5.2l 10-cyl. 4v Fuel Injection Ignition, Engine Code(s): Bxa Audi S6 C6

Safety precautions

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

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

1. For safety reasons, if the battery is not disconnected, Fuel Pump (FP) Control Module J538 fuse must be removed before opening fuel system. Otherwise, the fuel pump will be activated by the drivers door contact switch.
2. Individuals with a pacemaker must not stay in the danger area of high voltage systems, e.g. ignition systems, xenon light.
3. Fuel lines must not be opened when engine is running.
4. Only disconnect and reconnect wires for injection and ignition system, including test leads, when ignition is switched off.

1. If engine is to be cranked at starting RPM without starting (e.g. for compression testing), disconnect connectors from ignition coils and remove fuse for electric fuel pump.
2. 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.
3. Cleaning engine should only be performed with ignition switched off.
4. The battery must only be disconnected and connected with the ignition switched off, since the Engine Control Module (ECM) can otherwise be damaged.

Cleanliness rules and instructions for working on fuel system

Even minor contaminations 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. Do not use fluffy cloths!
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored unpackaged (e.g. in tool boxes etc.).

1. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.

Procedure that must be performed before opening the high-pressure fuel injection system - Pay close attention!

High fuel pressure, reducing

Scheme 367

1. Disconnect electrical connector from Fuel Metering Valve N290 - 1 - and from Fuel Metering Valve 2 N402 - 2 -.
2. Allow engine to idle approx. 10 seconds.

Note. By disconnecting electrical connector from Fuel Metering Valve N290 and from Fuel Metering Valve 2 N402 at idle, fuel pressure is reduced to approx. 6 bar.

1. Switch off ignition.

1. After reducing high pressure, high pressure system must be opened immediately.
2. To do this, place a cloth around connection to reduce the residual pressure in the fuel system to approx. 6 bar. Escaping fuel must be absorbed.
3. After completing work, generate readiness codes in control module in "Guided Functions" operating mode.

Note. Falling pressure can be observed if a vehicle tester is connected and engine control module (ECM) selected. And select display group 140 under "Read measured value block" function. Fuel pressure (actual value) is shown in display field 3.

Technical data

Component locations, overview

Engine compartment, right

Scheme 368

1 - Engine control module J623

1. Removing and installing --> «Engine Control Module (ECM) J623 (master), removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__engine-control-module-ecm-j623-master)

2 - Engine control module (ECM) 2 J624

1. Removing and installing --> «Engine Control Module (ECM) 2 J624 (slave), removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__engine-control-module-ecm-2-j624)

3 - Camshaft Adjustment Valve 1 (exhaust) N318

1. Component location «Location on right cylinder bank 1»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

4 - Camshaft Adjustment Valve 1 N205

1. Component location «Location on right cylinder bank 1»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

5 - Low Fuel Pressure Sensor G410

1. Component location «Engine from behind»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

6 - Engine Coolant Temperature (ECT) Sensor G62

1. Component location «Engine from behind»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

7 - Throttle valve control module J338

1. After replacement, adapt in "Guided Functions" operating mode under "Adapting throttle valve control module"

8 - Components on front of engine

1. «Engine viewed from front»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)
2. Intake Manifold Runner Position Sensor G336
3. Variable Intake Manifold Runner Motor V183
4. Intake Flap Motor V157

1. Secondary air injection (AIR) solenoid valve N112
2. Intake Manifold Runner Position Sensor 2 G512
3. Oil pressure switch F1
4. Knock sensor 4 G199

1. Knock sensor 3 G198
2. Knock sensor 1 G61
3. Knock sensor 2 G66

9 - Knock sensor 2 G66

1. Component location «Location inside cylinder head»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)
2. Electrical harness connector «Engine viewed from front»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

10 - Knock sensor 1 G61

1. Component location «Location inside cylinder head»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)
2. Electrical harness connector «Engine viewed from front»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

11 - High pressure pump

1. with Fuel Metering Valve N290

12 - Camshaft Position (CMP) sensor G40

1. Component location «Location on right cylinder bank 1»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

13 - Fuel Metering Valve N290 electrical connector

1. Common component with high pressure pump

14 - Ignition coils, Cylinder bank 1

1. Ignition Coil 1 with Power Output Stage N70
2. Ignition Coil 2 with Power Output Stage N127
3. Ignition Coil 3 with Power Output Stage N291
4. Ignition Coil 4 with Power Output Stage N292

1. Removing and installing --> «Ignition coils with power output stage, removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__ignition-coils-with-power-output-stage)

15 - Camshaft position (CMP) sensor 3 G300

1. Component location «Location on right cylinder bank 1»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

16 - Mass Air Flow (MAF) Sensor G70/Intake Air Temperature (IAT) Sensor G42

1. Removing and installing --> «Mass Air Flow (MAF) Sensor G70 (cylinder bank 1), removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__mass-air-flow-maf-sensor-g70)
2. Installed in air filter housing

Engine compartment, left

Scheme 369

1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 1 N80

1. «Locations»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

2 - Throttle Valve Control Module 2 J544

1. After replacement, adapt in "Guided Functions" operating mode under "Adapting throttle valve control module"

3 - Camshaft Adjustment Valve 2 N208

1. Component location «Location on left cylinder bank 2»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

4 - Camshaft Adjustment Valve 2 (exhaust) N319

1. Component location «Location on left cylinder bank 2»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

5 - Mass Air Flow (MAF) Sensor 2 G246

1. Removing and installing --> «Mass Air Flow (MAF) Sensor 2 G246 (cylinder bank 2), removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__mass-air-flow-maf-sensor-2)
2. Installed in air filter housing

6 - Secondary Air Injection (AIR) Pump Motor V101

1. Below left longmember
2. Refer to --> «Secondary Air Injection (AIR) Pump Motor V101 (below left longmember)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

7 - Camshaft position (CMP) sensor 4 G301

1. Attached to outside of cylinder head
2. Component location «Location on left cylinder bank 2»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

8 - Ignition coils, Cylinder bank 2

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

1. Removing and installing --> «Ignition coils with power output stage, removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__ignition-coils-with-power-output-stage)

9 - Fuel Metering Valve 2 N402 electrical connector

1. Common component with high pressure pump

10 - Camshaft position (CMP) sensor 2 G163

1. Component location «Location on left cylinder bank 2»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

11 - High pressure pump

1. With Fuel Metering Valve 2 N402

12 - Components on front of engine

1. «Engine viewed from front»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)
2. Intake Manifold Runner Position Sensor G336
3. Variable Intake Manifold Runner Motor V183
4. Intake Flap Motor V157

1. Secondary air injection (AIR) solenoid valve N112
2. Intake Manifold Runner Position Sensor 2 G512
3. Oil pressure switch F1
4. Knock sensor 4 G199

1. Knock sensor 3 G198
2. Knock sensor 1 G61
3. Knock sensor 2 G66

13 - Fuel Pressure Sensor G247

1. Component location «Location inside cylinder head»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

14 - Knock sensor 3 G198

1. Component location «Location inside cylinder head»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)
2. Electrical harness connector «Engine viewed from front»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

15 - Knock sensor 4 G199

1. Component location «Location inside cylinder head»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)
2. Electrical harness connector «Engine viewed from front»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

A - Engine speed (RPM) sensor G28

1. Refer to --> «Engine Speed (RPM) Sensor G28»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

B - Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185

1. Refer to --> «Component location Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

C - Brake light switch F/Brake pedal switch F47

1. Refer to --> «Component location Brake Light Switch F/Brake Pedal Switch F47 , Clutch Pedal Switch F36 and Clutch Position Sensor G476»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

