4.2l - Fuel Injection System - Engine Code(s): Caua (coupe) Audi S5 I

SAFETY PRECAUTIONS

If special testing equipment is required during a road test, note the following

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

Scheme 175

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

CLEAN WORKING CONDITIONS

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

1. Before loosening, connections and surrounding areas must be cleaned thoroughly with engine or brake cleaner, and then cleaned area must be dried completely.
2. Plug open lines and connections immediately with appropriate protective caps.
3. Place parts that have been removed on a clean surface and cover them. Use lint-free cloths.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (for example in tool boxes etc.).
5. When the system is open: Do not work with compressed air. Do not move vehicle.

ON BOARD DIAGNOSTICS

1. The engine control module is equipped with a DTC memory.
2. The DTC memory should be checked before every repair or every fault finding session.
3. Check the vacuum hoses and connections (unmetered air).
4. Fuel hoses in engine compartment must only be secured with spring-type clips. The use of clamp or screw type clips is not permissible.
5. For the electric components to work properly, a voltage of at least 11.5 Volts is required.
6. 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.
7. The vehicles have a crash fuel shut-off. This function reduces the risk of fire during a collision because the fuel pump relay switches the fuel pump off.
8. This setup also makes it easier to start the engine. The fuel pump runs for approximately 2 seconds when the driver door opens to build pressure in the fuel system. Refer to «SAFETY PRECAUTIONS»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__safety-precautions) .

BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM

High fuel pressure, reducing

Connect Vehicle Diagnosis, testing & info. system VAS 5051B.

Scheme 176

Start engine and run at idle speed.

Select "engine electronics" in OBD.

Then select "Measured values".

Select "Fuel pressure" from the list.

When the engine is at idle, fuel pressure between 30 and 40 bar is displayed.

Pry off the cover -1- on the left of the instrument panel, for example using the Trim Removal Wedge 3409 -arrow-.

Scheme 177

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

Check fuel pressure.

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

Switch the ignition off as soon as the fuel pressure drops 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).

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

Perform the following steps are completing all work

Install the fuse.

Erase the DTC memory and, using "Guided Fault Finding", generate the readiness code in the engine control module Vehicle Diagnosis, Testing and Information System VAS 5051B.

Scheme 178

1. Bolt 9 Nm
2. Intake Flap Motor -V157- Beginning with MY 2009, the Variable Intake Manifold Runner Motor -V157- has become the Intake Manifold Tuning Valve -N316
3. Bolt 9 Nm
4. Variable Intake Manifold Runner Motor -V183- Beginning with MY 2009, the Variable Intake Manifold Runner Motor -V183- has become the Intake Manifold Tuning Valve -N156
5. Circlip
6. Bolt 2.5 Nm
7. Intake Manifold Runner Position Sensor -G336- Right cylinder bank After replacing, perform "Adaptation" in "Guided Fault Finding" Vehicle Diagnostic, Testing, and Information System VAS 5051B.
8. Gasket Replace if damaged Open side faces Intake Manifold Runner Position Sensor -G336
9. Intake manifold Removing and installing, refer to «INTAKE MANIFOLD»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__intake-manifold)
10. O-ring Replace
11. Intake tube With crankcase housing ventilation connection
12. Bolt 9 Nm
13. Throttle Valve Control Module -J338- After replacing, perform "Adaptation" in "Guided Fault Finding" Vehicle Diagnostic, Testing, and Information System VAS 5051B.
14. O-ring Replace
15. O-ring Replace
16. Bolt 9 Nm
17. Crankcase housing ventilation pressure regulator valve
18. Bracket For vacuum hose
19. Bolt 9 Nm
20. Bolt 9 Nm
21. Bolt Tightening specification and sequence (Scheme 179)
22. Intake manifold seals Replace
23. Gasket Replace if damaged. open side faces Intake Manifold Runner Position Sensor 2 -G512
24. Intake Manifold Runner Position Sensor 2 -G512- Left cylinder bank After replacing, perform "Adaptation" in "Guided Fault Finding" vehicle diagnostic, testing, and information system VAS 5051B.
25. Bolt 2.5 Nm
26. Circlips

Scheme 179

Tighten intake manifold bolts in -1 through 10- sequence.

1. First tightening: 8 Nm
2. Second tightening: 9 Nm and tighten another 90 degrees.

Scheme 180

1. Radial adjustment Replace if damaged Clip together with support ring, see item 6
2. Combustion chamber seal Do not grease ring or treat with any other lubricant Replacing, refer to «FUEL INJECTORS»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__fuel-injectors) .
3. Fuel injector Removing and installing, refer to «FUEL INJECTORS»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__fuel-injectors)
4. Spacer ring Replacing, refer to «FUEL INJECTORS»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__fuel-injectors) . The fuel rail wields force via the support ring to hold the fuel injector tightly in the cylinder head.
5. O-ring Replace Coat with clean engine oil
6. Support ring Replace The fuel rail wields force via the support ring to hold the fuel injector tightly in the cylinder head.
7. Fuel rail Removing and installing, refer to «FUEL INJECTORS»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__fuel-injectors)
8. High-pressure line WARNING: Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure. Refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__before-opening-high-pressure-fuel-injection) . Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection. Connectors should not show any signs of damage Do not change bend shape 25 Nm
9. High-pressure line WARNING: Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure. Refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__before-opening-high-pressure-fuel-injection) . Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection. Connectors should not show any signs of damage Do not change bend shape 25 Nm High pressure lines, installing, refer to «HIGH PRESSURE LINES, INSTALLING»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__high-pressure-lines-installing)
10. Pressure relief valve 140 bar For high pressure line 25 Nm
11. Bolt 9 Nm Fasten in diagonal sequence in steps
12. Bolt 9 Nm Fasten in diagonal sequence in steps

Scheme 181

1. Tightening specifications: 25 Nm

Scheme 182

1. Bracket For the flange and fuel rail
2. Gasket Replace
3. Sleeve
4. Intake manifold lower section The intake manifold flaps must be all the way open in the intake manifold channel when the intake manifold lower section is being installed Removing and installing, refer to «INTAKE MANIFOLD, LOWER SECTION, WITH FUEL RAIL»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__intake-manifold-lower-section-with-fuel) 10 Nm
5. Support ring Replace if damaged Make sure it fits correctly when installed
6. O-ring Replace Coat with clean engine oil
7. Spacer ring Replace if damaged
8. Fuel injector Removing and installing, refer to «FUEL INJECTORS»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe)
9. Combustion chamber seal Do not grease ring or treat with any other lubricant Replace
10. Actuator lever For the vacuum actuator
11. Seal Replace if damaged Lift out with screwdriver to replace Press in by hand
12. Vacuum hose From the Intake Manifold Runner Control (IMRC) Valve -N316
13. Intake manifold runner control vacuum actuator
14. Intake Manifold Runner Position Sensor 2 -G512
15. Bolts 2.5 Nm
16. Threaded support 40 Nm
17. Cover For the spray nozzle valve and the oil check valve Removing and installing, refer to «Removal and Installation»(ref-520137-S10687647062012123100000)
18. To vacuum reservoir
19. High pressure fuel line
20. Bolts 9 Nm
21. Fuel rail Removing and installing, refer to «INTAKE MANIFOLD, LOWER SECTION, WITH FUEL RAIL»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__intake-manifold-lower-section-with-fuel)
22. Bolts 9 Nm
23. Bolts 9 Nm
24. Bolts 0.3 Nm

FUEL INJECTORS AND FUEL RAIL ASSEMBLY OVERVIEW

Note. The right fuel rail (cylinder bank 1) is shown in the illustration.

