3.0l - Multiport Fuel Injection - Engine Code(s): Ccba (sedan) Audi S4 B8 рестайлинг

SAFETY PRECAUTIONS

If testing equipment must be used during a road test, observe the following

Note the following when working on the fuel system

Procedures before opening the high pressure fuel injection system. Refer to RELEASING PRESSURE IN HIGH PRESSURE AREA .

To prevent personal injury and damage to the injection and ignition system, observe the following

1. Individuals with a pacemaker must not stay in the danger area of high voltage systems, for example ignition systems, xenon light.
2. Turn off the ignition before disconnecting and connecting the wiring for the injection and ignition system. This includes tester cables as well.
3. Fuel lines must not be opened when the engine is running.
4. Only clean the engine with the ignition turned off.
5. While testing it is possible that there may be some faults stored in the Engine Control Module (ECM). After completing all testing and repairs, check the Diagnostic Trouble Code (DTC) memory. If a fault has been stored

CLEAN WORKING CONDITIONS

Even a little contamination can lead to faults. When working on the fuel supply and fuel injection system, observe the following guidelines for a clean working environment

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 removed parts on a clean surface and cover them. Use lint-free cloths.
4. Carefully cover over opened components or seal, if repairs are not performed immediately.
5. Only install clean components: Remove the replacement parts from their packaging just prior to installing them. Do not use parts that have been stored loose (for example in Tool boxes etc.).
6. When the system is open: Do not work with compressed air. Do not move the vehicle unless absolutely necessary.
7. Protect the disconnected connectors from dirt and moisture and only connect when they are dry.

Scheme 86

1. The Engine Control Module (ECM) 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. If it is difficult to disconnect the connectors, use a release Tool f/ rev. light switch conn.T40138.

Scheme 87

1. Hose Clamp
2. Air Guide Hose To throttle valve control module -J338- Pay attention to the marking when installing (the arrow points toward the throttle valve control module bolt)
3. Air Filter Always use an original air filter For the maintenance interval, refer to «MAINTENANCE, DIAGNOSIS»(/audi/s4/b8-2011-2015/remont/procedures/#how-to-diagnosis-the-maintenance-maintenance-intervals-sedan) Removing and installing, refer to «AIR FILTER»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__air-filter) Clean snow screen also (if present)
4. Air Guide Clipped into upper section of air filter Clean air duct of dirt and leaves
5. Air Guide Clean air duct of dirt and leaves
6. Air Guide To lock carrier Clean air duct of dirt and leaves
7. Rubber Grommet
8. Water Drain Hose lean water drain hose of dirt and leaves
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. Air Filter Housing Lower Section Clean the lower section of the air filter from salt, dirt and leaves. Check for water drain for dirt; clean if necessary.
12. Air Filter Housing Lower Section Mount
13. Secondary Air Injection (AIR) Pump Intake Hose Not installed on all vehicles
14. Intake Air Switch-Over Valve -N335- Not installed on all vehicles The valve is installed but is not functional
15. Bolt For the intake air switch-over valve -N335
16. Bolt
17. Air Filter Upper Section Clean the upper section of the air filter from salt, dirt and leaves.
18. Bolt For securing the air filter element

COMPONENT LOCATION OVERVIEW

Engine Compartment, Right

Scheme 88

1. 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-511969-S22690946842012102900000)
2. Heated Oxygen Sensor (HO2S) -G39- with Oxygen Sensor (O2S) Heater -Z19- 55 Nm Component location (Scheme 114)Connector location (Scheme 112)Removing and installing, refer to «Heated Oxygen Sensor -G39»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__heated-oxygen-sensor-g39)
3. Camshaft Adjustment Valve 1 -N205- Component location (Scheme 100)
4. Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- with Heater for Oxygen Sensor (O2S) 1 after Catalytic Converter -Z29- 55 Nm Component location (Scheme 114)Connector location (Scheme 112)Removing and installing, refer to «Oxygen Sensor after Three Way Catalytic Converter -G130»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__oxygen-sensor-after-three-way-catalytic)
5. Secondary Air Injection (AIR) Sensor 1 -G609- Component location, refer to «Description and Operation»(/audi/s4/b8-2011-2015/remont/exhaust/#30l-exhaust-system-emission-controls-engine-codes-ccba-sedan)
6. Secondary Air Injection (AIR) Solenoid Valve -N112- Component location (Scheme 95)
7. Intake Air Temperature (IAT) Sensor -G42- /Manifold Absolute Pressure (MAP) Sensor -G71
8. Intake Manifold Runner (IMR) Control Valve -N316- Component location (Scheme 95)
9. Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80- Component location (Scheme 97)
10. Secondary Air Injection (AIR) Solenoid Valve 2 -N320- Component location (Scheme 95)
11. Control Valve Control Unit -J808- Component location (Scheme 99)After replacing the control valve control unit perform an Adaptation in Guided Functions. Refer to the vehicle diagnostic tester. Removing and installing, refer to «Control Valve Control Unit -J808»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__control-valve-control-unit-j808)
12. Throttle Valve Control Module -J338- Component location (Scheme 98)After replacing the throttle valve control module perform an Adaptation in Guided Functions. Refer to the vehicle diagnostic tester. Removing and installing, refer to «Throttle Valve Control Module -J338»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__throttle-valve-control-module-j338)
13. Knock Sensor (KS) 1 -G61- Component location (Scheme 102)Connector location (Scheme 94)
14. Fuel Injectors, Cylinder Bank 1 Cylinder 1 fuel injector -N30- Cylinder 2 fuel injector -N31- Cylinder 3 fuel injector -N32- Removing and installing, refer to «FUEL INJECTORS»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__fuel-injectors)
15. Intake Manifold Runner (IMR) Position Sensor -G336- Component location (Scheme 106)
16. Camshaft Position (CMP) Sensor -G40- Component location (Scheme 100)
17. Charge Air Pressure Sensor -G31- / Intake Air Temperature (IAT) Sensor -G72- Component location (Scheme 110)
18. High Pressure Pump With fuel metering valve -N290- With low fuel pressure sensor -G410- Component location (Scheme 108)Removing and installing, refer to «HIGH PRESSURE Pump»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__high-pressure-pump)
19. Secondary Air Injection (AIR) Pump Motor -V101- Component location (Scheme 116)