D - Clutch Pedal Switch F36 and Clutch Position Sensor G476

1. Refer to --> «Component location Brake Light Switch F/Brake Pedal Switch F47 , Clutch Pedal Switch F36 and Clutch Position Sensor G476»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

E - Heated Oxygen Sensor (HO2S) G39 before catalytic converter with Oxygen Sensor (O2S) Heater Z19

1. Exhaust bank I (cylinder 1, 2, 3)
2. Location of electrical connector
3. Removing and installing --> «Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__heated-oxygen-sensor-ho2s-g39-and)

F - Heated Oxygen Sensor (HO2S) 2 G108 before catalytic converter with Oxygen Sensor (O2S) 2 Heater Z28

1. Exhaust bank II (cylinder 4, 5)
2. Location of electrical connector --> «Location of electrical connectors for oxygen sensors G108 , G130 , G131 , G286 , G287 , G288»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__location-of-electrical-connectors-for-oxygen)
3. Removing and installing --> «Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__heated-oxygen-sensor-ho2s-g39-and)

G - Heated Oxygen Sensor (HO2S) 3 G285 before catalytic converter with Oxygen Sensor (O2S) 3 Heater Z62

1. Exhaust bank III (cylinder 6, 7, 8)
2. Location of electrical connector --> «Location of electrical connectors for Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__location-of-electrical-connectors-for-heated)
3. Removing and installing --> «Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__heated-oxygen-sensor-ho2s-g39-and)

H - Heated Oxygen Sensor (HO2S) 4 G286 before catalytic converter with Oxygen Sensor (O2S) 4 Heater Z63

1. Exhaust bank IV (cylinder 9, 10)
2. Location of electrical connector --> «Location of electrical connectors for oxygen sensors G108 , G130 , G131 , G286 , G287 , G288»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__location-of-electrical-connectors-for-oxygen)
3. Removing and installing --> «Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__heated-oxygen-sensor-ho2s-g39-and)

I - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 with Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater Z29

1. Exhaust bank I (cylinder 1, 2, 3)
2. Location of electrical connector --> «Location of electrical connectors for oxygen sensors G108 , G130 , G131 , G286 , G287 , G288»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__location-of-electrical-connectors-for-oxygen)
3. Removing and installing --> «Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__heated-oxygen-sensor-ho2s-g39-and)

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

1. Exhaust bank II (cylinder 4, 5)
2. Location of electrical connector --> «Location of electrical connectors for oxygen sensors G108 , G130 , G131 , G286 , G287 , G288»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__location-of-electrical-connectors-for-oxygen)
3. Removing and installing --> «Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__heated-oxygen-sensor-ho2s-g39-and)

K - Oxygen Sensor (O2S) 3 Behind Three Way Catalytic Converter (TWC) G287 with Oxygen Sensor (O2S) 3 (behind Three Way Catalytic Converter (TWC)) Heater Z64

1. Exhaust bank III (cylinder 6, 7, 8)
2. Location of electrical connector --> «Location of electrical connectors for oxygen sensors G108 , G130 , G131 , G286 , G287 , G288»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__location-of-electrical-connectors-for-oxygen)
3. Removing and installing --> «Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__heated-oxygen-sensor-ho2s-g39-and)

L - Oxygen Sensor (O2S) 4 Behind Three Way Catalytic Converter (TWC) G288 with Oxygen Sensor (O2S) 4 (behind Three Way Catalytic Converter (TWC)) Heater Z65

1. Exhaust bank IV (cylinder 9, 10)
2. Location of electrical connector --> «Location of electrical connectors for oxygen sensors G108 , G130 , G131 , G286 , G287 , G288»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__location-of-electrical-connectors-for-oxygen)
3. Removing and installing --> «Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__heated-oxygen-sensor-ho2s-g39-and)

Scheme 370

1 - Shows Engine Control Module (ECM) 2 J624 (slave)

2 - Shows Engine Control Module (ECM) J623 (master)

Scheme 371

1. In accelerator pedal module - arrow -.

Note. The Throttle Position (TP) Sensor G79 and Accelerator Pedal Position Sensor 2 G185 are integrated into the accelerator pedal module and cannot be replaced separately.

Scheme 372

1. On pedal bracket.

1. Clutch Position Sensor G476
2. Clutch pedal switch F36
3. Brake light switch F/Brake pedal switch F47

Scheme 373

1 - Power Supply Relay (terminal 15) J329

See --> Electrical Wiring Diagrams, Troubleshooting and Component Locations

Scheme 374

1.2 - Auxiliary engine coolant (EC) pump relay J496

2 - Engine Component Power Supply Relay J757

See --> Electrical Wiring Diagrams, Troubleshooting and Component Locations

Scheme 375

3 - Secondary Air Injection (AIR) Pump Relay J299

B - Secondary Air Injection (AIR) Pump Relay J299 fuse

See --> Electrical Wiring Diagrams, Troubleshooting and Component Locations

Scheme 376

1 - Low Fuel Pressure Sensor G410

2 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve N80

3 - Throttle Valve Control Module 2 J544

4 - Throttle valve control module J338

After replacing throttle valve control module, an "adaptation" must be done, see "Guided Functions".

Scheme 377

1 - Low Fuel Pressure Sensor G410

2 - Engine Coolant Temperature (ECT) Sensor G62 , removing and installing --> 19 - ENGINE - COOLING SYSTEM

Scheme 378

Scheme 379

1 - Intake Manifold Runner Position Sensor G336

2 - Variable Intake Manifold Runner Motor V183

3 - Intake Flap Motor V157

4 - Secondary air injection (AIR) solenoid valve N112

5 - Intake Manifold Runner Position Sensor 2 G512

6 - Oil Pressure Switch F1 , removing and installing --> 17 - ENGINE - LUBRICATION

7 - Knock sensor 4 G199 (blue connector)

8 - Knock Sensor 3 G198 (white connector)

9 - Knock Sensor (KS) 1 G61 (orange connector)

10 - Knock Sensor (KS) 2 G66 (gray connector)

Note. Intake manifold must be removed in order to remove knock sensors. Intake manifold, removing and installing --> Intake manifold, removing and installing .

Scheme 380

1 - Engine Coolant Temperature (ECT) Sensor G62

2 - Knock sensor 4 G199

3 - Knock sensor 3 G198

4 - Fuel Pressure Sensor G247

5 - Knock sensor 1 G61

6 - Knock sensor 2 G66

7 - Camshaft Adjustment Valve 1 N205

8 - Low Fuel Pressure Sensor G410

Note. Intake manifold must be removed to remove Fuel Pressure Sensor G247 or knock sensors. Intake manifold, removing and installing --> Intake manifold, removing and installing .

Scheme 381

1 - Camshaft Adjustment Valve 1 (exhaust) N318

2 - Camshaft Adjustment Valve 1 N205

3 - Camshaft Position (CMP) sensor G40

4 - Camshaft position (CMP) sensor 3 G300

Scheme 382

1 - Camshaft position (CMP) sensor 4 G301

2 - Camshaft position (CMP) sensor 2 G163

3 - Camshaft Adjustment Valve 2 N208

4 - Camshaft Adjustment Valve 2 (exhaust) N319

Scheme 383

1 - Heated Oxygen Sensor (HO2S) G39 (in front of catalytic converter) black connection

2 - Heated Oxygen Sensor (HO2S) 3 G285 (in front of catalytic converter) brown connector

Scheme 384

1 - Gray Oxygen Sensor (O2S) 4 Behind Three Way Catalytic Converter (TWC) G288

2 - Black Oxygen Sensor (O2S) 3 Behind Three Way Catalytic Converter (TWC) G287

3 - Brown Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130

4 - Brown Heated Oxygen Sensor (HO2S) 4 G286 (in front of catalytic converter)

5 - Black Heated Oxygen Sensor (HO2S) 2 G108 (in front of catalytic converter)

6 - Black Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131

Scheme 385

1. Removing and installing --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

Air filter, component overview

Note. Illustration shows left air filter.