Scheme 183

1. Bolts 0.3 Nm
2. Bracket For the flange and fuel rail
3. Support ring Replace if damaged Clip together with support ring, see item 8
4. O-ring Replace Coat with clean engine oil
5. Spacer ring Replace if damaged
6. Fuel injector Removing and installing, refer to «FUEL INJECTORS»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe)
7. Combustion chamber seal Do not grease ring or treat with any other lubricant Replace
8. Support ring Replace The fuel rail wields force via the support ring to hold the fuel injector tightly in the cylinder head.
9. Fuel rail Removing and installing, refer to «INTAKE MANIFOLD, LOWER SECTION, WITH FUEL RAIL»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__intake-manifold-lower-section-with-fuel)
10. Fuel Pressure Sensor -G247- Coat the sealing ball with oil 25 Nm
11. Intake manifold lower section Removing and installing, refer to «INTAKE MANIFOLD, LOWER SECTION, WITH FUEL RAIL»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__intake-manifold-lower-section-with-fuel) 10 Nm

Scheme 184

1. Vacuum hose with check valve
2. Intake manifold flap vacuum actuator For cylinder bank 1 Check with Hand Vacuum Pump VAS 6213
3. Intake manifold flap 2 vacuum actuator For cylinder bank 2 Check with Hand Vacuum Pump VAS 6213
4. Intake Manifold Tuning (IMT) Valve -N156
5. Intake manifold change-over valve vacuum actuator Check with Hand Vacuum Pump VAS 6213
6. Intake Manifold Runner Control (IMRC) Valve -N316- To remove and install, remove intake manifold
7. To vacuum reservoir Component location: under the intake manifold To remove and install, remove intake manifold
8. To vacuum reservoir

COMPONENT LOCATION OVERVIEW

Right side of the engine compartment

Scheme 185

1. Mass Air Flow (MAF) Sensor -G70- /Intake Air Temperature (IAT) Sensor -G42- Removing and installing, refer to «MASS AIR FLOW SENSOR»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe).
2. Camshaft Adjustment Valve 1 (exhaust) -N318- 2.4 Nm
3. Electrical connectors for Heated Oxygen Sensor (HO2S) -G39- before catalytic converter with Oxygen Sensor (O2S) Heater -Z19- Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- with Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater -Z29- Component location (Scheme 191)
4. Camshaft Adjustment Valve 1 -N205- Component location (Scheme 198)2.4 Nm
5. Throttle Valve Control Module -J338- connector
6. Throttle valve control module -J338- After replacing the Throttle Valve Control Module -J338-, select "adapt throttle valve control module" in "Guided Functions".
7. Knock Sensor (KS) 2 -G66- Component location (Scheme 198)Electrical harness connector (Scheme 202)Removing and installing, refer to «KNOCK SENSORS»(ref-520193-S11157897532012123100000) 20 Nm
8. Fuel Pressure Sensor -G247- Component location (Scheme 198)Removing and installing, refer to «FUEL PRESSURE SENSOR»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe) 25 Nm Coat the thread with clean oil
9. Knock Sensor (KS) 1 -G61- Component location (Scheme 198)Electrical harness connector (Scheme 202)Removing and installing, refer to «KNOCK SENSORS»(ref-520193-S11157897532012123100000) 20 Nm
10. Components on front of engine Locations (Scheme 202)Intake Flap Motor -V157- Beginning with MY 2009, the Variable Intake Manifold Runner Motor -V157- has become the Intake Manifold Tuning Valve -N316- Intake Manifold Runner Position Sensor -G336- Variable Intake Manifold Runner Motor -V183- Beginning with MY 2009, the Variable Intake Manifold Runner Motor -V183- has become the Intake Manifold Tuning Valve -N156- Intake Manifold Runner Position Sensor 2 -G512- Electrical connector from Knock Sensor (KS) 4 -G199- Electrical connector from Knock Sensor (KS) 3 -G198- Electrical connector from Knock Sensor (KS) 1 -G61- Electrical connector from Knock Sensor (KS) 2 -G66- Oil Pressure Switch -F1- for checking removing and installing, refer to «Removal and Installation»(ref-520137-S10687647062012123100000)
11. Camshaft Position (CMP) sensor -G40- Component location (Scheme 198)Removing and installing, refer to «CAMSHAFT POSITION SENSOR»(ref-520193-S06392965372012123100000) 10 Nm
12. Fuel Metering Valve -N290- Component location (Scheme 204)
13. High pressure pump With Fuel Metering Valve -N290- Component location (Scheme 204)Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__high-pressure-pump)
14. 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- Ignition Coil 4 with Power Output Stage -N292- Removing and installing, refer to «IGNITION COILS»(ref-520193-S23850162282012123100000)
15. Camshaft Position (CMP) Sensor 3 -G300- Attached to outside of cylinder head Component location (Scheme 196)Removing and installing, refer to «CAMSHAFT POSITION SENSOR»(ref-520193-S06392965372012123100000) 10 Nm
16. Secondary Air Injection (AIR) Pump Motor -V101- Component location (Scheme 206)Removing and installing, refer to «Removal and Installation»(/audi/s5/i-2007-2011/remont/exhaust/#42l-exhaust-system-emission-controls-engine-codes-caua-coupe)
17. Intake Air Switch-Over Valve -N335- Component location (Scheme 195)

Left side of the engine compartment

Components A through J are not shown in the exploded view.