Engine Compartment, Left

Scheme 89

1. Fuel Pressure Sensor -G247- 22 Nm Component location (Scheme 103)Oil the threads
2. Knock Sensor (KS) 2 -G66- Component location (Scheme 103)Connector location (Scheme 94)
3. Fuel Injectors, Cylinder Bank 2 Cylinder 4 Fuel Injector -N33- Cylinder 5 Fuel Injector -N83- Cylinder 6 Fuel Injector -N84- Removing and installing, refer to «FUEL INJECTORS»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__fuel-injectors)
4. Reduced Oil Pressure Switch -F378- Component location (Scheme 104)
5. Control Valve Control Unit -J808- Component location (Scheme 99)Removing and installing, refer to «Control Valve Control Unit -J808»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__control-valve-control-unit-j808) -- After replacing the control valve control unit perform an Adaptation in Guided Functions using the vehicle diagnostic tester.
6. Secondary Air Injection (AIR) Solenoid Valve -N112- Component location (Scheme 95)
7. Intake Air Temperature (IAT) Sensor -G42- /Manifold Absolute Pressure (MAP) Sensor -G71- Component location (Scheme 96)
8. Intake Manifold Runner (IMR) Control Valve -N316- Component location (Scheme 95)
9. Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80
10. Secondary Air Injection (AIR) Solenoid Valve 2 -N320- Component location (Scheme 95)
11. Oil Pressure Switch -F22- Component location (Scheme 93)
12. Engine Speed (RPM) Sensor -G28- 9 Nm Component location (Scheme 109)Removing and installing, refer to «Engine Speed Sensor -G28»(ref-511969-S23862080622012102900000)
13. Oxygen Sensor 2 after Catalytic Converter -G131- with Heater for Oxygen Sensor 2 after Catalytic Converter -Z30- 55 Nm Component location (Scheme 115)Connector location (Scheme 113)Removing and installing, refer to «Oxygen Sensor 2 after Catalytic Converter -G131»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__oxygen-sensor-2-after-catalytic-converter)
14. Camshaft Adjustment Valve 2 -N208- Component location (Scheme 101)
15. Heated Oxygen Sensor 2 -G108- with Oxygen Sensor 2 Heater -Z28- 55 Nm Component location (Scheme 115)Connector location (Scheme 113)Removing and installing, refer to «Heated Oxygen Sensor 2 -G108»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__heated-oxygen-sensor-2-g108)
16. Engine Control Module (ECM) -J623- Component location (Scheme 90)Removing and installing, refer to «Engine Control Module -J623»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__engine-control-module-j623) -- After replacing, perform an Adaptation in Guided Functions using the vehicle diagnostic tester.
17. 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-511969-S22690946842012102900000)
18. Oil Pressure Regulation Valve -N428- Component location (Scheme 105)
19. After-Run Coolant Pump -V51- Not installed in all versions Component location (Scheme 117)
20. Intake Air Temperature (IAT) Temperature Sensor 2 -G430- /Charge Air Pressure Sensor 2 -G447- Component location (Scheme 110)
21. Camshaft Position (CMP) Sensor 2 -G163- Component location (Scheme 101)
22. Intake Manifold Runner (IMR) Position Sensor 2 -G512- Component location (Scheme 106)After replacing, perform an Adaptation in Guided Functions using the vehicle diagnostic tester.
23. Engine Coolant Temperature (ECT) Sensor -G62- Component location (Scheme 107)

Scheme 90

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

Scheme 91

2) - Connector

Note. The accelerator pedal position sensor and accelerator pedal position sensor 2 are integrated in the gas pedal module and cannot be replaced individually.

Removing and installing, refer to Removal and Installation .

Scheme 92

1) - Brake lamp switch -F- /brake pedal switch -F47

2) - Clutch position sensor -G476- integrated functionality: clutch pedal starter interlock switch -F194- and clutch pedal switch -F36

Note. To ensure that they are absolutely securely seated, the switches may only be installed once.

Removing and installing, refer to Removal and Installation .

Scheme 93

1. To Knock Sensor (KS) 1 -G61
2. To the fuel injectors, cylinder bank 1
3. Oil pressure switch -F22

Scheme 94

1. To cylinder bank 2 fuel injectors and to fuel pressure sensor -G247
2. To Knock Sensor (KS) 2 -G66

Scheme 95

1. Secondary Air Injection (AIR) solenoid valve -N112
2. Intake Manifold Runner (IMR) control valve -N316
3. Secondary Air Injection (AIR) solenoid valve 2 -N320

1. Behind, on the supercharger with the charge air cooler.

Scheme 96

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

1. Behind, on the supercharger with the charge air cooler.

Scheme 97

Scheme 98

1. Behind the supercharger.

Scheme 99

3) - Control valve control unit

1. Behind the supercharger.

Scheme 100

1. Camshaft adjustment valve 1 -N205
2. Camshaft Position (CMP) sensor -G40

Scheme 101

1) - Camshaft Position (CMP) sensor 2 -G163

3) - Camshaft adjustment valve 2 -N208

Scheme 102

1. Cylinder 1 fuel injector -N30
2. Cylinder 2 fuel injector -N31
3. Cylinder 3 fuel injector -N32
4. Knock sensor 1 -G61

Scheme 103

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 104

Scheme 105

4) - Oil pressure regulation valve -N428

1. Left side, underneath on the engine.

Removing and installing, refer to Removal and Installation .

