i.e. set temperature potentiometer -2- to max. heat output and two-stage air flow switch -3- to position 3.

Note. Then use hot-air blower to heat thread of catch into which shear bolts are screwed. This operation is designed to reduce the inhibiting action of the locking fluid on the shear bolt thread to make it easier to screw out the shear bolts afterward.

Scheme 558

1. Direct nozzle -1- of hot air blower onto thread of catch, so that nozzle "encloses" thread. Nozzle can safely be allowed to contact upper end of metal housing.
2. Switch on hot-air blower and heat thread for approx. 20 to 25 seconds.

Scheme 559

1. Then grip bolt head -2- with locking pliers -1- and screw out shear bolt in direction of (arrow).

Use the same procedure for the second shear bolt, taking particular care to avoid the control module connectors in the immediate vicinity.

Scheme 560

1. Direct nozzle -1- of hot air blower onto thread of catch again, so that nozzle "encloses" thread. Nozzle can safely be allowed to contact upper end of metal housing.
2. Switch on hot-air blower and heat thread for 20 to 25 seconds.

Scheme 561

1. Then grip bolt head -2- with locking pliers -1- and screw out shear bolt in direction of (arrow).

Engine control module can now be separated from protective enclosure.

1. Release connectors of engine control module and disconnect.

Scheme 562

1. Connect test box V.A.G 1598/31 to wiring harness connector. Ground clip (arrow) must be connected to ground (GND). Whether or not engine control module is additionally to be connected to test box is indicated in the appropriate test sequences.
2. Perform testing as described in appropriate repair operations.

Installing engine control module

Install in reverse order of removal; protective enclosure is always to be reinstalled to engine control module. Use new shear bolts.

1. Check Diagnostic Trouble Code (DTC) memory and erase, if necessary.

Refer to Vehicle diagnostic, testing and information system VAS 5051

Motronic Engine Control Module (ECM) -J220-, 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 engine control module

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

Scheme 563

The display on V.A.S 5051 shows control module identification code and code -2-.

1. Display and print out control module identification.
2. Switch ignition off.

1. Remove rubber seal of plenum chamber cover in direction of (arrow).
2. Remove plenum chamber cover -1- to front.

1. Pry off two caps -3- using screwdriver.
2. Loosen hex nuts -4- by several turns.
3. Loosen wiper arms -2- from wiper shaft by tilting slightly.
4. Remove hex nuts and detach wiper arms.

1. Remove securing clips -1- and detach cowl panel grille -5-.

1. Remove cover for electronics box in plenum chamber (arrows).

1. Carefully pry off fastener (arrow) using a screwdriver.

Note. Item -1- in illustration shows engine control module with protective enclosure.

To render access to the connectors on the engine control module more difficult, the engine control module -1- is bolted by the way of a catch -2- and shear bolts -3- to a protective enclosure -4-.

Locking fluid is applied to thread of shear bolts to make bolts more difficult to remove.

Engine control module must be separated from protective enclosure. To unplug connectors from engine control module (e.g. when connecting up test box or replacing engine control module). This procedure is described in the following.

Tools required

1. Hot-air blower -1- (from wiring-harness repair set VAS 1978)
2. Nozzle attachment -2- (also from wiring-harness repair set VAS 1978)
3. Commercially available locking pliers

Procedure

1. Tilt engine control module with protective enclosure toward engine compartment so the catch (item -2-) becomes visible, and place a clean cloth beneath engine control module with protective enclosure.

1. Make settings on hot-air blower as shown in illustration, i.e. set temperature potentiometer -2- to max. heat output and two-stage air flow switch -3- to position 3.

Note. Then use hot-air blower to heat thread of catch into which shear bolts are screwed. This operation is designed to reduce the inhibiting action of the locking fluid on the shear bolt thread to make it easier to screw out the shear bolts afterward.

1. Move nozzle -1- of hot-air blower toward thread of catch such that nozzle "surrounds" thread. Allow nozzle to rest on upper end of protective enclosure.
2. Switch on hot-air blower and heat thread for 20 to 25 seconds.

1. Grasp head of bolt -2- with locking pliers -1- and screw out shear bolt in direction of (arrow).

Use the same procedure for the second shear bolt, taking particular care to avoid the control module connectors in the immediate vicinity.

1. Move nozzle -1- of hot-air blower toward thread of catch such that nozzle "surrounds" thread. Allow nozzle to rest on upper end of protective enclosure.
2. Switch on hot-air blower and heat thread for 20 to 25 seconds.