Scheme 386

1 - Rubber grommet

2 - Lower part of air filter housing

1. Clean air filter housing-lower part of salt residue, dirt and leaves
2. Check water drain for dirt, clean if necessary (important)

3 - Rubber grommet

4 - Bolt

1. 1.5 Nm

5 - Air duct

1. Clean air duct of dirt and leaves

6 - Upper part of air filter housing

1. Clean air filter housing-upper part of salt residue, dirt and leaves

7 - Air guide hose

1. To Throttle Valve Control Module J338

8 - Bolt

1. 1.5 Nm

9 - Air duct

1. To lock carrier
2. Clean air duct of dirt and leaves

10 - Air duct

1. To lock carrier
2. Clean air duct of dirt and leaves

11 - Screws

1. 1.5 Nm

12 - Mass Air Flow (MAF) Sensor G70

1. Mass Air Flow (MAF) Sensor G70 with Intake Air Temperature (IAT) Sensor G42 (cylinder bank 1), removing and installing --> «Mass Air Flow (MAF) Sensor G70 (cylinder bank 1), removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__mass-air-flow-maf-sensor-g70)
2. Mass Air Flow (MAF) Sensor 2 G246 (cylinder bank 2), removing and installing --> «Mass Air Flow (MAF) Sensor 2 G246 (cylinder bank 2), removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__mass-air-flow-maf-sensor-2)

13 - Screws

1. 1.5 Nm

14 - Air filter element

1. Always use a genuine air filter element
2. Maintenance intervals 405
3. Removing and installing --> «Left and right air filter insert, removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__left-and-right-air-filter-insert)
4. Clean snow screen also (if present)

Left and right air filter insert, removing and installing

Remove left air filter housing

Scheme 387

1. Remove bolts - arrows - and remove left air duct.

Scheme 388

1. Loosen hose clamp - 1 - and remove screws - 2 to 4 -.

Scheme 389

1. Disconnect electrical connector - arrow - on mass air flow (MAF) sensor 2 G246.
2. Remove upper part of left air filter housing.
3. Remove air filter element.

Remove right air filter housing

Scheme 390

1. Remove bolts - arrows - and remove right air duct.

Scheme 391

1. Separate vacuum lines - 4 - and - 5 -.
2. Loosen hose clamp - 6 - and remove screws - 1 to 3 -.

Scheme 392

1. Disconnect electrical connector - arrow - on Mass Air Flow (MAF) Sensor G70.
2. Remove upper part of right air filter housing.
3. Remove air filter element.

Installing

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

For trouble-free function of the Mass Air Flow (MAF) sensor, it is important to observe the following notes and perform the work procedures exactly.

Note. If the air filter element is very dirty or soaked, dirt particles or moisture may have contaminated the mass air flow (MAF) sensor 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. Air filter housing must always be clean. Secure all hose connections using hose clamps appropriate for the model type . Note the following when blowing out air filter housing with compressed air: To prevent malfunctions, cover critical air-flow engine components such as Mass Air Flow (MAF) sensor, air duct pipes etc. with a clean cloth. Observe disposal regulations!

Scheme 393

1. Clean water drain (small hole in lower part of air filter housing - arrow -), blow out with compressed air if necessary.
2. Clean air filter housing (upper and lower sections) of salt residue, dirt or leaves (use vacuum cleaner if necessary).
3. Check Mass Air Flow (MAF) sensor and air duct hose (clean air side) for salt residue, dirt and leaves.
4. Check air duct from lock carrier to air filter housing for dirt and leaves.

1. When installing air filter element, make sure it is put on centered in mount in lower section of air filter housing.
2. Place upper section of air filter housing on to lower section or air filter housing carefully and without using excessive force. When doing this, make sure that upper section of air filter housing is not placed tilted on the air filter element (pay attention to sealing lip of air filter element).
3. Make sure that air duct hose is connected securely to Mass Air Flow (MAF) sensor.

Torque specifications

Left and right air filter housing, removing and installing

1. Remove air filter insert on affected side of vehicle --> «Left and right air filter insert, removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__left-and-right-air-filter-insert) .

Scheme 394

Remove left air filter housing

1. Remove lower part of air filter housing from side connection.
2. Tilt upper part of air filter housing up and out - arrow -.

Remove right air filter housing

1. Remove lower part of air filter housing from side connection.

Scheme 395

1. Tilt upper part of air filter housing up and out - arrow -.

Installing

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

Note. Air filter housing must always be clean. Secure all hose connections using hose clamps appropriate for the model type . Note the following when blowing out air filter housing with compressed air: To prevent malfunctions, cover critical air-flow engine components such as Mass Air Flow (MAF) sensor, air duct pipes etc. with a clean cloth.

1. Clean water drain (small hole in lower part of air filter housing - arrow -), blow out with compressed air if necessary.
2. Clean air filter housing (upper and lower sections) of salt residue, dirt or leaves (use vacuum cleaner if necessary).
3. Check Mass Air Flow (MAF) sensor and air duct hose (clean air side) for salt residue, dirt and leaves.
4. Check air duct from lock carrier to air filter housing for dirt and leaves.

1. Place upper section of air filter housing on to lower section or air filter housing carefully and without using excessive force. When doing this, make sure that upper section of air filter housing is not placed tilted on air filter element (pay attention to sealing lip of air filter element).

Mass Air Flow (MAF) Sensor G70 (cylinder bank 1), removing and installing

Removing

1. Remove bolts - arrows - and remove right air duct.
2. Separate vacuum lines - 4 - and - 5 -.

1. Loosen hose clamp - 6 - and remove screws - 1 to 3 -.

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

Scheme 396

1. Open hose clamps - 1 - and remove both bolts - 2 -.
2. Carefully pull Mass Air Flow (MAF) Sensor G70 out of guide at upper section on air filter housing.

Installing

For trouble-free function of the Mass Air Flow (MAF) sensor, it is important to observe the following notes and perform the work procedures exactly.

Note. If the air filter element is very dirty or soaked, dirt particles or moisture may have contaminated the mass air flow (MAF) sensor 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. Always replaced damaged mass air flow sensor O-ring (air leak). Use a silicon-free lubricant to install the air duct hose. Secure all hose connections using hose clamps appropriate for the model type .

1. Check Mass Air Flow (MAF) Sensor and air duct hose (intake air side) for salt residue, dirt, and leaves.
2. Check intake ducting up to the air filter element for dirt. If any contaminants are discovered, clean air filter housing (upper and lower parts) of salt residue, dirt and leaves (if necessary, clean by washing or vacuuming). Upper part of air filter housing, removing and installing --> «Left and right air filter insert, removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__left-and-right-air-filter-insert)

1. If upper part of air filter housing was removed, check water drain - arrow - in lower part for dirt and contamination (clean by blowing out if necessary).

Note. Illustration shows left side of lower part of air filter housing.

1. Ensure air guide hose is seated securely between Mass Air Flow (MAF) Sensor G70 and Throttle Valve Control Module J338.

Further installation is in reverse order of removal.