Scheme 106

1. At the front on the left lower section of the intake manifold.

Note. The intake manifold runner position sensor -G336- is installed as a mirror image.

Scheme 107

1. ECT sensor

1. At front on engine.

Scheme 108

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

1. At right side of the cylinder head

Scheme 109

1. installed in the transmission housing from behind

Scheme 110

1. On the right side, on the supercharger with the charge air cooler.

Note. The intake air temperature sensor 2 -G430- / charge air pressure sensor 2 -G447- are arranged as mirror image of each other.

Removing and installing, refer to Removal and Installation .

Scheme 111

1. On the left and right engine mounts -arrow-.

Scheme 112

1. For the fuel injectors (cylinder bank 1)
2. Throttle valve control module -J338
3. KS 1 -G61
4. For the Heated Oxygen Sensor (HO2S) -G39- with Oxygen Sensor (O2S) Heater -Z19
5. For oxygen sensor after three way catalytic converter -G130- with heater for oxygen sensor 1 after catalytic converter -Z29

Scheme 113

1. For Oxygen Sensor (O2S) 2 after catalytic converter -G131- with heater for O2S 2 after catalytic converter -Z30
2. For the Heated Oxygen Sensor (HO2S) 2 -G108- with O2S 2 heater -Z28
3. For the fuel injectors (cylinder bank 2) and for the fuel pressure sensor -G247
4. For knock sensor 2 -G66

Scheme 114

1. Oxygen Sensor (O2S) after three way catalytic converter -G130- with heater for O2S 1 after catalytic converter -Z29
2. Heated Oxygen Sensor (HO2S) -G39- with Oxygen Sensor (O2S) Heater -Z19

Scheme 115

1. Heated oxygen sensor 2 -G108- with oxygen sensor 2 heater -Z28
2. O2S 2 after catalytic converter -G131- with heater for O2S 2 after catalytic converter -Z30

Scheme 116

1. Under the right headlamp.

Removing and Installing, refer to Removal and Installation .

Scheme 117

1. Left side, at the front, on the engine

Note. Not all versions have an after-run coolant Pump. It is only for extreme hot climate countries.

Removing and installing, refer to Removal and Installation .

Scheme 118

1. Low Fuel Pressure Sensor -G410- 15 Nm
2. Seal Replace
3. Bolt Tighten by hand in a diagonal sequence and then tighten to 5 Nm Final tightening specification: 20 Nm Do not tilt the high pressure Pump
4. High Pressure Pump With fuel metering valve -N290- Removing and installing, refer to «HIGH PRESSURE Pump»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__high-pressure-pump) Do not disassemble
5. Threaded Connection 27 Nm Connectors should not show any signs of damage
6. Fuel Supply Hose Low pressure side
7. High Pressure Fuel Line 27 Nm WARNING: Do not let fuel come into contact with skin. The fuel pressure must be reduced to residual pressure before opening the high pressure area of the fuel injection system. Refer to «RELEASING PRESSURE IN HIGH PRESSURE AREA»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__releasing-pressure-in-high-pressure-area) . Reduce the fuel pressure in the high pressure area, refer to «RELEASING PRESSURE IN HIGH PRESSURE AREA»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__releasing-pressure-in-high-pressure-area) . Removing and installing, refer to «HIGH PRESSURE LINE»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__high-pressure-line) .
8. Gasket Replace
9. Housing
10. Camshaft Position (CMP) Sensor -G40- Removing and installing, refer to «Camshaft Position Sensor -G40- / Camshaft Position Sensor 2 -G163»(ref-511969-S04058206012012102900000)
11. Bolt 9 Nm
12. O-ring Replace Lubricate O-rings with clean engine oil before installing
13. Protective Plate For high pressure line
14. Nut 9 Nm
15. Double Bolt 9 Nm
16. Roller Tappet Can be installed in one position only Lubricate O-rings with clean engine oil before installing
17. O-ring Replace Lubricate O-rings with clean engine oil before installing