Scheme 186

1. Fuel Metering Valve 2 -N402- Common component with high pressure pump Component location (Scheme 204)
2. Low Fuel Pressure Sensor -G410- Component location (Scheme 204)
3. Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- Component location (Scheme 205)Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 -N115
4. Camshaft Adjustment Valve 2 -N208- Component location (Scheme 200)2.4 Nm
5. High pressure pump With Fuel Metering Valve 2 -N402- Component location (Scheme 204)
6. Electrical connectors for Heated Oxygen Sensor (HO2S) 2 -G108- before catalytic converter with Oxygen Sensor (O2S) 2 Heater -Z28- Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- with Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater -Z30- Component location (Scheme 192)
7. Camshaft Adjustment Valve 2 (exhaust) -N319- Component location (Scheme 197)2.4 Nm
8. Engine Control Module -J623- Component location (Scheme 187)Removing and installing, refer to «ENGINE CONTROL MODULE»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__engine-control-module)
9. Camshaft position (CMP) sensor 4 -G301- Component location (Scheme 197)Removing and installing, refer to «CAMSHAFT POSITION SENSOR»(ref-520193-S06392965372012123100000) 10 Nm
10. Ignition coils, Cylinder bank 2 Ignition Coil 5 with Power Output Stage -N323- Ignition Coil 6 with Power Output Stage -N324- Ignition Coil 7 with Power Output Stage -N325- Ignition Coil 8 with Power Output Stage -N326- Component location (Scheme 197)Removing and installing, refer to «IGNITION COILS»(ref-520193-S23850162282012123100000)
11. Electrical harness connectors Knock Sensor (KS) 3 -G198- Knock Sensor (KS) 4 -G199
12. Camshaft position (CMP) sensor 2 -G163- Component location (Scheme 200)Removing and installing, refer to «CAMSHAFT POSITION SENSOR»(ref-520193-S06392965372012123100000) 10 Nm
13. Knock Sensor (KS) 3 -G198- Component location (Scheme 200)Removing and installing, refer to «KNOCK SENSORS»(ref-520193-S11157897532012123100000) 20 Nm
14. Knock Sensor (KS) 4 -G199- Component location (Scheme 200)Removing and installing, refer to «KNOCK SENSORS»(ref-520193-S11157897532012123100000) 20 Nm
15. Components on front of engine Electrical harness connector (Scheme 202)Intake Flap Motor -V157- Beginning with MY 2009, the Variable Intake Manifold Runner Motor -V157- has become the Intake Manifold Tuning Valve -N316- Intake Manifold Runner Position Sensor -G336- Variable Intake Manifold Runner Motor -V183- Beginning with MY 2009, the Variable Intake Manifold Runner Motor -V183- has become the Intake Manifold Tuning Valve -N156- Intake Manifold Runner Position Sensor 2 -G512- Electrical connector from Knock Sensor (KS) 4 -G199- Electrical connector from Knock Sensor (KS) 3 -G198- Electrical connector from Knock Sensor (KS) 1 -G61- Electrical connector from Knock Sensor (KS) 2 -G66
16. A - Engine Coolant Temperature (ECT) Sensor -G62- Component location (Scheme 194)Removing and installing, refer to «Removal and Installation»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe)
17. B - Engine Speed (RPM) Sensor -G28- Component location (Scheme 193)Removing and installing, refer to «ENGINE SPEED SENSOR»(ref-520193-S10749841032012123100000)
18. C - Throttle Position (TP) Sensor -G79- /Accelerator Pedal Position Sensor 2 -G185- in footwell on accelerator pedal (both sensors are integrated into one housing) Component location (Scheme 190) Removing and installing «Removal and Installation»(/audi/s5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-cala-caua-coupe-as-of-042008)
19. D - Brake Light Switch -F- /Brake Pedal Switch -F47- In footwell at brake pedal Removing and installing, refer to «Removal and Installation»(/audi/s5/i-2007-2011/remont/anti-locktraction-control/#anti-lock-brake-system-coupe)
20. E - Clutch Position Sensor -G476- The following components are integrated in the Clutch Position Sensor -G476-: Clutch Pedal Starter Interlock Switch -F194- and Clutch Vacuum Vent Valve Switch -F36- Only for vehicles with manual transmission In footwell on clutch pedal
21. F - Fuel Pump (FP) Control Module -J538- Component location (Scheme 188)
22. G - Heated Oxygen Sensor (HO2S) -G39- before catalytic converter with Oxygen Sensor (O2S) Heater -Z19- Location of electrical connector (Scheme 191)Component location of oxygen sensors (Scheme 191)Removing and installing, refer to «HEATED OXYGEN SENSOR IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 1»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__heated-oxygen-sensor-in-front-of) Tightening Specifications, refer to «OXYGEN SENSORS ASSEMBLY OVERVIEW»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe)
23. H - Heated Oxygen Sensor (HO2S) 2 -G108- before catalytic converter with Oxygen Sensor (O2S) 2 Heater -Z28- Location of electrical connector (Scheme 192)Component location of oxygen sensors (Scheme 192)Removing and installing, refer to «HEATED OXYGEN SENSOR IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 1»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__heated-oxygen-sensor-in-front-of) Tightening Specifications, refer to «OXYGEN SENSORS ASSEMBLY OVERVIEW»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe)
24. I - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- with Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater -Z29- Location of electrical connector (Scheme 191)Component location of oxygen sensors (Scheme 191)Removing and installing, refer to «HEATED OXYGEN SENSOR IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 1»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__heated-oxygen-sensor-in-front-of) Tightening Specifications, refer to «OXYGEN SENSORS ASSEMBLY OVERVIEW»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe)
25. J - Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- with Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater -Z30- Location of electrical connector (Scheme 192)Component location of oxygen sensors (Scheme 191)Removing and installing, refer to «HEATED OXYGEN SENSOR IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 1»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__heated-oxygen-sensor-in-front-of) Tightening Specifications, refer to «OXYGEN SENSORS ASSEMBLY OVERVIEW»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe)

Scheme 187

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

Removing and installing, refer to ENGINE CONTROL MODULE .

Scheme 188

Removing and installing, refer to Removal and Installation .

Scheme 189

A - Engine Component Power Supply Relay -J757

B - Starter Relay -J53- (black/purple socket color)

B - Starter Relay 2 -J695- (black/blue socket color)

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

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

E - Coolant circulation pump relay -J151- (brown/blue socket color)

E - Brake Booster Relay -J569- (brown/purple socket color)

Refer to appropriate SYSTEM WIRING DIAGRAM.

Scheme 190

Scheme 191

1. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130
2. Oxygen sensor (O2S) behind three way catalytic converter (TWC) -G130- connector
3. Oxygen sensor -G39- connector
4. Oxygen sensor -G39

Removing and installing, refer to HEATED OXYGEN SENSOR IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 1 .

1. Tightening Specifications, refer to «OXYGEN SENSORS ASSEMBLY OVERVIEW»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe) .

Scheme 192

1. Heated Oxygen Sensor (HO2S) 2 -G108
2. Oxygen Sensor 2 -G108- connector
3. Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- connector
4. Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131

Removing and installing, refer to HEATED OXYGEN SENSOR 2 IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR 2 BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 2 .

1. Tightening Specifications, refer to «OXYGEN SENSORS ASSEMBLY OVERVIEW»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe) .

Scheme 193

The Engine Speed Sensor -G28- is located in the transmission at the bottom.

Scheme 194

Removing and installing, refer to Removal and Installation .

Scheme 195

Scheme 196

1. Camshaft Position (CMP) Sensor 3 -G300
2. Camshaft Adjustment Valve 1 (exhaust) -N318
3. Ignition Coil 4 with Power Output Stage -N292
4. Ignition Coil 3 with Power Output Stage -N291
5. Ignition Coil 2 with Power Output Stage -N127
6. Ignition Coil 1 with Power Output Stage -N70

Scheme 197

1. Ignition Coil 5 with Power Output Stage -N323
2. Ignition Coil 6 with Power Output Stage -N324
3. Ignition Coil 7 with Power Output Stage -N325
4. Ignition Coil 8 with Power Output Stage -N326
5. Camshaft Adjustment Valve 2 (exhaust) -N319
6. Camshaft position (CMP) sensor 4 -G301

Scheme 198

1. Fuel Pressure Sensor -G247
2. Knock Sensor (KS) 1 -G61
3. Camshaft Position (CMP) Sensor -G40
4. Cylinder 1 Fuel Injector -N30
5. Cylinder 2 Fuel Injector -N31
6. Cylinder 3 Fuel Injector -N32
7. Cylinder 4 Fuel Injector -N33
8. Camshaft Adjustment Valve 1 -N205
9. Knock Sensor (KS) 2 -G66

Installation locations, on the inside on the right cylinder head (beginning with MY 2009), see next illustration.

Scheme 199

1. Intake Manifold Runner Position Sensor -G336
2. Camshaft Position (CMP) sensor -G40
3. Fuel Metering Valve -N290
4. Camshaft Adjustment Valve 1 -N205
5. Low Fuel Pressure Sensor -G410
6. Cylinder 1 Fuel Injector -N30
7. Cylinder 2 Fuel Injector -N31
8. Cylinder 3 Fuel Injector -N32
9. Cylinder 4 Fuel Injector -N33
10. Fuel Pressure Sensor -G247
11. Intake Manifold Runner Control (IMRC) Valve -N316
12. Knock Sensor (KS) 1 -G61
13. Knock Sensor (KS) 2 -G66

Scheme 200

1. Knock Sensor (KS) 4 -G199
2. Camshaft Adjustment Valve 2 -N208
3. Camshaft position (CMP) sensor 2 -G163
4. Cylinder 8 Fuel Injector -N86
5. Cylinder 7 Fuel Injector -N85
6. Cylinder 6 Fuel Injector -N84
7. Cylinder 5 Fuel Injector -N83
8. Knock Sensor (KS) 3 -G198

Installation locations, on the inside on the left cylinder head (beginning with MY 2009), see next illustration.

Scheme 201

1. Camshaft Adjustment Valve 2 -N208
2. Fuel metering valve 2 -N402- (inside the high pressure pump)
3. Camshaft position (CMP) sensor 2 -G163
4. Intake Manifold Runner Position Sensor 2 -G512
5. Cylinder 5 Fuel Injector -N83
6. Cylinder 6 Fuel Injector -N84
7. Cylinder 7 Fuel Injector -N85
8. Cylinder 8 Fuel Injector -N86
9. Low Fuel Pressure Sensor -G410
10. Knock Sensor (KS) 4 -G199
11. Knock Sensor (KS) 3 -G198

Scheme 202

1 - Right high pressure pump (cylinder bank 1)

2 - Variable Intake Manifold Runner Motor -V183

3 - Intake Flap Motor -V157

4 - Left high pressure pump (cylinder bank 2)

5 - Intake Manifold Runner Position Sensor 2 -G512

6 - Electrical connector from Knock Sensor (KS) 4 -G199

7 - Electrical connector from Knock Sensor (KS) 3 -G198

8 - Oil pressure switch -F1

9 - Electrical connector from Knock Sensor (KS) 2 -G66

10 - Electrical connector from Knock Sensor (KS) 1 -G61

11 - Intake Manifold Runner Position Sensor -G336

Beginning in MY 2009, items -2 and 3- have been replaced by vacuum-controlled valves.