Mass Air Flow (MAF) Sensor 2 G246 (cylinder bank 2), removing and installing

Removing

1. Remove bolts - arrows - and remove left air duct.

1. Loosen hose clamp - 1 - and remove screws - 2 to 4 -.

1. Disconnect electrical connector - arrow - on mass air flow (MAF) sensor 2 G246.

1. Open hose clamps - 1 - and remove both bolts - 2 -.
2. Carefully pull Mass Air Flow (MAF) Sensor 2 G246 out of guide at upper section on air filter housing.

Installing

For trouble-free function of the Mass Air Flow (MAF) sensor, it is important to observe the following notes and perform the work procedures exactly.

Note. If the air filter element is very dirty or soaked, dirt particles or moisture may have contaminated the mass air flow (MAF) sensor 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. Always replaced damaged mass air flow sensor O-ring (air leak). Use a silicon-free lubricant to install the air duct hose. Secure all hose connections using hose clamps appropriate for the model type .

1. Check Mass Air Flow (MAF) Sensor and air duct hose (intake air side) for salt residue, dirt, and leaves.
2. Check intake ducting up to air filter element for dirt. If any contaminants are discovered, clean air filter housing (upper and lower parts) of salt residue, dirt and leaves (if necessary, clean by washing or vacuuming). Upper part of air filter housing, removing and installing --> «Left and right air filter insert, removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__left-and-right-air-filter-insert)

1. If upper part of air filter housing was removed, check water drain - arrow - in lower part for dirt and contamination (clean by blowing out if necessary).
2. Ensure air guide hose is seated securely between Mass Air Flow (MAF) Sensor G246 and Throttle Valve Control Module 2 J544.

Further installation is in reverse order of removal.

Scheme 397

1 - Intake Flap Motor V157

2 - Bolt

1. 9 Nm

3 - Bolt

1. 9 Nm

4 - Variable Intake Manifold Runner Motor V183

5 - Bolt

1. 2.5 Nm

6 - Intake Manifold Runner Position Sensor G336

1. Right cylinder bank
2. After replacing, perform "Adaptation" in "Guided Functions".

7 - Gasket

1. Replace if damaged
2. Open side faces Intake Manifold Runner Position Sensor G336

8 - Intake manifold

1. Removing and installing --> «Intake manifold, removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

9 - Gasket

1. Replace

10 - Gasket

1. Replace

11 - Throttle valve control module J338

1. After replacing, perform "Adaptation" in "Guided Functions".

12 - Bolt

1. 9 Nm

13 - Bolt

1. 9 Nm

14 - Air duct

15 - Gasket

1. Replace

16 - Throttle Valve Control Module 2 J544

1. After replacing, perform "Adaptation" in "Guided Functions".

17 - Bolt

1. 9 Nm

18 - Bracket

19 - O-ring

1. Replace

20 - Supports with coolant connection

1. For crankcase ventilation

21 - Bolt

1. 9 Nm

22 - Bolt

1. Always observe tightening sequence and torque, intake manifold, removing and installing --> «Intake manifold, removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

23 - Gasket for intake manifold

1. Replace

24 - Mounting pins

1. 2 pieces
2. Check availability

25 - Gasket

1. Replace if damaged
2. Open side faces Intake Manifold Runner Position Sensor 2 G512

26 - Intake Manifold Runner Position Sensor 2 G512

1. Left cylinder bank
2. After replacing, perform "Adaptation" in "Guided Functions".

27 - Bolt

1. 2.5 Nm

28 - Circlip

Scheme 398

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331
2. SW 17 socket V.A.G 1331/6
3. SW 14 socket, open ring V.A.G 1331/8

Removing

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

1. With ignition switched off, disconnect Battery Ground (GND) wire.
2. Drain the coolant --> «19 - ENGINE - COOLING SYSTEM»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
3. Remove radiator --> «19 - ENGINE - COOLING SYSTEM»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
4. Remove fan shroud --> «19 - ENGINE - COOLING SYSTEM»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

Scheme 399

1. Remove front engine cover - 1 - - arrows - and rear - 2 - - arrows -.

Scheme 400

1. Remove left air duct hose - arrows -.

Scheme 401

1. Remove vacuum hoses - 1 - and - 2 -.

1. Remove right air guide hose - arrows -.

Scheme 402

1. Disconnect electrical harness connector - 1 - from Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.
2. Remove vacuum hose - 2 - from Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.
3. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 from bracket and lay aside with hose connected.

Scheme 403

1. Remove crankcase ventilation vacuum hose - arrows -.

Scheme 404

1. Remove bolts - arrows -.
2. Remove crankcase ventilation pressure control valve toward rear.

Note. Crankcase ventilation pressure regulator valve remains in engine compartment with return hose connected.

Scheme 405

1. Disconnect electrical connectors - arrow - at Throttle Valve Control Module J338 and Throttle Valve Control Module 2 J544 at left and right on intake manifold.

Scheme 406

1. Remove vacuum hose - 1 - from intake manifold.
2. Remove bolts - arrows - and remove air duct.

Scheme 407

1. Remove coolant hoses - 1 - and - 2 - from intake connection.
2. Remove hood seal on lock carrier and fender edges.

Scheme 408

1. Separate vacuum lines - 1 - and - 2 -.
2. Free up vacuum hoses.

Scheme 409

1. Disconnect electrical harness connectors for

1. Intake Manifold Runner Position Sensor G336
2. Variable Intake Manifold Runner Motor V183 (black connector)
3. Secondary air injection (AIR) solenoid valve N112
4. Intake Manifold Runner Position Sensor 2 G512
5. Intake Flap Motor V157 (blue connector)

Scheme 410

1. Disconnect electrical harness connectors for

1. Knock Sensor (KS) 2 G66 (gray connector)
2. Knock Sensor (KS) 1 G61 (orange connector)
3. Knock Sensor 3 G198 (white connector)
4. Knock sensor 4 G199 (blue connector)

1. Disconnect electrical connectors - 3 - from Fuel Metering Valve N290 on right high pressure pump and on Fuel Metering Valve 2 N402 on left high pressure pump.
2. Disconnect left and right electrical connectors - 2 - on Camshaft Position (CMP) Sensor G40 and on Camshaft Position (CMP) Sensor 2 G163 on cylinder head.

Scheme 411

1. Remove Ground (GND) line - 1 - at right and left from cylinder head.

Scheme 412

1. Disconnect fuel supply line - arrow -.

Scheme 413

1. Loosen connections - 1 through 4 - and remove fuel supply line to right high pressure pump.

Scheme 414

1. Loosen connections - 1 through 8 - and remove fuel supply line and high pressure line to left of high pressure pump.

Scheme 415

1. Remove left and right bolts - arrows - and remove both high pressure pumps.

Scheme 416

1. Remove bolts and nut - arrows - and remove left front engine lifting eye.

Scheme 417

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

Scheme 418

1. Remove intake manifold bolts in sequence - 12 to 1 -.
2. Remove intake manifold from engine compartment.

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

Installing

Installation is in reverse order of removal, note the following

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.

1. Replace intake manifold seals, be careful of locating pins when doing so.
2. Be aware of alignment pins when setting intake manifold in place.

1. Tighten intake manifold bolts in 2 stages as follows.
2. Pre-tighten bolts to 9 Nm - 1 to 12 - in sequence.
3. Pre-tighten bolts to 9 Nm again - 1 to 12 - in sequence.

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

1. Hand-tighten union nuts for high-pressure lines.
2. Make sure high-pressure lines are seated free of stress.
3. To fasten SW 14 union nut for high pressure lines, use torque wrench V.A.G 1331 with 17 mm open end wrench socket V.A.G 1331/8.