Scheme 119

1. Bolts 2.5 Nm
2. Intake Manifold Runner (IMR) Position Sensor Left intake manifold runner position sensor 2 -G512-, right intake manifold runner position sensor -G336
3. Seal Replace if damaged Lift out with screwdriver to replace Press in by hand
4. Sleeve
5. Fuel Pressure Sensor -G247- 22 Nm Oil the threads
6. Bracket
7. Bolt 9 Nm
8. High-Pressure Lines 27 Nm WARNING: There is a risk of injury because the fuel is under very high pressure. The fuel pressure must be reduced to residual pressure before opening the high pressure area of the fuel injection system. Refer to «RELEASING PRESSURE IN HIGH PRESSURE AREA»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__releasing-pressure-in-high-pressure-area) . Reduce the fuel pressure in the high pressure area, refer to «RELEASING PRESSURE IN HIGH PRESSURE AREA»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__releasing-pressure-in-high-pressure-area) . Connectors should not show any signs of damage Do not change the shape of the line Removing and installing, refer to «HIGH PRESSURE LINE»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__high-pressure-line) Counter hold the connecting pieces when loosening and tightening fuel line Tighten fuel line connecting pieces before installing the fuel line
9. Bolt 9 Nm
10. Nut 9 Nm
11. Bolt 9 Nm
12. Bolt 2.5 Nm
13. Fuel Rail Retaining Bracket
14. Threaded Connection 40 Nm
15. Fuel Rail
16. Gasket Replace
17. Intake Manifold Lower Section Removing and installing, refer to «INTAKE MANIFOLD LOWER SECTION, WITH FUEL RAIL»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__intake-manifold-lower-section-with-fuel) The intake manifold flaps must be completely open when installing the intake manifold lower section
18. Gasket Replace
19. Support Ring Make sure it fits correctly. The fuel rail wields force via the support ring to hold the fuel injector tightly in the cylinder head.
20. O-ring Replace Coat with clean engine oil
21. Spacer Ring Replace if damaged
22. Fuel Injector Removing and installing, refer to «FUEL INJECTORS»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__fuel-injectors)
23. Upper Sealing Washer
24. Lower Sealing Washer
25. Locking Ring
26. Combustion Chamber Seal Removing and installing, refer to «FUEL INJECTORS»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__fuel-injectors)
27. Seal Replace if damaged Lift out with screwdriver to replace Press in by hand
28. Actuator Lever For the vacuum actuator
29. Vacuum Hose To Intake Manifold Runner Control (IMRC) valve -N316
30. Intake Manifold Runner Control Vacuum Actuator

Scheme 120

Tighten the bolts and nuts -arrows- in a diagonal sequence on the intake manifold lower section and in steps.

1. 10 Nm

OXYGEN SENSORS OVERVIEW

1. For the fuel injectors (cylinder bank 1)
2. Throttle valve control module -J338
3. Knock Sensor (KS) 1 -G61
4. For the Heated Oxygen Sensor (HO2S) -G39- with Oxygen Sensor (O2S) heater -Z19
5. For O2S after three way catalytic converter -G130- with heater for O2S 1 after catalytic converter -Z29

1. For Oxygen Sensor (O2S) 2 after Three Way Catalytic Converter (TWC) -G131- with heater for oxygen sensor 2 after catalytic converter -Z30
2. For the Heated Oxygen Sensor (HO2S) 2 -G108- with oxygen sensor 2 heater -Z28
3. For the fuel injectors (cylinder bank 2) and fuel pressure sensor -G247
4. For Knock Sensor (KS) 2 -G66

1. Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- with heater for Oxygen Sensor (O2S) 1 after catalytic converter -Z29
2. Heated Oxygen Sensor (HO2S) -G39- with Oxygen Sensor (O2S) Heater -Z19

1. Tightening Specifications: 55 Nm

1. Heated oxygen sensor 2 -G108- with Oxygen Sensor (O2S) 2 heater -Z28
2. Oxygen Sensor (O2S) 2 after catalytic converter -G131- with heater for Oxygen Sensor (O2S) 2 after catalytic converter -Z30

1. Tightening Specifications: 55 Nm

Note. Coat new oxygen sensors with an assembly paste. When installing the previous oxygen sensor, coat the thread with hot bolt paste. Assembly paste or hot bolt paste must not enter the slots on the oxygen sensor body. Always install the oxygen sensor wire in the same location so it does not come into contact with the exhaust pipe. When installing, bring all cable ties back to the same positions.

Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19-, removing and installing, refer to Heated Oxygen Sensor -G39 .

Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- with heater for Oxygen Sensor (O2S) 1 after catalytic converter -Z29-, removing and installing, refer to Oxygen Sensor after Three Way Catalytic Converter -G130 .

Heated Oxygen Sensor (HO2S) 2 -G108- with Oxygen Sensor (O2S) 2 heater -Z28-, refer to Heated Oxygen Sensor 2 -G108 .

Oxygen Sensor (O2S) 2 after catalytic converter -G131- with heater for Oxygen Sensor (O2S) 2 after catalytic converter -Z30-, refer to Oxygen Sensor 2 after Catalytic Converter -G131 .

RELEASING PRESSURE IN HIGH PRESSURE AREA

High Fuel Pressure, Reducing

Connect a vehicle diagnosis tester.

Start engine and run at idle speed.

Select "engine electronics" in OBD.

Then select "Measured values".

Select "Fuel pressure" from the list.

1. Specified value: between 35 and 45 bar

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

Scheme 121

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 the appropriate SYSTEM WIRING DIAGRAMS information.

Scheme 122

Note. By removing fuse, the voltage supply to terminal 30 for the FP Control Module is interrupted.

Check the fuel pressure displayed.

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

Turn off the ignition as soon as the fuel pressure has decreased to approximately 8 bar.

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

The fuel rail will continue to be filled with fuel, but it will no longer be under high pressure.

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

Note. If the high pressure system is not opened immediately, the pressure will increase because of post-heating.

Lay clean cloths around connectors and catch escaping fuel.

Final Procedures

Install the fuse.

Install the instrument panel cover. Refer to Removal and Installation .

Erase the Diagnostic Trouble Code (DTC) memory and generate the readiness code in the Engine Control Module (ECM) in "Guided Functions".

FASTENER TIGHTENING SPECIFICATIONS

Tightening Specification, Intake Manifold Lower Section

Tighten the bolts and nuts -arrows- in a diagonal sequence on the intake manifold lower section and in steps.