1. The Variable Intake Manifold Runner Motor -V183- has become the Intake Manifold Tuning Valve -N156-.
2. The Intake Flap Motor -V157- has become the Intake Manifold Runner Control Valve -N316-.

Scheme 203

1 - Knock Sensor (KS) 2 -G66- (brown connector)

2 - Knock Sensor (KS) 1 -G61- (black connector)

3 - Fuel Metering Valve -N290

4 - Intake Manifold Runner Position Sensor -G336

5 - Fuel Pressure Sensor -G247

6 - Intake manifold runner control valve -N316- (CVTS tumble flaps)

7 - Intake Manifold Tuning (IMT) Valve -N156

8 - Intake Manifold Runner Position Sensor 2 -G512

9 - Fuel Metering Valve -N290

10 - Knock Sensor (KS) 4 -G199- (black connector)

11 - Knock Sensor (KS) 3 -G198- (brown connector)

Scheme 204

1 - Right high pressure pump (cylinder bank 1)

2 - Low Fuel Pressure Sensor -G410

3 - Left high pressure pump (cylinder bank 2)

4 - Fuel Metering Valve 2 -N402

5 - Fuel Metering Valve -N290

Scheme 205

Scheme 206

Scheme 207

1. Hose clamp
2. Air guide hose To Throttle Valve Control Module -J338- Note the marking when installing the arrow on the air guide hose points toward the screw on the Throttle Valve Control Module -J338
3. Hose clamp
4. Mass Air Flow (MAF) Sensor Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42-, removing and installing, refer to «MASS AIR FLOW SENSOR»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe)
5. O-ring Replace if damaged
6. Air filter element Always use a genuine air filter element Maintenance intervals, refer to 811 Service Procedures Removing and installing, refer to «AIR FILTER ELEMENT»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe) . Clean snow screen also (if present)
7. Air duct Clipped into upper section of air filter Make sure it is clipped correctly (unmetered air) Clean air duct of dirt and leaves
8. Air duct Clean air duct of dirt and leaves
9. Air duct To lock carrier Clean air duct of dirt and leaves
10. Rubber grommet
11. Water drain hose Important: clean water drain hose of dirt and leaves
12. Water drain hose guide
13. Warm air intake (cold climate countries only) Slide the warm air intake into the air filter as far as the stop and then turn it clockwise until it engages.
14. Air filter lower section Clean air filter housing of salt residue, dirt and leaves Important: Check for water drain for dirt; clean if necessary.
15. Air filter housing lower section mount
16. Secondary Air Injection (AIR) Pump Intake Hose
17. Intake Air Switch-Over Valve -N335- With intake air switch-over flap
18. Bolt For the Intake Air Switch-Over Valve -N335
19. Bolt
20. Air filter upper section Clean the upper section of the air filter from salt, dirt and leaves. Make sure it is clipped correctly (unmetered air)
21. Bolt For securing the air filter element

PLASTIC INTAKE MANIFOLD, FROM MY 2009 ASSEMBLY OVERVIEW

As a MY 2009 running change, a plastic intake manifold is being installed (it is possible to have mixed installation in MY 2009)

Scheme 208

1. Intake manifold change-over valve vacuum diaphragm
2. Intake Manifold Tuning (IMT) Valve -N156
3. Intake flap vacuum diaphragm (cylinder bank 1) For cylinder bank 1 CVTS tumble flaps
4. Bolt 2.5 Nm
5. Intake Manifold Runner Position Sensor -G336- Cylinder Bank 1 After replacing, perform "Adaptation" in "Guided Fault Finding" Vehicle Diagnostic, Testing, and Information System VAS 5051B.
6. Gasket Replace if damaged The open side faces the potentiometer
7. Intake manifold Removing and installing, refer to «INTAKE MANIFOLD»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe)
8. Bolt 9 Nm
9. Throttle Valve Control Module -J338- After replacing, perform "Adaptation" in "Guided Fault Finding" Vehicle Diagnostic, Testing, and Information System VAS 5051B.
10. O-ring Replace
11. O-ring Replace
12. Crankcase housing ventilation adapter Tighten to 2.5 Nm.
13. O-ring Replace
14. Bolt 9 Nm
15. Crankcase housing ventilation pressure regulator valve
16. Intake manifold bolts Tightening specification and sequence (Scheme 209)
17. Intake manifold lower section bolts Tightening specification and sequence (Scheme 210)
18. Intake manifold lower section
19. Intake manifold seals Replace
20. Intake flap vacuum diaphragm (cylinder bank 2) For cylinder bank 2 CVTS tumble flaps
21. Gasket Replace if damaged The open side faces the potentiometer
22. Intake Manifold Runner Position Sensor 2 -G512- Cylinder Bank 2 After replacing, perform "Adaptation" in "Guided Fault Finding" vehicle diagnostic, testing, and information system VAS 5051B.
23. Bolt 2.5 Nm
24. Intake Manifold Runner Control (IMRC) Valve -N316

Scheme 209

Tighten intake manifold bolts in -1 through 16- sequence.

1. First tightening according to sequence: 8 Nm
2. Second tightening according to sequence: 11 Nm

Scheme 210

Tighten the bolts -arrows- on the intake manifold lower section diagonally and in steps.

1. 10 Nm

Scheme 211

1. High pressure pump The Fuel Metering Valve -N290- is installed in the right high pressure pump (cylinder bank 1) Fuel Metering Valve 2 -N402- is installed in the left high pressure pump (cylinder bank 2) The Low Fuel Pressure Sensor -G410- is installed in the left high pressure pump (cylinder bank 2) Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__high-pressure-pump)
2. Bolt 9 Nm
3. Seal Replace
4. Low Fuel Pressure Sensor -G410- 10 Nm Installed only in the left high pressure pump (cylinder bank 2)
5. High-pressure line WARNING: Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure. Refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__before-opening-high-pressure-fuel-injection) . Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection. Observe safety precautions when disconnecting the battery. Refer to «Removal and Installation»(/audi/s5/i-2007-2011/remont/charging-system/#battery-starter-generator-cruise-control-coupe) . Before loosening, disconnect Ground (GND) cable at battery with ignition switched off Connectors should not show any signs of damage Do not change bent shape 25 Nm
6. Fuel supply line WARNING: Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure. Refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__before-opening-high-pressure-fuel-injection) . Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection. Observe safety precautions when disconnecting the battery. Refer to «Removal and Installation»(/audi/s5/i-2007-2011/remont/charging-system/#battery-starter-generator-cruise-control-coupe) . Before loosening, disconnect Ground (GND) cable at battery with ignition switched off Connectors should not show any signs of damage Do not change bent shape 25 Nm
7. O-ring Replace
8. Roller tappet