Scheme 419

1. To tighten SW 17 union nut for high pressure lines, use torque wrench V.A.G 1331 with SW 17 socket V.A.G 1331/6.
2. Only install retaining tabs after high pressure lines have been tightened.
3. Install left and right high pressure pumps --> «High pressure pump, removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
4. Install radiator --> «19 - ENGINE - COOLING SYSTEM»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

1. Remove fan shroud --> «19 - ENGINE - COOLING SYSTEM»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
2. Fill with coolant --> «19 - ENGINE - COOLING SYSTEM»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
3. Observe safety precautions after connecting battery --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .

Torque specifications

Scheme 420

1 - Radial adjustment

1. Replace if damaged

2 - Combustion chamber seal

1. Do not grease ring or treat with any other lubricant
2. Replacing --> «Fuel injectors, removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .

3 - Fuel injector

1. Removing and installing --> «Fuel injectors, removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

4 - Spacer ring

1. Replace if damaged

5 - O-ring

1. Replace
2. Moisten with clean engine oil

6 - Support ring

1. Replace
2. The fuel rail wields force via support ring to hold the fuel injector tightly in cylinder head.

7 - Fuel rail

8 - High-pressure line

1. Connectors should not show any signs of damage
2. Do not change bent shape
3. 25 Nm

9 - High-pressure line

1. Connectors should not show any signs of damage
2. Do not change bent shape
3. 25 Nm

10 - Pressure relief valve 120 bar

1. For high pressure line
2. 25 Nm

11 - High-pressure line

1. Connectors should not show any signs of damage
2. Do not change bent shape
3. 25 Nm

12 - Bolt

1. 9 Nm
2. Fasten in diagonal sequence in steps

13 - Bolt

1. 9 Nm
2. Fasten in diagonal sequence in steps

Scheme 421

1 - High pressure pump

1. Removing and installing --> «High pressure pump, removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa)

2 - Bolt

1. 9 Nm

3 - Seal

1. Replace

4 - Locking bolt

1. 10 Nm

5 - High-pressure line

1. Connectors should not show any signs of damage
2. Do not change bent shape
3. 25 Nm

6 - High pressure line (fuel supply line)

1. Connectors should not show any signs of damage
2. Do not change bent shape
3. 25 Nm

7 - O-ring

1. Replace

8 - Roller tappet

Scheme 422

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331
2. SW 17 socket V.A.G 1331/6
3. SW 14 socket, open ring V.A.G 1331/8

Removing

1. Disconnect electrical connector - 1 - from respective high pressure pump.

Scheme 423

Right high pressure pump (in direction of travel)

Scheme 424

Left high pressure pump (in direction of travel)

1. Remove union nuts - 3 - and - 4 -.
2. Remove bolts - 2 -.

Note. Do not change bent shape of high pressure lines.

1. Carefully remove high pressure pump.
2. Remove roller tappet from cylinder head.

Installing

Installation is in reverse order of removal, note the following

Tightening torques, see component overview --> High pressure pump, component overview

Note. Always replace O-ring.

1. Insert roller tappet in cylinder head.
2. To set high pressure pump in place, lift high pressure lines only slightly.
3. Insert high pressure pump with new O-ring in cylinder head and tighten.

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

1. Hand-tighten union nuts for high-pressure lines.
2. Make sure high-pressure lines are seated free of stress.
3. To fasten SW 14 union nut for high pressure line, use torque wrench V.A.G 1331 with 17 mm open end wrench socket V.A.G 1331/8.

1. To tighten SW 17 union nut for high pressure line, use torque wrench V.A.G 1331 with SW 17 socket V.A.G 1331/6.

Scheme 425

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331
2. SW 17 socket V.A.G 1331/6
3. SW 14 socket, open ring V.A.G 1331/8
4. Tool set T10133 with T10133/10

Removing

1. Remove intake manifold --> «Intake manifold, removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .

Note. Seal intake channels in cylinder heads with a clean cloth.

Scheme 426

1. Disconnect electrical harness connectors at fuel injectors.
2. Remove high pressure line - 1 - from connector on fuel rail.
3. Remove high pressure line - 2 - from connector on fuel rail. To do this, counterhold at hex head with and open-end wrench and loosen union nut.
4. Remove bolts - arrows -.

Note. Illustration depicts left cylinder head. Do not change bent shape of high pressure lines.

1. Remove fuel rail with fuel injectors.

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

Scheme 427

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

Scheme 428

1. Install hammer T10133/3 to puller T10133/10.
2. Guide puller T10133/10 into groove of fuel injector and carefully drive fuel injector out.

Note. When setting the puller in place, the radial adjustment can be destroyed, because the retaining tabs break. The combustion chamber seal must always be replaced before re-installing the high-pressure fuel injector.

Combustion chamber sealing ring (Teflon sealing ring), replacing

Scheme 429

1. Carefully remove old Teflon seal - arrow - with appropriate tool (e.g. with cut 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 groove base.

Note. 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 moisten fuel injector O-rings with clean engine oil. Re-insert injector lines at same cylinder.

Scheme 430

1. Clean hole in cylinder head with nylon cylinder brush T10133/4.

Scheme 431

1. Clip radial adjustment - 1 - to support ring - 2 -.
2. When re-installing a fuel injector, use a clean cloth to clean combustion residue from groove for combustion chamber seal and shaft of fuel injector.

Scheme 432

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

Scheme 433

1. Push combustion chamber seal as fast possible onto assembly cone T10133/5 using assembly sleeve T10133/6.
2. Turn assembly sleeve T10133/6 around and push combustion chamber seal into groove.

Scheme 434

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.

1. Press calibrating sleeve T10133/7 using a gentle turning motion (approx. 180°) on to fuel injector until it stops.
2. Pull sizing sleeve T10133/7 off again, turning it in opposite direction.

Scheme 435

1. Press sizing sleeve T10133/8 with a slight turning motion (approx. 180°) onto fuel injector until it stops.
2. Pull off calibrating T10133/8 again using turning motion in opposite direction.
3. Moisten new O-ring 3 with clean engine oil before installing.

Note. The combustion chamber seal must not be oiled.

Scheme 436

1. Using assembly drift T10133/9 , press fuel injector into hole in cylinder head until it stops.

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

1. Make sure fuel injectors are correctly positioned in cylinder head.

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

1. Press fuel rail onto fuel injectors with uniform pressure.
2. Fasten bolts - arrows - in a diagonal sequence and in steps.

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

1. Hand-tighten union nuts for high-pressure lines.
2. Make sure high-pressure lines are seated free of stress.
3. To fasten SW 14 union nut for high pressure line, use torque wrench V.A.G 1331 with 17 mm open end wrench socket V.A.G 1331/8.

1. To tighten SW 17 union nut for high pressure line, use torque wrench V.A.G 1331 with SW 17 socket V.A.G 1331/6.
2. Only install retaining tabs after high pressure lines have been tightened.

Further installation is in reverse order of removal of removal, note the following

1. Install intake manifold --> «Intake manifold, removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
2. Fill with coolant --> «19 - ENGINE - COOLING SYSTEM»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

Torque specifications

Fuel pressure and residual pressure before high pressure pump, checking

Special tools, testers and auxiliary items required

Scheme 437

1. Pressure gauge K-Jetronic V.A.G 1318
2. Pressure gauge adapter V.A.G 1318/10-12

Scheme 438

1. Remote Control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3
2. Measuring container, fuel-resistant

Test conditions

1. Battery voltage at least 12.5 Volts.

Scheme 439

1. Fuse 1 of right fuse panel in center bracket of instrument panel - 2 - is OK.
2. Fuel Pump (FP) Control Module J538 OK; check in "Guided Fault Finding" with Vehicle Diagnosis, Testing and Information System VAS 5051B.
3. Fuel filter OK.
4. Fuel tank at least 1 / 4 filled.