1. 10 Nm

TEST DATA

FUEL PRESSURE AND RESIDUAL PRESSURE BEFORE HIGH PRESSURE PUMP, CHECKING

Special Tools and workshop equipment required

1. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
2. Adapter V.A.G 1318/10-12
3. Connector Test Set V.A.G 1594C
4. Remote Control V.A.G 1348/3A with Remote Control for VAG 1348 V.A.G 1348/3-3
5. Measuring container, fuel-resistant

Test Conditions

1. Battery voltage at least 12.5 Volts
2. Fuel filter OK.
3. Fuel tank minimum 1 / 4 full.
4. Fuel Pump (FP) control module -J538- OK; for checking, refer to «Diagnosis and Testing»(/audi/s4/b8-2011-2015/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-ccba-sedan) .
5. Ignition turned off

Fuel Pressure, Checking

Remove rear seat bench. Refer to Removal and Installation .

Remove the cover from the locking flange -arrows-.

Scheme 123

Disconnect electrical harness connector -1- at locking flange.

Scheme 124

Note. Ignore -2-.

Connect the 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 125

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

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

Remove the seal -arrow-.

Scheme 126

Unclip the plenum chamber cover -2- and remove it.

Note. Ignore -1 and 3-.

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

Scheme 127

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

Remove the bolts -arrows-, remove the air guides -1 and 2-.

Scheme 128

Reduce fuel pressure in high pressure area. Refer to RELEASING PRESSURE IN HIGH PRESSURE AREA .

Remove the fuel supply hose from the high pressure Pump -arrow- and free it up.

Scheme 129

Connect the V.A.G 1318 with the V.A.G 1318/11 and V.A.G 1318/15 in the fuel line.

Scheme 130

Connect assisting hose -arrow- on the pressure gauge and hold in a measuring container.

Open the shut-off valve on the pressure gauge.

1. The lever points in the direction of flow.

Bleed the fuel system by briefly pressing the remote control.

Close the shut-off valve on the pressure gauge.

Scheme 131

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

Press the remote control switch long enough until the pressure gauge stops registering an increase in pressure.

1. Specified value: approximately 6 bar

If the specified value is not reached, check the fuel Pump delivery rate. Refer to Diagnosis and Testing .

Residual Pressure, Checking

Check for leaks and constant pressure, watch the manometer to see if there is a drop in pressure.

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

If the holding pressure drops below 3 bar

1. Check connection between pressure gauge and fuel line for leaks.
2. Check pressure gauge for leaks.
3. Check fuel lines and their connections for leaks.
4. Replace the fuel filter with an integrated fuel pressure regulator, refer to «Removal and Installation»(/audi/s4/b8-2011-2015/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-ccba-sedan) .
5. Fuel Pump check-valve is faulty, refer to «Diagnosis and Testing»(/audi/s4/b8-2011-2015/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-ccba-sedan) .

Assembling

Assemble in reverse order of disassembling. Note the following

Connect the fuel supply hose -arrow- to the high pressure Pump. Make sure the hose is clean.

1. Tightening Specifications: High pressure Pump assembly overview, refer to «HIGH PRESSURE Pump OVERVIEW»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan)

Install the rear bench seat. Refer to Removal and Installation .

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.

Turn off the ignition.

Check the entire fuel system for leaks.

If there are leaks in spite of correct tightening specifications, the corresponding component must be replaced.

Then perform a road test and depress the accelerator pedal all the way at least one time.

Then check the high pressure area again for leaks.

VACUUM SYSTEM, CHECKING

Special Tools and workshop equipment required

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

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 the 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 105 PIN V.A.G 1598/42

Special Tools and workshop equipment required

1. Adapter Lead - V.A.G 1598/39-1
2. Adapter Lead - V.A.G 1598/39-2
3. Test Box 105 Pin - V.A.G 1598/42

Note. The test box has 105 terminals. The connection cable can be separated from the test box. This means that as the 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. For testing at the 60-pin harness connection, the - V.A.G 1598/39-1- is connected to the test box with connector "A". Components of the 60-pin harness connection, refer to the appropriate SYSTEM WIRING DIAGRAMS information. For testing at the 94-pin harness connection, the - V.A.G 1598/39-2- is connected to the test box with connectors "A and B". Components of the 94-pin harness connection, refer to the appropriate SYSTEM WIRING DIAGRAMS information. The V.A.G 1598/42 is designed so that it can be connected simultaneously to the ECM harness and the ECM itself. This is advantageous because the 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 ECM is to remain connected to the test box or not.

Procedure

The ECM must be removed to disconnect the ECM multi-pin connectors. Refer to Engine Control Module -J623 .

Connect - V.A.G 1598/42- to wiring harness with - V.A.G 1598/39-1- or - V.A.G 1598/39-2-. Clamp test box Ground (GND) clip to battery negative terminal. The procedure will indicate whether the ECM is to be connected to the test box or not.

Connect the test box ground clip on the negative terminal clamp in the engine compartment.

Note. The procedure will indicate whether the ECM is to be connected to the test box or not.

Perform test as described in respective repair procedure.

Installing ECM

Install in reverse order of removal.

The ECM must be installed with a housing.

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

Always use new shear bolts.

Perform the following work after the ECM is reconnected

Check the Diagnostic Trouble Code (DTC) memory.

AIR FILTER

Removing

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

Scheme 132

Remove the screws -arrows- from the air filter upper section and remove it.

Scheme 133

Note. Always use an original air filter. Use a siliCone -free lubricant for installing the air guide 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 134

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

Check the intake channels up to the air filter for dirt.

When installing the air filter, make sure it is centered in the air filter housing upper section.

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

Scheme 135

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

Scheme 136

Set the upper section of the air filter housing onto lower section of the air filter housing, without using much force.

Note. Make sure the air filter housing upper section is installed correctly into the groove in the lower section before tightening the screws.

Then, fasten the upper section of the air filter housing to the lower section of the air filter housing.

Make sure the air guide hoses are secure.

Further installation is in the reverse sequence to removal.

CONTROL VALVE CONTROL UNIT -J808

Removing

Remove the rear engine cover -2- upward.