1. Grasp head of bolt -2- with locking pliers -1- and screw out shear bolt in direction of (arrow).

Engine control module can now be separated from protective enclosure.

1. Release connectors of engine control module and disconnect.
2. Take out old engine control module and insert new one.

Installing engine control module

Install in reverse order of removal; protective enclosure is always to be reinstalled to engine control module. New shear bolts must be used.

The following operations must be performed after installing the engine control module

1. Adapt immobilizer to: Motronic engine control module (ECM) -J220- (otherwise vehicle will not start).
2. Encode new engine control module.
3. If vehicle is installed with cruise control system (can be seen from steering column switch), this must be released in engine control module.
4. Check Diagnostic Trouble Code (DTC) memory and erase, if necessary.

1. Activate engine control module in "Guided fault-finding" routine under diagnosis item "Replacing engine control module".

Vehicle diagnostic, testing and information system VAS 5051 is to be used for this purpose.

Scheme 564

1 - Intake manifold

1. Removing and installing. Refer to «Intake manifold, removing and installing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf__intake-manifold-removing-and-installing)

2 - O-ring

1. For injectors
2. Always replace

3 - 10 Nm

4 - Fuel supply line

1. Loosening and tightening union nut.

5 - Fuel rail

6 - Pressure control valve

1. For crankcase breather

7 - 10 Nm

1. Tighten diagonally in stages

8 - Lifting eye

9 - 23 Nm

10 - Gasket

1. For intake manifold
2. Always replace

11 - Locating bolt, 0.6 Nm

Loosening and tightening union nut for fuel supply line

Loosening

1. Unscrew fuel hose from connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head -1- and -3- and unscrew union nut -2-.

Tightening

1. Secure fuel hose to connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head -1- and -3- and tighten union nut -2- to 22 Nm.

Intake manifold, removing and installing

Removing

Note. All cable ties unfastened or cut open on removal are to be re-attached in same position on installation.

1. Move lock carrier to service position. Refer to «Lock carrier in service position, overview»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf)

Scheme 565

1. Remove rear engine cover (arrows).

Scheme 566

1. Remove front engine cover (arrows -1- and -2-).

Scheme 567

1. Remove vacuum line (arrow) from brake servo at bulkhead.

Scheme 568

1. Remove vacuum line (arrow) from vacuum reservoir.

Scheme 569

1. Disconnect vacuum hose (arrow) at intake manifold.

Scheme 570

1. Disconnect connector -1- at throttle valve control module -J338-.
2. Remove vacuum hose -2-.
3. Remove air hose -3-.
4. Detach crankcase breather hose -4- at intake manifold.

Scheme 571

1. Take hose connection off (arrow).

Scheme 572

1. Disconnect connectors -1- to -4- forward off holders at intake manifold.

Note. Connectors are not to be unplugged.

Scheme 573

1. Disconnect vacuum hose (arrow) at T-piece.

Scheme 574

1. Disconnect connector consoles -1- and -5- at injectors.
2. Disconnect vacuum line -4- at fuel pressure regulator.
3. Screw out retaining bolts -2- and -3- of fuel rail.
4. Lift fuel rail together with injectors evenly off intake manifold and place it on a clean cloth in the engine compartment.

Note. Make sure injectors removed are properly protected against contamination. Item -4- in illustration is not blocked.

Scheme 575

1. Remove bolts (arrows) left rear engine lifting eye.

Scheme 576

1. Remove bolts (arrows) and take out intake manifold.

Note. Seal intake ducts in cylinder heads with clean cloths.

Installing

Install in reverse order, paying attention to the following

Note. Replace gaskets and O-rings. Re-attach all cable ties at same location on installation. Secure all hose connections with standard hose clamps.

Scheme 577

1. Remove locating bolts -1- and replace intake manifold gaskets.
2. Pay attention to locating pins -2- when installing intake manifold.

1. Screw bolts on intake manifold diagonally and in stages (arrows).
2. Install lock carrier with attachments.

Refer to

1. «50 BODY, FRONT»(/audi/s4/b7-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior)
2. «50 - BODY - FRONT»(/audi/s4/b7-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

Scheme 578

1. Allow torque reaction support to settle on rubber buffer stop for torque reaction support and tighten bolts (arrows) to 28 Nm.
2. Install front bumper.