Scheme 212

1. Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- with Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater -Z30- 50 Nm Coat new oxygen sensors with an assembly paste On a used oxygen sensor, only the thread may be coated with hot bolt paste. Assembly paste or hot bolt paste must not get into the slits on the oxygen sensor body. Removing and installing. Refer to «HEATED OXYGEN SENSOR 2 IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR 2 BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 2»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__heated-oxygen-sensor-2-in-front)
2. Heated Oxygen Sensor (HO2S) 2 -G108- with Oxygen Sensor (O2S) 2 Heater -Z28- 50 Nm Coat new oxygen sensors with an assembly paste On a used oxygen sensor, only the thread may be coated with hot bolt paste. Assembly paste or hot bolt paste must not get into the slits on the oxygen sensor body. Removing and installing. Refer to «HEATED OXYGEN SENSOR 2 IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR 2 BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 2»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__heated-oxygen-sensor-2-in-front)
3. Heated Oxygen Sensor (HO2S) -G39- with Oxygen Sensor (O2S) Heater -Z19- 50 Nm Coat new oxygen sensors with an assembly paste On a used oxygen sensor, only the thread may be coated with hot bolt paste. Assembly paste or hot bolt paste must not get into the slits on the oxygen sensor body. Removing and installing. Refer to «HEATED OXYGEN SENSOR IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 1»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__heated-oxygen-sensor-in-front-of)
4. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- with Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater -Z29- 50 Nm Coat new oxygen sensors with an assembly paste On a used oxygen sensor, only the thread may be coated with hot bolt paste. Assembly paste or hot bolt paste must not get into the slits on the oxygen sensor body. Removing and installing. Refer to «HEATED OXYGEN SENSOR IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 1»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__heated-oxygen-sensor-in-front-of)

1. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130
2. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- connector
3. Heated Oxygen Sensor (HO2S) -G39- connector
4. Heated Oxygen Sensor (HO2S) -G39

Removing and installing. Refer to HEATED OXYGEN SENSOR IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 1 .

1. Heated Oxygen Sensor (HO2S) 2 -G108
2. Heated Oxygen Sensor (HO2S) 2 -G108- connector
3. Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- connector
4. Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131

Removing and installing. Refer to HEATED OXYGEN SENSOR 2 IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR 2 BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 2 .

TECHNICAL DATA

FASTENER TIGHTENING SPECIFICATIONS

INTAKE MANIFOLD TIGHTENING SEQUENCE

Tighten intake manifold bolts in -1 through 10- sequence.

1. First tightening: 8 Nm
2. Second tightening: 9 Nm and tighten another 90 degrees.

FUEL SUPPLY LINE TIGHTENING SPECIFICATION

1. Tightening specifications: 25 Nm

INTAKE MANIFOLD, TIGHTENING SPECIFICATION AND SEQUENCE

Tighten intake manifold bolts in -1 through 16- sequence.

1. First tightening according to sequence: 8 Nm
2. Second tightening according to sequence: 11 Nm

INTAKE MANIFOLD LOWER SECTION, TIGHTENING SPECIFICATION

Tighten the bolts -arrows- on the intake manifold lower section diagonally and in steps.

1. 10 Nm

VACUUM SYSTEM, CHECKING

Special tools and workshop equipment required

1. Hand Vacuum Pump VAS 6213

Procedure

Check all vacuum lines in the vacuum system for

1. Cracks
2. Damage caused by animals
3. Crimps
4. Leaks and leakage

Check the vacuum line leading to and from the solenoid valve.

If there is a fault, check the vacuum lines for the named component, but also all the vacuum lines to the other components.

If using the Hand Vacuum Pump 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.

FUEL PRESSURE AND RESIDUAL PRESSURE BEFORE HIGH PRESSURE PUMP, CHECKING

Special tools and workshop equipment required

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

Fuel Pressure, Checking

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

Remove rear seat bench. Refer to Removal and Installation .

Remove the locking flange cover -arrows-.

Scheme 213

Disconnect electrical harness connector -1- at locking flange.

Scheme 214

Note. Ignore -2-.

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

Cover 2nd connector terminal of Adapter Cable V.A.G 1348/3-3 with insulating tape to prevent short circuit -arrow-.

Scheme 215

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

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

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

Remove fuel filler cap from fuel filler tube.

Remove engine cover.

Scheme 216

Connect Fuel Inj. Pressure Gauge-CIS V.A.G 1318 with adapter and Adapter Set V.A.G 1318/10-12 in fuel line.

Scheme 217

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

Open shut-off valve of pressure gauge.

1. The lever points in the flow direction.

Bleed fuel system by pressing remote control briefly.

Close shut-off valve of pressure gauge.

Scheme 218

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

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

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

If the specification is not obtained

Check the fuel pump delivery quantity. Refer to Diagnosis and Testing .

Checking residual pressure

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

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

If the residual pressure drops below 3 bar

1. Check connection between fuel pressure gauge and fuel line for leaks.
2. Check pressure gauge for leaks.
3. Check fuel lines and their connections for leaks.
4. Check the fuel pump delivery quantity. Refer to «Diagnosis and Testing»(/audi/s5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-cala-caua-coupe-as-of-042008) .
5. Replace the fuel filter with the integrated fuel pressure regulator. Refer to «Removal and Installation»(/audi/s5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-cala-caua-coupe-as-of-042008) .
6. Fuel pump check-valve is faulty. Refer to «Diagnosis and Testing»(/audi/s5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-cala-caua-coupe-as-of-042008) .

Assembly is in reverse order of removal, note the following

Switch off ignition.

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

Install the fuel supply line on the distribution piece. Make sure it is clean and there are no leaks.

TIGHTENING SPECIFICATIONS

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

Special tools and workshop equipment required

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

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

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

Connect the Test Box V.A.G 1598/42 to the wiring harness connector. Connect the ground clip on the test box to the battery negative. The procedures will indicate whether the Engine Control Module (ECM) -J623- is to be connected to the test box.

Perform test as described in relevant repair sequences.

Installing the engine control module (ECM)

Install in reverse order of removal.

Thereafter, the engine control module must be equipped with the metal retainer.

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

Always use new shear bolts.

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

REMOVING

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

Disconnect battery. Refer to Removal and Installation .

Remove the engine cover -arrows-.

Scheme 219

Disconnect fuel lines -1, 3, 4 and 6-.

Scheme 220

Remove bolts -2- and -5- and remove fuel rail with high pressure lines.

Free up fuel line and vacuum line to EVAP canister on air guide hose.

Disconnect the electrical connector -2- on Solenoid Valve 1 for the EVAP Cannister -N80- and disconnect the vacuum hose -1-.

Scheme 221

Remove the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- from the bracket and lay it aside with the hose connected.

Disconnect electrical connector -1- on Mass Air Flow (MAF) Sensor -G70-.

Scheme 222

Disconnect the vacuum line -3- to the air guide pipe.

Loosen the clamps -4-, open the clips -arrows- and move the air guide hose to the side with the crankcase ventilation hose still connected -2-.

Disconnect vacuum hose -2-.

Scheme 223

Note. Ignore -1-.

Disconnect electrical connector -1- on Throttle Valve Control Module -J338-.

Scheme 224

Remove bolts -arrows- and remove Throttle Valve Control Module -J338-.

Loosen bolt -3- a few turns.

Scheme 225

Remove the bolts -2- and remove the crankcase ventilation pressure control valve from the throttle valve connection.

Note. Ignore -1- and -arrow-. To provide a better illustration, component location is shown from behind with engine removed.

Open the cap on the coolant reservoir.

Disconnect and remove the coolant hose -1- with Hose Clamps Up to 25 mm diameter 3094.

Scheme 226

Remove the coolant hose -2-.

Disconnect the vacuum hose -3- and move it to the side.

Remove the bolt -4- on the high pressure line clamp.

Remove the bolts -1- and remove the left rear engine lifting eye.

Remove the bolt -2- on the wiring harness bracket.

Scheme 227

Remove the bolts -3- and move the left front engine lifting eye and the connectors to the side.

Push the wiring harness to the left side.

Remove the bolt -3- and remove the right rear engine lifting eye.

Scheme 228

Remove the bolt -2- on the wiring harness bracket.

Remove the intake manifold bolts in sequence -10 through 1-.

Cover the high pressure lines to avoid scratching the intake manifold.

First lift the intake manifold toward the front and then up -arrow 1-.

Scheme 229

Disconnect the connectors.