Scheme 137

Disconnect the connector -3- from the control valve control module.

Scheme 138

Remove the bolts -5 and 6-.

Remove the bypass connection -1- with the adapter -2- and control valve control module -4-.

Installing

Install in reverse order, paying attention to the following

Note. Replace the O-rings.

Install the bypass connection -1- with the adapter -2- and control valve control module -4-. Use new O-rings.

Install the bolts -5 and 6- hand-tight.

First tighten the bolts -6- to the tightening specification.

1. Tightening Specifications: 10 Nm

Then tighten the bolts -5- to the same tightening specification.

Connect the connector -3-.

After replacing the control valve control module perform an Adaptation in Guided Functions using a vehicle diagnostic tester.

ENGINE CONTROL MODULE -J623

Special Tools and workshop equipment required

1. Hot Air Blower VAS 1978/14A with Nozzle Attachment from the Wiring Harness Repair Set VAS 1978 B
2. Small commercially available locking pliers

Note. Some Engine Control Modules (ECMs) are not equipped with a protective housing. The removal and installation of the protective housing depends on the engine and transmission combination. The 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. The protective housing must be removed to disconnect the connectors from the ECM.

Removing

If the ECM was replaced, select diagnostic object "Replacing engine control module " in "Guided Functions". Use a vehicle diagnosis tester.

Turn the ignition and remove the ignition key.

Pull the plenum chamber cover rubber seal in front of the nut -1- slightly.

Scheme 139

Disengage the wiring harness -2- at the mounts -A-.

Remove nut -1-.

Remove the filler neck -3- with the filler tube from the washer fluid reservoir and the opening in the body.

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

Scheme 140

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

The ECM -1- is secured in a metal housing -5- with retaining tabs -2- and shear bolts -3 and 4- to make it harder to access it.

Scheme 141

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 on both ECM shear bolts -3- are not coated with 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 airflow switch -3- Set to level 3.

Scheme 142

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

Scheme 143

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

Scheme 144

The shear bolts installed in the ECM do not need to be heated for removal. They can be removed without heat.

Disconnect metal retainers from the ECM connectors.

Disengage the connectors from the ECM and disconnect the connector.

Remove old ECM and install the new ECM.

Installing

Install in reverse order of removal.

The ECM must be installed with a housing.

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 ECM in "Guided Functions" under "replace engine control module". Use a vehicle diagnosis tester for this.

FUEL INJECTORS

Special Tools and workshop equipment required

1. Tool Set T10133
2. Puller T10133/2A
3. Hammer T10133/3
4. Nylon Cylinder Brush T10133/4
5. Assembly Cone T10133/5
6. Assembly Sleeve T10133/6
7. Sizing Sleeve T10133/7
8. Sizing Sleeve T10133/8
9. Removal Tool T10133/16

Removing

Reduce the fuel pressure in high pressure area. Refer to RELEASING PRESSURE IN HIGH PRESSURE AREA .

Remove the supercharger. Refer to Removal and Installation .

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

Position the T10133/2A in the groove on the fuel injector.

Scheme 145

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

Disassemble the Fuel Injector

Scheme 146

Remove the support ring -4-, O-ring -3- and spacer ring -2- from the fuel injector -1-.

Remove the circlip -7- and upper sealing washer -5- and lower sealing washer -6-.

Carefully remove the old combustion chamber seal -8- by cutting the sealing ring with a knife and prying it open with a small screwdriver.

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 combustion chamber seal and O-ring. Replace spacer ring if damaged. Lightly coat the fuel injector O-rings with clean engine oil. Install the cylinder at the same cylinder.

Clean the bore in cylinder head with T10133/4.

Scheme 147

Place the T10133/5 with a new combustion chamber seal -1- from the repair Set onto the fuel injector -2-.

Scheme 148

Slide the combustion chamber seal as far possible onto the T10133/5 using T10133/6.

Scheme 149

Turn the T10133/6 around and slide the 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 the T10133/7 with a slight turning motion (approximately 180°) onto the fuel injector until it stops.

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

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

Scheme 150

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

Install the parts form the repair Set on the injector valve -1

2 - Spacer ring

3 - O-ring

4 - Support ring

5 - Upper sealing washer - note installation position

6 - Lower sealing washer - note installation position

7 - Circlip - do not overstretch

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

Note. The combustion chamber seal -8- must not be oiled.

Press the fuel injector by hand into the bore in the cylinder head (free of oil and grease) until it stops. Make sure the fuel injectors are positioned correctly in cylinder head.

Note. The fuel injector must not be difficult to install. If necessary, wait as the seal continues to pull itself together. Check the fuel injectors for correct seating and installation position in cylinder head. If it is difficult to install the fuel injector by hand use the T10133/2A -2- with the T10133/3.

1. The electrical connection of the fuel injector must engage in the intended recess of the cylinder head.
2. Coat the high pressure fuel injector O-rings with clean engine oil so they are easier to guide into the fuel rail.
3. Replace all seals.

Further installation is performed in reverse order of removal, noting the following

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

Install the supercharger. Refer to Removal and Installation .

HEATED OXYGEN SENSOR -G39

Special Tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Remove the rear engine cover -2- upward.

Free up the fuel line -4- and hose connection -1- from the EVAP canister on the air filter housing and on the air guide tube.

Scheme 151

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

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

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

Disconnect the connector -4- on the Heated Oxygen Sensor (HO2S) 2 -G39- and free up the wire.

Remove the HO2S 2 -2- using a Tool from the 3337.

Note. To provide a better illustration, component location is shown from behind with engine removed.