Refer to

1. «63 BUMPER»(/audi/s4/b7-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior)
2. «63 - BUMPERS»(/audi/s4/b7-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

Front bumper

1. Adjust headlights.

Refer to

1. «94 LIGHTS, SWITCHES - EXTERIOR»(/audi/s4/b7-2004-2008/remont/cruise-control-systems/#electrical-equipment)
2. 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET

Headlight adjustment

1. Bleed air from fuel system. Refer to «Bleed air from fuel system»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf__bleed-air-from-fuel-system)
2. Warm engine for 10 minutes, switch engine off and retorque intake manifold bolts in diagonal sequence to 10 Nm.

Tightening torques

Scheme 579

Move lock carriers to service position. Refer to Lock carriers in service position

1 - 50 Nm

2 - Support tool 3369

1. Tighten to 10 Nm

3 - 10 Nm

4 - 10 Nm

5 - 10 Nm

6 - 10 Nm

7 - Support tool 3369

1. Tighten to 10 Nm

8 - 50 Nm

Lock carriers in service position

Special tools and equipment

Scheme 580

1. 3369 Support tool

Scheme 581

1. On vehicles with auxiliary heater, screw out bolts (arrows) for exhaust pipe of auxiliary/additional heater at noise insulation.

Scheme 582

1. Unfasten quick-release fasteners -1-, screw out bolts -2- and detach noise insulation.
2. Remove front bumper

Refer to

1. «63 BUMPER»(/audi/s4/b7-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior)
2. «63 - BUMPERS»(/audi/s4/b7-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

Remove front bumper

Scheme 583

1. Detach cover -1- on left of engine compartment.

Scheme 584

1. Take the electrical connections -1- and -2- from the holder.
2. Open lines to lock carrier.

Scheme 585

1. Detach cover -1- on right of engine compartment.

Scheme 586

1. Detach the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- 1 at the air ducting.
2. Remove screws (arrows).
3. Remove air duct -2-.

Scheme 587

1. Remove air duct on the left (arrow) in front of the auxiliary radiator.

Scheme 588

1. Remove air duct on the right (arrow) in front of auxiliary radiator.

Scheme 589

1. Remove screws (arrows) at the left and right of the lock carrier.
2. Remove hood seal at lock carrier and at fender edges.

Scheme 590

1. Screw in special tool 3369 on left and right into empty holes.
2. Remove screws at impact absorbers (arrows) on left and right.
3. Carefully pull lock carrier forward.

Installing

Install in reverse order, paying attention to the following

1. Install lock carrier with attachments

Refer to

1. «50 BODY, FRONT»(/audi/s4/b7-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior)
2. «50 - BODY - FRONT»(/audi/s4/b7-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

1. Allow torque reaction support to settle on rubber buffer stop for torque reaction support and tighten bolts (arrows) to 28 Nm.
2. Install front bumper

Refer to

1. «63 BUMPER»(/audi/s4/b7-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior)
2. «63 - BUMPERS»(/audi/s4/b7-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

1. Adjust headlights

Refer to

1. «94 LIGHTS, SWITCHES - EXTERIOR»(/audi/s4/b7-2004-2008/remont/cruise-control-systems/#electrical-equipment)
2. 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET

Tightening torques

Heated Oxygen sensor (HO2S) before catalytic converter, bank 1 (right), removing and installing

Special tools and equipment

Scheme 591

1. 3337 Ring spanner set

Removing

Note. All cable ties unfastened or cut open on removal are to be re-attached in same position on installation.

1. Remove rear engine cover (arrows).

1. Remove cover -1- on right side of engine compartment.

Scheme 592

1. Remove air hose (arrows).

Scheme 593

1. Take connectors -1- to -4- out of holder on right of bulkhead.
2. Disconnect connector -2-.
3. Lay free the oxygen sensor probe wiring.

Scheme 594

1. Remove Heated Oxygen sensor (HO2S) (arrow) using special tool 3337.

Note. Illustration shows engine removed.

Installing

Install in reverse order, paying attention to the following

Note. Thread of new Heated Oxygen sensor (HO2S) is coated with assembly paste which must not be allowed to ingress into openings in probe. Re-attach all cable ties in same location on installation. Secure all hose connections with standard hose clamps.

Tightening torque

1) If a Heated Oxygen sensor (HO2S) is to be re-used, grease thread only with hot bolt paste. The holt bolt paste must not be allowed to go into openings in probe. .