Scheme 230

1. Intake Flap Motor -V157- (brown connector)
2. Intake Manifold Runner Position Sensor -G336
3. Variable Intake Manifold Runner Motor -V183- (black connector)
4. Intake Manifold Runner Position Sensor 2 -G512

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

Move the intake manifold toward the right side of the vehicle under the high pressure fuel lines -arrow 2-.

Remove the intake manifold from the engine compartment.

INSTALLING

Installation is in reverse order of removal, note the following

Note. Replace seals and O-rings. Secure all hose connections using hose clamps appropriate for the model type. High pressure line connections must not show any signs of damage.

Pay attention to the locating point -1- when installing the intake manifold gaskets.

Scheme 231

Tighten the intake manifold bolts. Refer (Scheme 179).

High pressure lines, installing HIGH PRESSURE LINES, INSTALLING .

FUEL INJECTORS

Special tools and workshop equipment required

1. Tool Set T10133

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

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

Special tools and workshop equipment required

1. Round file approximately 6 mm

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

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

Scheme 232

Remove intake manifold. Refer to INTAKE MANIFOLD .

Note. Seal injector channels in cylinder heads with clean cloths.

Disconnect electrical harness connectors at fuel injectors.

Remove high pressure line -5- from connector on fuel rail.

Scheme 233

Remove high pressure line -7- from connector on fuel rail. To do this, counterhold at hex head with and open-end wrench and loosen the union nut.

Remove bolts -1, 2, 3, 4, 6, 8-.

Note. Do not change the angles of the high pressure lines.

Remove fuel rail with fuel injectors.

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

Scheme 234

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

Remove O-ring from fuel injector.

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

Scheme 235

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

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

Carefully remove the old Teflon seal -arrow- with the appropriate tool (for example with cut the seal open with a razor and spread seal open with a small screwdriver and pull it forward and off.) When doing this, make sure not to damage the groove and circumferential rib in the groove base.

Scheme 236

Note. If the groove is damage, the fuel injector must be replaced.

Before installing the new Teflon seal, the seal groove and the shaft of the fuel injector must be cleaned of combustion residue using a clean rag.

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

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

Scheme 237

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

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

Scheme 238

Slide combustion chamber seal as far possible onto Assembly Cone T10133/5 using Assembly Sleeve T10133/6.

Scheme 239

Turn Assembly Sleeve T10133/6 around and slide combustion chamber seal into groove.

Note. When pushing the combustion chamber seal onto the fuel injector, the seal spreads open. This combustion chamber seal must therefore be made smaller after pushing it on in 2 steps.

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

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

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

Scheme 240

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

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

Note. The combustion chamber seal must not be oiled. Do not put any grease, oil or other lubricants on the combustion chamber seal.

FUEL INJECTORS, INSTALLING

Clean bore in cylinder head with Nylon Cylinder Brush T10133/4.

Scheme 241

Slide the injector valve into the hole in the cylinder housing using the Assembly Drift T10133/9.

Scheme 242

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

Make sure fuel injectors are correctly positioned in cylinder head.

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

Press the fuel rail onto the fuel injectors with uniform pressure.

Tighten bolts -1, 2, 3, 4, 6, 8- diagonally in stages.

Further installation is in reverse order.

1. For the tightening specifications. Refer to «FUEL INJECTORS WITH FUEL RAIL ASSEMBLY OVERVIEW»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe) .

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

Install intake manifold. Refer to INTAKE MANIFOLD .

High pressure lines, installing. Refer to HIGH PRESSURE LINES, INSTALLING .

INTAKE MANIFOLD

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1331
2. 17 mm Socket V.A.G 1331/6
3. SW 14 Socket, Open Ring V.A.G 1331/8
4. Assembly Tool T10118
5. Hose Clamps Up to 25 mm diameter 3094

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

With ignition switched off, disconnect Battery Ground (GND) cable.

Remove engine cover.

Pull the cover -1- forward and remove it upward.

Scheme 243

Disconnect the connector -1- and disconnect the vacuum lines -arrows-.

Scheme 244

Remove vacuum line -4- at air guide hose.

Scheme 245

Note. Ignore -1-.

Lay aside air guide hose with connected crankcase ventilation hose -3- by loosening hose clamps -2- and -5-.

Disconnect electrical connector -2- on Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- and remove vacuum hose -1-.

Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- from bracket and lay aside with hose connected.

Disconnect the fuel lines -1 and 4- on the high pressure pumps.

Remove bolts -2 and 3-.

Disconnect electrical connection -1- at Throttle Valve Control Module -J338-.

Remove bolts -arrows- and remove Throttle Valve Control Module -J338-.

Disconnect vacuum lines -arrows- to brake booster.

Scheme 246

Lay vacuum lines aside.

Note. Ignore -1-.

Open cap of coolant expansion tank.

Remove crankcase ventilation house at placed marked with -1- and -2- by pressing release buttons.

Scheme 247

Clamp off the coolant hose -4- with a Hose Clamps Up to 25 mm diameter 3094 and remove the coolant hose from connection on the intake manifold.

Loosen bolt -5- several turns.

Remove bolts -3- and press crankcase ventilation pressure control valve carefully off intake manifold supports.

Note. Disregard -arrow-. To improve clarity, the removed engine is shown from the rear.

Note. Place a cloth under intake manifold supports to collect escaping coolant.

Remove coolant hose -arrow- and lay it aside.

Remove vacuum hose -arrow- to intake manifold supports.

Scheme 248

Remove the intake manifold bolts in sequence -16 to 1-.

Remove intake manifold from engine compartment.

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

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

Check the gaskets in the intake manifold for damage and correct fit.

Make sure the hoses or cables do not get caught.

Tighten the intake manifold bolts in sequence -1 to 16-.

1. Tightening Specifications. (Scheme 209)
2. Tightening specifications. Refer to «FUEL INJECTORS AND FUEL RAIL ASSEMBLY OVERVIEW»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__fuel-injectors-and-fuel-rail-assembly).

Further installation is in reverse order.

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

Hand-tighten the union nuts for the high-pressure lines.

Make sure the high-pressure lines are seated free of stress.

To tighten 14 mm diameter union nut on high pressure lines, use Torque Wrench V.A.G 1331 with Socket Insert AF 14, open ring V.A.G 1331/8.

Scheme 249

To tighten union nut (17 mm diameter) on high pressure lines, use Torque Wrench V.A.G 1331 with Socket Insert, AF 17 V.A.G 1331/6.

Scheme 250

Only install retaining tabs after high pressure lines have been tightened.

Observe safety precautions after connecting battery. Refer to Removal and Installation .

If necessary, fill the coolant. Refer to General Information .

INTAKE MANIFOLD, LOWER SECTION, WITH FUEL RAIL

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1331
2. 17 mm Socket V.A.G 1331/2
3. Hand Vacuum Pump VAS 6213

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 fuel pressure in high pressure area. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

Disconnect the vacuum hose on the vacuum diaphragm for the intake manifold flap.

Counterhold the threaded connection and remove the fuel high pressure line union nut on the high pressure pump.

Disconnect the connector -1- on the intake manifold runner position sensor and disconnect the vacuum hose -2-.

Remove the union nut -3- while counterholding the threaded connection.

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

Installation is in reverse order of removal, note the following

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

The intake manifold flaps must be moved in direction of -arrow- when installing the intake manifold lower section.

Scheme 251

Connect the Hand Vacuum Pump VAS 6213 to the vacuum diaphragm connection for the intake manifold flaps.

Scheme 252

Generate vacuum using hand vacuum pump.

1. The intake flaps are opened.

Note. If the intake flaps are not opened, they could have seized when installing the lower section of the intake manifold in the cylinder head.

Push the intake manifold lower section evenly onto the injection valves.

Tighten the bolts on the intake manifold lower section diagonally.

1. Intake manifold tightening specification. Refer to «PLASTIC INTAKE MANIFOLD, FROM MY 2009 ASSEMBLY OVERVIEW»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__plastic-intake-manifold-from-my-2009)

Remove the hand vacuum pump from the connection on the vacuum diaphragm for the intake manifold flaps.