Installing

Install in reverse order, paying attention to the following

Note. Coat new oxygen sensors with an assembly paste. When installing the previous oxygen sensor, coat the thread with hot bolt paste. Assembly paste or hot bolt paste must not enter the slots on the oxygen sensor body. Always install the oxygen sensor wire in the same location so it does not come into contact with the exhaust pipe. When installing, bring all cable ties back to same positions.

1. Tightening specifications: Heated oxygen sensors, assembly overview, refer to «OXYGEN SENSORS OVERVIEW»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__oxygen-sensors-overview)

HEATED OXYGEN SENSOR 2 -G108

Special Tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Remove the rear engine cover -2- upward.

Remove bolt -arrow-.

Scheme 152

Disconnect the 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- attached.

Disconnect the connector -2- on the Heated Oxygen Sensor (HO2S) 2 -G108- and free up the wire.

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

Note. To provide a better illustration, component location is shown from behind with engine removed.

Installing

Install in reverse order, paying attention to the following

Note. Coat new oxygen sensors with an assembly paste. When installing the previous oxygen sensor, coat the thread with hot bolt paste. Assembly paste or hot bolt paste must not enter the slots on the oxygen sensor body. Always install the oxygen sensor wire in the same location so it does not come into contact with the exhaust pipe. When installing, bring all cable ties back to same positions.

1. Tightening specifications: Heated oxygen sensors, assembly overview, refer to «OXYGEN SENSORS OVERVIEW»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__oxygen-sensors-overview)

HIGH PRESSURE LINE

Special Tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Tool Insert, AF 17 V.A.G 1331/6

Removing

Reduce fuel pressure in high pressure area. Refer to RELEASING PRESSURE IN HIGH PRESSURE AREA .

Remove the supercharger. Refer to Removal and Installation .

Remove the front secondary air hose -arrow- from its bracket and disconnect it; to do this, press the release buttons.

Scheme 153

Remove the bolts -arrows- and move the intake manifold runner position sensor -G336- and the intake flap vacuum actuator to the side.

Note. Ignore -1-. Cylinder bank 2 (left) is shown in the illustration.

Remove the bolts -arrows- and threaded connection -1-.

Scheme 154

Remove the union nuts -2 and 3- while counter holding the threaded connection.

Note. Do not change the bent shape of the high pressure line.

Installing

1. Tightening specifications: High pressure Pump assembly overview, refer to «HIGH PRESSURE Pump OVERVIEW»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan)

Note. High pressure line connections must not show any signs of damage. Do not change the bent shape of the high pressure line.

First tighten the union nut by hand making sure that it contact the high pressure line free-of-stress.

Scheme 155

Counter hold the fuel rail using an open-end wrench on the threaded connection and tighten the union nut using a V.A.G 1331 and a V.A.G 1331/6.

First tighten the bolt of the retaining strap, after that, the high pressure line is tightened.

Install the supercharger. Refer to Removal and Installation .

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 Insert AF 14 V.A.G 1331/8

Removing

Note. The high pressure Pump can only be removed and installed when the engine is cold. When installing, 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.

Reduce fuel pressure in high pressure area. Refer to RELEASING PRESSURE IN HIGH PRESSURE AREA .

Remove the air duct -1-.

Remove the nuts -arrows- and the protective plate -1-.

Scheme 156

Disconnect the connectors -1 and 6-.

Scheme 157

Remove the bolt -3- on the retaining clamp.

Remove the threaded connections -2 and 5-.

Remove the bolts -arrows-.

Carefully pull out the high-pressure fuel Pump. The Sleeve can remain installed.

Note. Do not change bent shape. Ignore -4-.

Installing

Install in reverse order, paying attention to the following

Note. High pressure line connections must not show any signs of damage. Do not bend the high pressure line to a different angle.

Replace the O-ring for the high-pressure Pump.

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

Scheme 158

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

Rotate the 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.

Tighten the bolts on the high pressure Pump hand-tight.

Tighten the bolts crosswise with the required torque.

1. Tightening specifications: High pressure Pump assembly overview, refer to «HIGH PRESSURE Pump OVERVIEW»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan)

Install the high pressure line -2 and 5-. Refer to HIGH PRESSURE LINE .

Connect the connectors -1 and 6-.

Remove the bolt -3- on the clamp.

Note. Check fuel system for leaks.

INTAKE MANIFOLD LOWER SECTION, WITH FUEL RAIL

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
3. Hand Vacuum Pump VAS 6213

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.

Reduce the fuel pressure in high pressure area. Refer to RELEASING PRESSURE IN HIGH PRESSURE AREA .

Remove the supercharger. Refer to Removal and Installation .

Push the vacuum hoses to the side.

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

Remove the union nut -1- while counter holding the threaded connection.

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

Disconnect the connector -2- on the intake manifold runner position sensor and remove the vacuum hose -3-.

Installing

Install in reverse order, paying attention to the following

Note. If a fuel injector was removed form the cylinder head, then the Teflon® seal must be replaced. Replace the seals and the O-rings. Coat the fuel injector O-rings lightly with clean engine oil.

Move the intake manifold flaps in direction of -arrow- when installing the intake manifold lower section.

Scheme 159

Connect VAS 6213 to intake manifold runner control vacuum actuator, as shown in the illustration.

Scheme 160

Generate vacuum using hand vacuum Pump.

1. The intake flaps are opened.

Note. If the intake manifold flaps are not opened, they may get jammed when installing the intake manifold lower section on the cylinder head.

Press the intake manifold lower section evenly on the fuel injectors.

Tighten the bolts and nuts in a diagonal sequence on the intake manifold lower section according to the tightening specification.