1. Ignition switched off.

Checking fuel pressure

1. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/s6/c6-2006-2008/remont/gauges-instrument-panels/#body-interior) .

Scheme 440

1. Remove cover - arrows - for right locking flange.

Scheme 441

1. Disconnect electrical harness connector - arrow - at locking flange.

Scheme 442

1. Connect Remote Control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3 with an adapter cable from Connector Test Set V.A.G 1594C at terminal - 1 -.
2. Cover 2nd connector terminal of adapter cable V.A.G 1348/3-3 with insulating tape to prevent short circuit - arrow -.
3. Route Remote Control V.A.G 1348/3A switch forward in engine compartment.
4. Release retaining clip and open cover - A - over positive terminal pick-off.

1. Connect alligator clip to positive terminal pick-off (+).
2. Connect contact - 5 - to vehicle Ground (GND) using a jumper cable from connector test set V.A.G 1594C.
3. Remove fuel filler cap from fuel filler tube.

1. Remove rear engine cover - 2 - - arrows -.

Note. Ignore - 1 -.

1. Disconnect fuel line - arrow - on fuel rail.

Scheme 443

1. Connect Fuel Inj. Pressure Gauge-CIS V.A.G 1318 with Adapter V.A.G 1318/11 and V.A.G 1318/12 in fuel line.
2. Connect assisting hose - arrow - on pressure gauge and hold it in a container.
3. Open pressure gauge shut-off valve. Shut-off valve faces in direction of flow.
4. Bleed fuel system by pressing remote control briefly.

1. Close pressure gauge shut-off valve. Shut-off valve is perpendicular to direction of flow.
2. Press remote control switch until pressure gauge no longer shows pressure increasing.

1. Specified value: approx. 6 bar (5 to 7 bar) positive pressure

If specification is not obtained

1. Check delivery quantity of Fuel Pumps (FP) --> «20 - FUEL SUPPLY»(/audi/s6/c6-2006-2008/remont/fuel-system/#fuel-supply-system) .

Checking residual pressure

1. Check for leaks and residual pressure by observing pressure drop on Fuel Inj. Pressure Gauge-CIS K-Jetronic V.A.G 1318.

1. After 10 minutes there must be a residual pressure of at least 3.75 bar.

The holding pressure drops below 3.75 bar

1. Check connection between Fuel Inj. Pressure Gauge-CIS K-Jetronic V.A.G 1318 and fuel line for leaks.
2. Check pressure gauge for leaks.
3. Check fuel lines and their connections for leaks.
4. Replace fuel filter with integrated fuel pressure regulator --> «20 - FUEL SUPPLY»(/audi/s6/c6-2006-2008/remont/fuel-system/#fuel-supply-system) . Then repeat test.

1. Replace right Fuel Pump (FP) G23 if necessary --> «20 - FUEL SUPPLY»(/audi/s6/c6-2006-2008/remont/fuel-system/#fuel-supply-system) .

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

1. Switch off ignition.

Note. Before disconnecting pressure gauge, release pressure by opening shut-off valve. Hold assisting hose in a container.

1. Re-install fuel supply line (ensure cleanliness).

Torque specifications

Scheme 444

I - Primary catalytic converter for cylinder 1, 2, 3 (exhaust bank I)

II - Primary catalytic converter for cylinders 4, 5 (exhaust bank II)

III - Primary catalytic converter for cylinder 6, 7, 8 (exhaust bank III)

IV - Primary catalytic converter for cylinders 9, 10 (exhaust bank IV)

1 - Oxygen Sensor (O2S) 3 Behind Three Way Catalytic Converter (TWC) G287 with Oxygen Sensor (O2S) 3 (behind Three Way Catalytic Converter (TWC)) Heater Z64

1. Exhaust bank III (cylinder 6, 7, 8)
2. Location of electrical connector --> «Location of electrical connectors for oxygen sensors G108 , G130 , G131 , G286 , G287 , G288»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__location-of-electrical-connectors-for-oxygen)
3. Removing and installing --> «Oxygen sensors G108 , G130 , G131 , G286 , G287 , G288 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__oxygen-sensors-g108-g130)

2 - Heated Oxygen Sensor (HO2S) 3 G285 before catalytic converter with Oxygen Sensor (O2S) 3 Heater Z62

1. Exhaust bank III (cylinder 6, 7, 8)
2. Location of electrical connector --> «Location of electrical connectors for Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__location-of-electrical-connectors-for-heated)
3. Removing and installing --> «Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__heated-oxygen-sensor-ho2s-g39-and)

3 - Oxygen Sensor (O2S) 4 Behind Three Way Catalytic Converter (TWC) G288 with Oxygen Sensor (O2S) 4 (behind Three Way Catalytic Converter (TWC)) Heater Z65

1. Exhaust bank IV (cylinder 9, 10)
2. Location of electrical connector --> «Location of electrical connectors for oxygen sensors G108 , G130 , G131 , G286 , G287 , G288»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__location-of-electrical-connectors-for-oxygen)
3. Removing and installing --> «Oxygen sensors G108 , G130 , G131 , G286 , G287 , G288 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__oxygen-sensors-g108-g130)

4 - Heated Oxygen Sensor (HO2S) 4 G286 before catalytic converter with Oxygen Sensor (O2S) 4 Heater Z63

1. Exhaust bank IV (cylinder 9, 10)
2. Location of electrical connector --> «Location of electrical connectors for oxygen sensors G108 , G130 , G131 , G286 , G287 , G288»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__location-of-electrical-connectors-for-oxygen)
3. Removing and installing --> «Oxygen sensors G108 , G130 , G131 , G286 , G287 , G288 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__oxygen-sensors-g108-g130)

5 - Heated Oxygen Sensor (HO2S) 2 G108 before catalytic converter with Oxygen Sensor (O2S) 2 Heater Z28

1. Exhaust bank II (cylinder 4, 5)
2. Location of electrical connector --> «Location of electrical connectors for oxygen sensors G108 , G130 , G131 , G286 , G287 , G288»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__location-of-electrical-connectors-for-oxygen)
3. Removing and installing --> «Oxygen sensors G108 , G130 , G131 , G286 , G287 , G288 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__oxygen-sensors-g108-g130)

6 - Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 with Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater Z30

1. Exhaust bank II (cylinder 4, 5)
2. Location of electrical connector --> «Location of electrical connectors for oxygen sensors G108 , G130 , G131 , G286 , G287 , G288»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__location-of-electrical-connectors-for-oxygen)
3. Removing and installing --> «Oxygen sensors G108 , G130 , G131 , G286 , G287 , G288 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__oxygen-sensors-g108-g130)

7 - Heated Oxygen Sensor (HO2S) G39 before catalytic converter with Oxygen Sensor (O2S) Heater Z19

1. Exhaust bank I (cylinder 1, 2, 3)
2. Location of electrical connector
3. Removing and installing --> «Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__heated-oxygen-sensor-ho2s-g39-and)

8 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 with Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater Z29