Counterhold the threaded connection and tighten the fuel high pressure line union nut on the high pressure pump.

Tighten the union nut -3- while counterholding the threaded connection.

1. Tightening Specifications High pressure pump. Refer to «HIGH PRESSURE PUMP ASSEMBLY OVERVIEW»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe)

Make sure the high pressure line is free of tension.

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1331
2. 17 mm Socket V.A.G 1331/6
3. SW 14 Socket, Open Ring V.A.G 1331/8
4. Tool Set T10133

Note. The following describes removing and installing and the left injectors (cylinder bank 2).

Remove intake manifold. Refer to INTAKE MANIFOLD .

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

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

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

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

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

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

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

Clean bore in cylinder head with Nylon Cylinder Brush T10133/4.

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

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

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

Slide combustion chamber seal as far possible onto Assembly Cone T10133/5 using Assembly Sleeve T10133/6.

Turn Assembly Sleeve T10133/6 around and slide combustion chamber seal into groove.

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

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

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

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

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

Note. The combustion chamber seal must not be oiled.

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

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

Make sure fuel injectors are correctly positioned in cylinder head.

1. The electrical connection of the fuel injector must engage in the intended recess of the cylinder head.
2. Coat the 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 in reverse order of removal, note the following

1. Tightening Specifications Intake manifold. Refer to «PLASTIC INTAKE MANIFOLD, FROM MY 2009 ASSEMBLY OVERVIEW»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__plastic-intake-manifold-from-my-2009)

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

Only install retaining tabs after high pressure lines have been tightened.

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

Install intake manifold. Refer to INTAKE MANIFOLD .

Carefully remove the engine cover from the 4 bolts -arrow- one after the other. Do not remove the engine cover one-sidedly or in a jerking manner.

To prevent damages, do not hit engine cover with fist or tools.

First push the engine cover with both hands into the rubber grommets in the rear and then into the rubber grommets in the front.

Disconnect electrical harness connector -2- at Mass Air Flow (MAF) Sensor -G70-.

Scheme 253

Loosen the hose clamp -3- and remove the air guide hose from the Mass Air Flow (MAF) Sensor -G70-.

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

Remove the 2 bolts -arrows- from air filter element.

Scheme 254

Observe the following to ensure the Mass Air Flow (MAF) Sensor -G70- functions correctly.

Note. If the air filter element is very dirty or soaked, dirt particles or moisture may have contaminated the Mass Air Flow (MAF) Sensor -G70- and may be causing false mass air flow values. This results in a reduction of power, since a lower injection quantity is calculated. Always use an original equipment air filter element. Use a lubricant (silicone-free) for installing the intake hose. Secure all hose connections using hose clamps appropriate for the model type.

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

Scheme 255

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

Check the Mass Air Flow (MAF) Sensor and air duct hose (intake air side) for salt residue, dirt, and leaves.

Check the intake ducting up to the air filter element 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.

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

Scheme 256

Set the upper section of air filter housing onto lower section of 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 bolts.

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

Make sure that air duct hose is connected securely to Mass Air Flow (MAF) Sensor -G70- (note the marking between air duct hose and Mass Air Flow (MAF) Sensor -G70-).

Reconnect the connector on the Mass Air Flow (MAF) Sensor -G70-.

Further installation is performed in reverse order.

Remove the cover above the radiator grille (4 screws).

Remove the air duct -1- completely.

Disconnect electrical harness connector -2- at Mass Air Flow (MAF) Sensor -G70-.

Loosen the hose clamp -3- and remove the air guide hose from the Mass Air Flow (MAF) Sensor -G70-.

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

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

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

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

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

Scheme 257

Disconnect the Intake Air Switch-Over Valve -N335- connector.

Carefully remove the air filter housing lower section.

Observe the following to ensure the Mass Air Flow (MAF) Sensor -G70- functions correctly.

Note. If the air filter element is very dirty or soaked, dirt particles or moisture may have contaminated the Mass Air Flow (MAF) Sensor -G70- and may be causing false mass air flow values. This results in a reduction of power, since a lower injection quantity is calculated. Always use an original equipment air filter element. Use a lubricant (silicone-free) for installing the intake hose. Secure all hose connections using hose clamps appropriate for the model type.

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

Scheme 258

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

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

Check the Mass Air Flow (MAF) Sensor and air duct hose (intake air side) for salt residue, dirt, and leaves.

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

Connect the Intake Air Switch-Over Valve -N335- connector.

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

Install the air filter housing lower section.

Note. The water drain hose must be routed straight down and without any bends.

Slide the vacuum hose -1- onto the Intake Air Switch-Over Valve -N335- connection.

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

Set the upper section of air filter housing onto lower section of 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 air filter housing to lower section of air filter housing.

Make sure that air duct hose is connected securely to Mass Air Flow (MAF) Sensor -G70- (note the marking between air duct hose and Mass Air Flow (MAF) Sensor -G70- "arrows").

Reconnect the connector on the Mass Air Flow (MAF) Sensor -G70-.

Further installation is in reverse order.

Disconnect electrical harness connector from Mass Air Flow (MAF) Sensor -G70- -1-.

Open the air guide hose clamp -3- and remove the hose from the Mass Air Flow (MAF) Sensor -G70-.

Open both clips on the Mass Air Flow (MAF) Sensor -G70-.

Carefully remove the Mass Air Flow (MAF) Sensor -G70- out of guide at air filter housing.

For problem-free operation of the Mass Air Flow (MAF) Sensor -G70- it is very important to observe the following notes and procedures.

Note. If the air filter element is very dirty or soaked, dirt particles or moisture may have contaminated the Mass Air Flow (MAF) Sensor -G70- and may be causing false mass air flow values. This results in a reduction of power, since a lower injection quantity is calculated. Always use an original equipment air filter element. Use a lubricant (silicone-free) for installing the intake hose. Secure all hose connections using hose clamps appropriate for the model type.

Check the Mass Air Flow (MAF) Sensor -G70- and air duct hose (intake air side) for salt residue, dirt, and leaves.

Check the intake ducting up to the air filter element for dirt. If any contaminants are discovered, clean the air filter housing (upper and lower sections) of salt residue, dirt and leaves (if necessary, clean by washing or vacuuming). Air filter, removing and installing. Refer to AIR FILTER ELEMENT

If the air filter was removed, then clean the water drain.

Align O-ring in air filter housing nut and carefully slide Mass Air Flow (MAF) Sensor -G70- into air filter housing.

Note. Replace the O-ring if damaged

Lock both clips.

Install the air guide hose and tighten the hose clamp.

Connect the Mass Air Flow (MAF) Sensor -G70- connector.

Remove intake manifold.

Open the high pressure line union nut at the fuel rail.

Remove the Fuel Pressure Sensor -G247- bolt -1-.

Note. The installation location may differ on vehicle from MY 2009.

Remove the Fuel Pressure Sensor -G247- with the high pressure line.

Note. Do not change the angles of the high pressure lines.

Tighten the Fuel Pressure Sensor -G247-.

1. Tightening Specifications. Refer to «COMPONENT LOCATION OVERVIEW»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe__component-location-overview)

Note. The high pressure line connectors -arrows- must not be damaged. Do not bend the high pressure line to a different angle.

Tighten the high pressure line union nut by hand.

Make sure the high pressure line is free of tension.

Tighten the 17 mm union nut on the high pressure line with the Torque Wrench V.A.G 1331 and 17 mm Socket Insert V.A.G 1331/6.

Further installation is in reverse order.

Install intake manifold.

HIGH PRESSURE PUMP

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1331
2. 17 mm Socket V.A.G 1331/6
3. SW 14 Socket, Open Ring V.A.G 1331/8

Note. The following description represents removal and installation of left high pressure pump.

With ignition switched off, disconnect Battery Ground (GND) cable.

Remove engine cover. Refer to ENGINE COVER .

Disconnect electrical connectors on Low Fuel Pressure Sensor -G410- -1- and on Fuel Metering Valve 2 -N402- -2-.