1. Intake manifold lower section tightening specification. (Scheme 120)

Remove hand vacuum Pump from the intake manifold runner control vacuum actuator.

Connect the fuel pressure sensor connector -4-.

Counter hold the threaded connection and tighten the union nut -1-.

1. Tightening Specifications: Intake manifold lower section assembly overview, refer to «LOWER INTAKE MANIFOLD SECTION OVERVIEW»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan)

Make sure the high pressure line is free of tension.

Install the supercharger. Refer to Removal and Installation .

OXYGEN SENSOR AFTER THREE WAY CATALYTIC CONVERTER -G130

Special Tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Remove the rear engine cover -2- upward.

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

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

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

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

Disconnect the connector -5- on the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) and free up the wire.

Remove the O2S after TWC converter -3- using a Tool from the 3337.

Note. To provide a better illustration, component location is shown from behind with engine removed.

Installing

Install in reverse order, paying attention to the following

Note. Coat new oxygen sensors with an assembly paste. When installing the previous oxygen sensor, coat the thread with hot bolt paste. Assembly paste or hot bolt paste must not enter the slots on the oxygen sensor body. Always install the oxygen sensor wire in the same location so it does not come into contact with the exhaust pipe. When installing, bring all cable ties back to same positions.

1. Tightening specifications: Heated oxygen sensors, assembly overview, refer to «OXYGEN SENSORS OVERVIEW»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__oxygen-sensors-overview)

OXYGEN SENSOR 2 AFTER CATALYTIC CONVERTER -G131

Special Tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Remove the rear engine cover -2- upward.

Remove bolt -arrow-.

Disconnect the 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- attached.

Disconnect the connector -1- on the Oxygen Sensor (O2S) 2 after catalytic converter and free up the wire.

Remove the noise insulation, to do this, loosen the mounting parts -1, 2, arrow-.

Scheme 161

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

Note. To provide a better illustration, component location is shown from behind with engine removed.

Installing

Install in reverse order, paying attention to the following

Note. Coat new oxygen sensors with an assembly paste. When installing the previous oxygen sensor, coat the thread with hot bolt paste. Assembly paste or hot bolt paste must not enter the slots on the oxygen sensor body. Always install the oxygen sensor wire in the same location so it does not come into contact with the exhaust pipe. When installing, bring all cable ties back to same positions.

1. Tightening specifications: Heated oxygen sensors, assembly overview, refer to «OXYGEN SENSORS OVERVIEW»(/audi/s4/b8-2011-2015/remont/fuel-system/#30l-multiport-fuel-injection-engine-codes-ccba-sedan__oxygen-sensors-overview)

Install the noise insulation. Refer to "Underbody Trim" in Description and Operation .

THROTTLE VALVE CONTROL MODULE -J338

Removing

Remove the rear engine cover -2- upward.

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

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

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

Disconnect the connector -1-.

Remove bolts -arrows- and remove throttle valve control module with the intermediate flange.

Installing

Install in reverse order, paying attention to the following

Note. Replace the O-rings.

Install the intermediate flange -2- and O-rings into the supercharger -1- -left arrows-.

Scheme 162

Install the throttle valve control module -3- on the intermediate flange -right arrows-.

1. Tightening specification: 10 Nm

After replacing the throttle valve control module perform an Adaptation in Guided Functions using a vehicle diagnostic tester.

SPECIAL TOOLS

Special Tools and workshop equipment required

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

1. Ring Spanner 7-Piece Set 3337
2. Tool Set T10133
3. Release Tool f/ Rev. Light Switch Conn.T40138
4. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
5. Adapter V.A.G 1318/10-12
6. Torque Wrench 5-50 Nm V.A.G 1331
7. Ratchet, Reversible V.A.G 1331/1
8. Tool Insert, AF 17 V.A.G 1331/6
9. Remote Control V.A.G 1348/3A with Remote Control for VAG 1348 V.A.G 1348/3-3
10. Adapter Lead - V.A.G 1598/39-1
11. Adapter Lead - V.A.G 1598/39-2
12. Test Box 105 Pin - V.A.G 1598/42
13. Hot Air Blower VAS 1978/14A -1- with Nozzle Attachment -2- from the Wiring Harness Repair Set VAS 1978 B
14. Small commercially available locking pliers -3
15. Hand Vacuum Pump VAS 6213
16. Not illustrated
17. Trim Removal Wedge 3409
18. Puller T10133/2A
19. Hammer T10133/3
20. Nylon Cylinder Brush T10133/4
21. Assembly Cone T10133/5
22. Assembly Sleeve T10133/6
23. Sizing Sleeve T10133/7
24. Sizing Sleeve T10133/8
25. Removal Tool T10133/16
26. Ring Spanner Insert V.A.G 1331/2
27. Socket Insert AF 14 V.A.G 1331/8
28. Connector Test Set V.A.G 1594C

See also:
• Removal and Installation
• MAINTENANCE, DIAGNOSIS
• Description and Operation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Description and Operation
• RELEASING PRESSURE IN HIGH PRESSURE AREA
• AIR FILTER
• Heated Oxygen Sensor -G39
• Oxygen Sensor after Three Way Catalytic Converter -G130
• Control Valve Control Unit -J808
• Throttle Valve Control Module -J338
• FUEL INJECTORS
• HIGH PRESSURE Pump
• Oxygen Sensor 2 after Catalytic Converter -G131
• Heated Oxygen Sensor 2 -G108
• Engine Control Module -J623
• HIGH PRESSURE LINE
• INTAKE MANIFOLD LOWER SECTION, WITH FUEL RAIL
• LOWER INTAKE MANIFOLD SECTION OVERVIEW
• OXYGEN SENSORS OVERVIEW