1. Exhaust bank I (cylinder 1, 2, 3)
2. Location of electrical connector --> «Location of electrical connectors for oxygen sensors G108 , G130 , G131 , G286 , G287 , G288»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__location-of-electrical-connectors-for-oxygen)
3. Removing and installing --> «Oxygen sensors G108 , G130 , G131 , G286 , G287 , G288 , removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__oxygen-sensors-g108-g130)

Location of electrical connectors for Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285

1. On vehicle floor.

1. Heated Oxygen Sensor (HO2S) G39 (in front of catalytic converter) black connection
2. Heated Oxygen Sensor (HO2S) 3 G285 (in front of catalytic converter) brown connector

Location of electrical connectors for oxygen sensors G108 , G130 , G131 , G286 , G287 , G288

1. At top of transmission.

1. Gray Oxygen Sensor (O2S) 4 Behind Three Way Catalytic Converter (TWC) G288
2. Black Oxygen Sensor (O2S) 3 Behind Three Way Catalytic Converter (TWC) G287
3. Brown for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130
4. Brown for Heated Oxygen Sensor (HO2S) 4 G286 (in front of catalytic converter)
5. Black Heated Oxygen Sensor (HO2S) 2 G108 (in front of catalytic converter)
6. Black Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131

Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285 , removing and installing

Special tools, testers and auxiliary items required

Scheme 445

1. Ring spanner 7-piece set for oxygen sensor 3337

Removing

Scheme 446

1. Loosen quick-release fasteners - 2 - and remove rear noise insulation.

Scheme 447

1. Remove electrical harness connectors from bracket and disconnect it

2 - Heated Oxygen Sensor (HO2S) G39 (in front of catalytic converter) black connection

3 - Heated Oxygen Sensor (HO2S) 3 G285 (in front of catalytic converter) brown connector

1. Remove affected oxygen sensor using tool from Ring Spanner Set 3337.

1 - Heated Oxygen Sensor (HO2S) G39 (before catalytic converter)

4 - Heated Oxygen Sensor (HO2S) 3 G285 (in front of catalytic converter)

Installing

Installation is in reverse order of removal, note the following

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

Torque specifications

Oxygen sensors G108 , G130 , G131 , G286 , G287 , G288 , removing and installing

Special tools, testers and auxiliary items required

1. Ring spanner 7-piece set for oxygen sensor 3337

Removing

Note. During installation, re-install all heat insulation sleeves and heat shields at the same locations. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

1. Remove engine --> «10 - ENGINE - ASSEMBLY»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
2. Leave engine with transmission installed on scissor lift platform VAS 6131.

Scheme 448

1. Remove right oxygen sensor connection heat shield from transmission - arrows -.

1. Remove affected oxygen sensor electrical connector from bracket on transmission.

1. Gray Oxygen Sensor (O2S) 4 Behind Three Way Catalytic Converter (TWC) G288
2. Black Oxygen Sensor (O2S) 3 Behind Three Way Catalytic Converter (TWC) G287
3. Brown for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130
4. Brown for Heated Oxygen Sensor (HO2S) 4 G286 (in front of catalytic converter)
5. Black Heated Oxygen Sensor (HO2S) 2 G108 (in front of catalytic converter)
6. Black Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131

1. Disconnect affected electrical connector and free up electrical wiring.

Left exhaust tract

Scheme 449

1. Remove affected oxygen sensor with the Ring Spanner Set 3337.

1. Heated Oxygen Sensor (HO2S) 4 G286 (in front of catalytic converter)
2. Oxygen Sensor (O2S) 4 Behind Three Way Catalytic Converter (TWC) G288
3. Oxygen Sensor (O2S) 3 Behind Three Way Catalytic Converter (TWC) G287

Right exhaust system tract

Scheme 450

1. Remove affected oxygen sensor using tool from Ring Spanner Set 3337.

1. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130
2. Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131
3. Heated Oxygen Sensor (HO2S) 2 G108 (in front of catalytic converter)

Installing

Installation is in reverse order of removal, note the following

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

1. Install engine --> «10 - ENGINE - ASSEMBLY»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

Torque specifications

Wiring and components, checking with Test box V.A.G 1598/42

Special tools, testers and auxiliary items required

1. Adapter cable V.A.G 1598/39-1
2. Adapter cable V.A.G 1598/39-2

Scheme 451

1. Test box V.A.G 1598/42

Note. The test box V.A.G 1598/42 is designed with 105 terminals. It can be connected to the engine control module (ECM) via 2 different adapter cables. The engine control module (ECM) is connected to the vehicle electrical harness via a 60-pin connector and a 94-pin connector. For testing at the 60-pin harness connection, the adapter cable V.A.G 1598/39-1 is connected to the test box with connector - A -. Components of the 60-pin harness connection --> Electrical Wiring Diagrams, Troubleshooting and Component Locations. For testing at the 94-pin harness connection, the adapter cable V.A.G 1598/39-2 is connected to the test box with connectors - A - and - B -. Components of the 94-pin harness connection --> Electrical Wiring Diagrams, Troubleshooting and Component Locations. 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 (e.g. measurement of signals with engine running) when the test box is attached. Always use connector test set V.A.G 1594 C to connect measuring equipment (e.g. voltage tester V.A.G 1527 B , portable multimeter V.A.G 1526 C , etc.)

ECMs must be removed in order to disconnect multi-pin connectors from them.

1. Switch off ignition.

Scheme 452

1. Remove rubber seal - 1 - and remove plenum chamber cover - 2 -.

Note. Both engine control modules are identical. If both engine control modules are removed, they must be marked before removal to prevent them from being interchanged when re-installing. Master-ECM 2: e.g. with a "M" Slave-ECM 1: e.g. with a "S" - 1 - faces Engine Control Module (ECM) 2 J624 (slave). - 2 - faces Engine Control Module (ECM) J623 (master).

1. Carefully pull cowl grill only as far as necessary out of retainer on windshield.

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

1. Engine Control Module (ECM) J623 , removing and installing --> «Engine Control Module (ECM) J623 (master), removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__engine-control-module-ecm-j623-master)
2. Engine Control Module (ECM) 2 J624 , removing and installing --> «Engine Control Module (ECM) 2 J624 (slave), removing and installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa__engine-control-module-ecm-2-j624)

1. Connect test box V.A.G 1598/42 to wiring harness with adapter cable V.A.G 1598/39-1 or adapter cable V.A.G 1598/39-2. Clamp test box Ground (GND) clip to battery negative terminal. The procedure will indicate whether the engine control module is to be connected to test box or not.
2. Perform test as described in corresponding repair procedure.

Installing engine control module (ECM)

Installation is in reverse order of removal.

1. Thereafter, the engine control module must be equipped with metal retainer.
2. Clean threaded holes for shear bolts of locking compound residue. Cleaning can be performed with a thread cutter (tap).
3. 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.

Engine Control Module (ECM) J623 (master), removing and installing

Engine management on V10 is controlled by two engine control modules.

Both engine control modules communicate via private CAN-Bus.

Engine Control Module (ECM) J623 (master) communicates which functions need to performed to Engine Control Module (ECM) 2 J624 (slave).

Note. Both engine control modules are identical. If both engine control modules are removed, they must be marked before removal to prevent them from being interchanged when re-installing. Engine Control Module (ECM) J623 (master): e.g. with an "M" Engine Control Module (ECM) 2 J624 (slave): e.g. with an "S" - 1 - faces Engine Control Module (ECM) 2 J624 (slave). - 2 - faces Engine Control Module (ECM) J623 (master).