Heated Oxygen Sensor before catalytic converter, bank 2 (left), removing and installing

Special tools and equipment

Scheme 595

1. 3094 Hose clamps

1. 3337 Ring spanner set

Removing

Note. All cable ties unfastened or cut open on removal are to be re-attached in same position on installation.

1. Remove rear engine cover (arrows).

1. Remove cover -1- on left side of engine compartment.

Scheme 596

1. Pinch off coolant hose -2- with hose clamp 3094 and detach at coolant expansion tank.
2. Remove coolant expansion tank (arrow).
3. Disconnect wire to Engine Coolant Level (ECL) Warning Switch -F66- at bottom of expansion tank and lay coolant expansion tank with attached coolant hose -1- aside.
4. Use suitable plug to seal connection, if necessary.

Scheme 597

1. Take connectors -1- to -4- out of holder on left side of bulkhead.
2. Disconnect connector -4-.
3. Remove holder at bulkhead.
4. Remove heat insulation sleeve at wiring harness and separate wiring harness.

1. Lay free Heated Oxygen sensor (HO2S) wiring.

Scheme 598

1. Remove Heated Oxygen Sensor (HO2S) (arrow) using special tool 3337.

Note. Illustration shows engine removed.

Installing

Install in reverse order, paying attention to the following

Note. Threads of new Heated Oxygen sensor (HO2S) is coated with assembly paste which must not be allowed to go into openings in probe. Re-attach all cable ties at same location on installation.

Tightening torque

1) If a Heated Oxygen sensor (HO2S) is to be re-used, grease thread only with hot bolt paste. This must not be allowed to go into openings in probe.

Heated Oxygen Sensor (HO2S) after catalytic converter, bank 1 (right), removing and installing

Special tools and equipment

1. 3337 Ring spanner set

Scheme 599

1. V.A.G 1383 A Engine/transmission jack

Removing

Note. All cable ties unfastened or cut open on removal are to be re-attached in same position on installation.

1. Remove rear engine cover (arrows).

1. Remove cover -1- on right side of engine compartment.

1. Remove air hose (arrows).

1. Take connectors -1- to -4- out of holder on right side of bulkhead.
2. Disconnect connector -4-.
3. Lay free Heated Oxygen sensor (HO2S) wiring downward.
4. Remove right front wheel.

1. Remove bolts (arrows) for exhaust pipe of auxiliary/additional heater at noise insulation, on vehicles with auxiliary heater.

1. Unfasten quick-release fasteners -1-, remove bolts -2- and detach noise insulation.

Scheme 600

1. Remove holder screws for noise insulation (arrows).

Scheme 601

1. Detach universal mount V.A.G 1359/2 from engine/transmission jack V.A.G 1383 A and place wooden block (arrow) on press tool instead.
2. Support rear cross member using engine/transmission jack V.A.G 1383 A.
3. Remove bolts -1- and -2-, then bolts -3- and -4-.

Scheme 602

1. Slowly lower rear cross member using engine/transmission jack V.A.G 1383 A, until distance between rear cross member and body is equal to dimension "x".

1. Dimension x = 60 mm

Note. Transmission must not be lowered any further, as joint of axle shaft and decoupling elements of exhaust system could be damaged.

Scheme 603

1. Remove heat shield (arrow) for right drive axle.

Scheme 604

1. Remove connecting rod -2-.
2. Remove socket-head bolt -1-.

Scheme 605

1. Lay free Heated Oxygen Sensor (HO2S) wires (arrows) at locations marked on transmission.

Note. Illustration shows engine/transmission assembly removed.

Scheme 606

1. Remove Heated Oxygen Sensor (HO2S) -1- using special tool 3337.

Installing

Install in reverse order, paying attention to the following

Note. Thread of new Heated Oxygen Sensor (HO2S) is coated with assembly paste which must not be allowed to go into openings in probe. Re-attach all cable ties at same location on installation. Secure all hose connections with standard hose clamps.

1. Install subframe.

Refer to 40 - FRONT SUSPENSION

1. Perform stress-free alignment of exhaust system.

Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS

Tightening torques

1) If a Heated Oxygen Sensor (HO2S) is to be re-used, grease thread only with hot bolt paste. This must not be allowed to go into openings in probe.

Scheme 607

Special tools and equipment

1. 3094 Hose clamps
2. 3337 Ring spanner set
3. V.A.G 1383 A Engine/transmission jack

Removing

Note. All cable ties unfastened or cut open on removal are to be re-attached in same position on installation.