Scheme 259

Note. The Low Fuel Pressure Sensor -G410- is installed only in the left high pressure pump (cylinder bank 2)

Remove both fuel line union nuts.

Remove bolts -3-.

Note. Do not change the angles of the high pressure lines.

Carefully remove high pressure pump.

Remove roller tappet from cylinder head.

Installation is in reverse order of removal, note the following

Note. Replace O-ring.

Insert roller tappet in cylinder head.

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

Rotate the crankshaft until the roller tappet is at the lowest point.

To set the high pressure pump in place, lift the high pressure lines only slightly.

Insert high pressure pump in cylinder head and tighten.

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

Hand-tighten the union nuts for the high-pressure lines.

Make sure the high-pressure lines are seated free of stress.

To tighten 14 mm diameter union nut on high pressure lines, use Torque Wrench V.A.G 1331 with Socket Insert AF 14, open ring V.A.G 1331/8.

To tighten union nut (17 mm diameter) on high pressure lines, use Torque Wrench V.A.G 1331 with Socket Insert, AF 17 V.A.G 1331/6.

1. Tightening specifications. Refer to «HIGH PRESSURE PUMP ASSEMBLY OVERVIEW»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe) .

Observe safety precautions after connecting battery. Refer to Removal and Installation .

Reconnect electrical connectors on Low Fuel Pressure Sensor -G410- -1- and Fuel Metering Valve 2 -N402- -2-.

Note. Check fuel system for leaks.

HIGH PRESSURE LINES, INSTALLING

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1331
2. 17 mm Socket V.A.G 1331/6
3. SW 14 Socket, Open Ring V.A.G 1331/8

Procedure

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

Coat the threads on the union nut with fuel.

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

Use a Torque Wrench V.A.G 1331 with the 14 mm Socket, Open Ring V.A.G 1331/8 to tighten the high pressure lines.

Use a Torque Wrench V.A.G 1331 with 17 mm Socket V.A.G 1331/6 to tighten the high pressure lines.

1. Tightening specification: 25 Nm

Tighten the clamps only after the high pressure lines are tightened.

Perform a leak test on the fuel system.

HEATED OXYGEN SENSOR IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 1

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set for Oxygen Sensor 3337

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

Remove the engine cover.

Disconnect electrical connector -1- on Mass Air Flow (MAF) Sensor -G70-.

Disconnect the vacuum line -3- to the air guide pipe.

Loosen the clamps -4-, open the clips -arrows- and move the air guide hose to the side with the crankcase ventilation hose still connected -2-.

Remove affected electrical connector from bracket and disconnect it.

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

3 - For Heated Oxygen Sensor (HO2S) -G39

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

Remove the Heated Oxygen Sensor (HO2S) -G39- -4- using a tool from the Ring Spanner 7-Piece Set for Oxygen Sensor 3337.

Remove the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- -1- using a tool from the Ring Spanner 7-Piece Set for Oxygen Sensor 3337.

1. Tightening Specifications. Refer to «OXYGEN SENSORS ASSEMBLY OVERVIEW»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe) .

Installation is in reverse order of removal, note the following

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

HEATED OXYGEN SENSOR 2 IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR 2 BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 2

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set for Oxygen Sensor 3337

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

Remove affected electrical connector from bracket and disconnect it.

2 - For Heated Oxygen Sensor (HO2S) 2 -G108

3 - For Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131

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

Remove the Heated Oxygen Sensor (HO2S) 2 -G108- -1- using a tool from the Ring Spanner 7-Piece Set for Oxygen Sensor 3337.

Remove the oxygen sensor (O2S) 2 behind three way catalytic converter (TWC) -G131- -4- using a tool from the Ring Spanner 7-Piece Set for Oxygen Sensor 3337.

1. Tightening Specifications. Refer to «OXYGEN SENSORS ASSEMBLY OVERVIEW»(/audi/s5/i-2007-2011/remont/fuel-system/#42l-fuel-injection-system-engine-codes-caua-coupe) .

Installation is in reverse order of removal, note the following

Note. Coat new oxygen sensors with an assembly paste. This paste must not come into contact with sensor slots. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with sensor slots. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.

ENGINE CONTROL MODULE

Special tools and workshop equipment required

1. Wiring Harness Repair Kit VAS 1978A
2. A small commercially available pliers

Note. Some engine control modules are not equipped with a protective housing. A protective housing is not installed in vehicles with automatic transmissions. The Engine Control Module (ECM) -1- is bolted to a protective housing -5-. To make removing the shear bolts -4- for the retaining tabs -2- more difficult, the threads are coated with locking compound. The protective housing must be removed to disconnect the connectors from the engine control module.

If the engine control module is replaced, select "Guided Functions" on the Vehicle Diagnosis, Testing and Information System VAS 5051B and then "Replace engine control module".

Turn the ignition and remove the ignition key.

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

Scheme 260

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 cover from the E-box.

Release the retainers -arrows A - and remove the Engine Control Module (ECM) -J623- -arrow B-.

The engine control module -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 261

Note. Some engine control modules are not equipped with a protective housing. A protective housing is not installed in vehicles with automatic transmissions.

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

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

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

Scheme 262

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

Scheme 263

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

Scheme 264

The shear bolts installed in the engine control module do not need to be heated for removal.

Disconnect metal retainers from the ECM connectors.

Disengage the connectors from the engine control module and disconnect the connector.

Remove old Engine Control Module (ECM) -J623- and install the Engine Control Module (ECM) -J623-.

Install in reverse order of removal.

After that, the Engine Control Module (ECM) -J623- must be equipped with the metal retainer.

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

Always use new shear bolts.

1. Tightening specification: Bolts for the E-box cover: 3.5 Nm

Perform the following step after installing a new engine control module

Activate the engine control module in the "Guided Functions" operating mode under "Replace engine control module" on the Vehicle Diagnosis, Testing and Information System VAS 5051B.

Scheme 265

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1331
2. 17 mm Socket V.A.G 1331/6
3. SW 14 Socket, Open Ring V.A.G 1331/8
4. Assembly Tool T10118

Special tools and workshop equipment required

Scheme 266

Scheme 267

Scheme 268

Scheme 269

Scheme 270

Scheme 271

Scheme 272

Scheme 273

1. Hand Vacuum Pump VAS 6213
2. Pressure Gauge K-Jetronic V.A.G 1318
3. Pressure Gauge Adapter V.A.G 1318/10-12
4. Connector Test Set V.A.G 1594C
5. Remote Control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3
6. Adapter cable V.A.G 1598/39-1
7. Adapter cable V.A.G 1598/39-2
8. Test box V.A.G 1598/42
9. Tool Set T10133
10. Hose Clamps Up to 25 mm diameter 3094
11. Ring Spanner 7-Piece Set for Oxygen Sensor 3337
12. Hot air gun -1- from the Wiring Harness Repair Kit VAS 1978A.
13. Nozzle attachment -2- also from the Wiring Harness Repair Kit VAS 1978A
14. A small commercially available pliers -3

See also:
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM
• SAFETY PRECAUTIONS
• INTAKE MANIFOLD
• FUEL INJECTORS
• HIGH PRESSURE LINES, INSTALLING
• INTAKE MANIFOLD, LOWER SECTION, WITH FUEL RAIL
• FUEL INJECTORS
• HIGH PRESSURE PUMP
• ENGINE CONTROL MODULE
• HEATED OXYGEN SENSOR IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 1
• HEATED OXYGEN SENSOR 2 IN FRONT OF CATALYTIC CONVERTER AND OXYGEN SENSOR 2 BEHIND THREE WAY CATALYTIC CONVERTER, CYLINDER BANK 2
• FUEL INJECTORS AND FUEL RAIL ASSEMBLY OVERVIEW
• PLASTIC INTAKE MANIFOLD, FROM MY 2009 ASSEMBLY OVERVIEW
• COMPONENT LOCATION OVERVIEW