Special tools, testers and auxiliary items required

Scheme 453

1. Heat Gun 220 V/50 Hz VAS 1978/14 - 1 - with nozzle attachment - 2 - from Wiring Harness Repair kit VAS 1978A
2. Small, commercially available locking pliers - 3 - (vise grips)

Scheme 454

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

Removing

1. Turn ignition and remove ignition key.

1. Remove rubber seal - 1 - and remove plenum chamber cover - 2 -.
2. Carefully pull cowl grill only as far as necessary out of retainer on windshield.

1. Remove Engine Control Module (ECM) J623 - 2 -.

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

Remove Engine Control Module (ECM) J623.

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

The threads of both shear bolts - 3 - (that are installed in 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).

Scheme 455

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

Scheme 456

Warm threads on connector side of shear bolts as shown in illustration.

Switch on heat gun and heat bolt for approx. 20 to 30 seconds.

Scheme 457

1. Remove shear bolts with locking pliers (see direction of arrow).
2. Both shear bolts that are installed into the ECM do not require heating to be removed. They can be removed without heat.
3. Disconnect metal retainers from connectors.
4. Remove both retainer bolts from Engine Control Module (ECM) J623.

1. Disengage connector from Engine Control Module (ECM) J623 and remove connector.
2. Remove old Engine Control Module (ECM) J623 and connect new one.

Installing

Installation is in reverse order of removal.

1. After that, the Engine Control Module (ECM) J623 must be equipped with the metal retainer.
2. Clean threaded holes for shear bolts of locking compound residue. Cleaning can be performed with a thread cutter (tap).
3. Always use new shear bolts.
4. Carefully clip cowl grille back into retainer on windshield.

The procedures to follow after connecting the new ECM are described in Guided Fault-Finding and Guided Functions.

Engine Control Module (ECM) 2 J624 (slave), removing and installing

Engine management on the V10 is controlled by two engine control modules.

Both engine control modules communicate via private CAN-Bus.

Engine Control Module (ECM) J623 (master) communicates which functions need to performed to Engine Control Module (ECM) 2 J624 (slave).

Note. Both engine control modules are identical. If both engine control modules are removed, they must be marked before removal to prevent them from being interchanged when re-installing. Engine Control Module (ECM) J623 (master): e.g. with an "M" Engine Control Module (ECM) 2 J624 (slave): e.g. with an "S" - 1 - faces Engine Control Module (ECM) 2 J624 (slave). - 2 - faces Engine Control Module (ECM) J623 (master).

Special tools, testers and auxiliary items required

1. Heat Gun 220 V/50 Hz VAS 1978/14 - 1 - with nozzle attachment - 2 - from Wiring Harness Repair kit VAS 1978A
2. Small, commercially available locking pliers - 3 - (vise grips)

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

Removing

1. Turn ignition and remove ignition key.

1. Remove rubber seal - 1 - and remove plenum chamber cover - 2 -.
2. Carefully pull cowl grill as far as necessary out of retainer on windshield.

1. Remove Engine Control Module (ECM) 2 J624 - 1 -.

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

Remove Engine Control Module (ECM) 2 J624.

Threads of the shear bolts - 4 - (that are not installed in 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 installed in 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 adjustment on the heat gun as shown in the illustration, with the temperature potentiometer - 2 - set to maximum heat and two-stage air flow switch - 3 - set to level 3.

Warm threads on connector side of shear bolts as shown in illustration.

Switch on heat gun and heat bolt for approx. 20 to 30 seconds.

1. Remove shear bolts with locking pliers (see direction of arrow).
2. Both shear bolts that are installed into the ECM do not require heating to be removed. They can be removed without heat.
3. Disconnect metal retainers from connectors.
4. Remove both retainer bolts from Engine Control Module (ECM) 2 J624.

1. Disengage connector from Engine Control Module (ECM) 2 J624 and remove connector.
2. Remove old Engine Control Module (ECM) 2 J624 and connect new one.

Installing

Installation is in reverse order of removal.

1. After that, the Engine Control Module (ECM) 2 J624 must be equipped with metal retainer.
2. Clean threaded holes for shear bolts of locking compound residue. Cleaning can be performed with a thread cutter (tap).
3. Always use new shear bolts.
4. Carefully clip cowl grille back into retainer on windshield.

The procedures to follow after connecting the new ECM are described in Guided Fault-Finding and Guided Functions.

Ignition system, general information

1. The engine control module is equipped with On Board Diagnostics (OBD).
2. For electric components to work properly, a voltage of at least 11.5 Volts is required.
3. 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.
4. If the engine only starts briefly and then turns off again after troubleshooting, repair or checking of the components, it may be that the immobilizer is blocking the Engine Control Module (ECM). DTC memory must then be checked and if necessary, control module must be adapted.

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

1. Do not touch or remove ignition wires when engine is running or turning at starter speed.
2. Always switch ignition off before disconnecting or reconnecting wires for the ignition system, including high voltage wiring and test leads.
3. If engine is to be cranked at starting RPM without starting (e.g. for compression testing), disconnect connectors from ignition coils and from fuel injectors. After performing work, check and erase DTC memory.
4. Cleaning engine should only be performed with ignition switched off.

1. The battery must only be disconnected and connected with ignition switched off, since Engine Control Module (ECM) can otherwise be damaged.

Test data

Ignition coils with power output stage, removing and installing

Special tools, testers and auxiliary items required

Scheme 458

1. Puller T40039

1. Remove rear engine cover - 2 -.

Removing cylinder bank 1 (right)

1. Remove bolts - arrows - and remove left air duct.

1. Open hose clamps - arrows - and remove right air guide hose.
2. Disconnect electrical connector - 1 - on Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank.

Scheme 459

1. Remove bolts - 2 - and - 3 - and lay aside coolant reservoir with connected coolant hoses - 4 - and - 5 -.

Scheme 460

1. Remove bolts - 1 - and - 2 -.

Scheme 461

1. Pull ignition coils approx. 30 mm out of spark plug shaft using Puller T40039.
2. Release electrical connectors and remove connectors simultaneously from ignition coils.

Removing cylinder bank 2 (left)

1. Remove bolts - arrows - and remove left air duct.

1. Open hose clamps - arrows - and remove left air guide hose.

Scheme 462

1. Remove bolts - 1 - and - 3 -.

1. Pull ignition coils approx. 30 mm out of spark plug shaft using Puller T40039.
2. Release electrical connectors and remove connectors simultaneously from ignition coils.

Installing ignition coils

1. Insert all ignition coils loosely into spark plug shaft.
2. Align ignition coils to the connectors and then connect all of connectors simultaneously onto ignition coils.
3. Press ignition coils uniformly onto spark plugs by hand (do not use an impact tool).

Torque specifications

See also:
• 19 - ENGINE - COOLING SYSTEM
• 27 - STARTER, GENERATOR, CRUISE CONTROL
• 72 - SEAT - FRAMES
• 20 - FUEL SUPPLY
• Procedure that must be performed before opening the high-pressure fuel injection system - Pay close attention!
• Engine Control Module (ECM) J623 (master), removing and installing
• Engine Control Module (ECM) 2 J624 (slave), removing and installing
• Location on right cylinder bank 1
• Ignition coils with power output stage, removing and installing
• Mass Air Flow (MAF) Sensor G70 (cylinder bank 1), removing and installing
• Mass Air Flow (MAF) Sensor 2 G246 (cylinder bank 2), removing and installing
• Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285 , removing and installing
• Location of electrical connectors for oxygen sensors G108 , G130 , G131 , G286 , G287 , G288
• Location of electrical connectors for Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 3 G285
• Left and right air filter insert, removing and installing
• Oxygen sensors G108 , G130 , G131 , G286 , G287 , G288 , removing and installing