1. Remove rear engine cover (arrows).

1. Remove cover -1- on left side of engine compartment.

1. Pinch off coolant hose -2- with hose clamp 3094 and detach at coolant expansion tank.
2. Remove coolant expansion tank bolt (arrow).
3. Disconnect Engine Coolant Level (ECL) Warning Switch -F66- wiring at bottom of expansion tank and lay aside coolant expansion tank with coolant hose -1- connected.
4. Use suitable plug to seal connection, if necessary.

1. Take connectors -1- to -4- out of holder on right side of bulkhead.
2. Disconnect connector -1-.
3. Remove holder at bulkhead.
4. Remove heat insulation sleeve at wiring harness.

1. Lay free Heated Oxygen Sensor (HO2S) wiring downward.
2. Remove left front wheel.

1. Screw out bolts (arrows) for exhaust pipe of auxiliary/additional heater at noise insulation, on vehicles with auxiliary heater.

1. Unfasten quick-release fasteners -1-, remove bolts -2- and detach noise insulation.

1. Remove holder screws for noise insulation (arrows).

1. Detach universal mount V.A.G 1359/2 from engine/transmission jack V.A.G 1383 A and place wooden block (arrow) on press tool instead.
2. Support rear cross member using engine/transmission jack V.A.G 1383 A.
3. Remove bolts -1- and -2-, then bolts -3- and -4-.

1. Slowly lower rear cross member, using engine/transmission jack V.A.G 1383 A, until distance between rear cross member and body is equal to dimension "x".

1. Dimension x = 60 mm

Note. Transmission must not be lowered any further as joint of drive shaft and decoupling elements of exhaust system could be damaged.

1. Remove heat shield for right drive axle (arrow).

1. Remove connecting rod -2-.
2. Remove socket-head bolt -1-.

1. Lay free Heated Oxygen Sensor (HO2S) wires (arrows) at locations marked on transmission.

Note. Illustration shows engine/transmission assembly removed.

1. Remove Heated Oxygen Sensor (HO2S) -2- using special tool 3337.

Installing

Install in reverse order, paying attention to the following

1. Thread of new Heated Oxygen Sensor (HO2S) is coated with assembly paste which must not be allowed to go into openings in probe.
2. Re-attach all cable ties at same location on installation.

1. Install subframe.

Refer to 40 - FRONT SUSPENSION

1. Perform stress-free alignment of exhaust system.

Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS

Tightening torques

1) If a Heated Oxygen Sensor (HO2S) is to be re-used, grease thread only with hot bolt paste. This must not be allowed to go into openings in probe.

General notes on ignition system

1. The engine control module is equipped with On Board Diagnostic (OBD).
2. A voltage of at least 11.5 V is necessary for satisfactory functioning of the electrical components.
3. In the case of some tests, a malfunction may be recognized and stored by the control module. At the end of all tests and repairs, the Diagnostic Trouble Code (DTC) memory should be checked and, if necessary, erased.
4. If the engine starts briefly and then stops after the DTC search, repair or tests on components, this may be because the immobilizer is blocking the engine control module. The DTC memory must then be checked and, if necessary, adaptation carried out on the control module.

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 cables when the engine is running or at starter speed.
2. Always switch off the ignition before connecting or disconnecting the battery, otherwise the engine control module may be damaged.
3. Always switch off the ignition before connecting or disconnecting injection or ignition system wiring or tester cables.
4. To run engine at starting speed without actually starting it (for example, in order to test compression), unplug connector from the output stages of the ignition coils and also the connectors on the injectors. After completing the work, check the DTC memory and erase it.

1. Always switch off the ignition before washing the engine.

Technical data for ignition system

See also:
• 01 - MAINTENANCE
• 01 - MAINTENANCE
• 30 CLUTCH
• 46 - BRAKES - MECHANICAL COMPONENTS
• 72 - SEAT - FRAMES
• 72 - SEAT - FRAMES
• 20 - FUEL SUPPLY SYSTEM
• 50 BODY, FRONT
• 50 - BODY - FRONT
• 94 LIGHTS, SWITCHES - EXTERIOR
• 40 - FRONT SUSPENSION
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS
• Vehicle with all-wheel drive
• Bleed air from fuel system
• Wiring and component check using test box V.A.G 1598/31
• Fuel pressure regulator and holding pressure, checking
• Intake manifold, removing and installing
• Lock carrier in service position, overview
• Lock carriers in service position