BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM
| WARNING | The injection system is separated into a high-pressure section (maximum approximately 120 bar) and a low-pressure section (approximately 6 bar). Before opening the high pressure area, the fuel pressure must be reduced to a residual pressure of approximately 6 bar. Refer to General Information . |
CLEAN WORKING CONDITIONS
Even a little contamination can lead to faults. Observe the following guidelines for cleanliness when working on the fuel system, injection system and turbocharger
- Before loosening, connections and surrounding areas must be cleaned thoroughly with engine or brake cleaner, and then the cleaned area must be dried completely.
- Seal the open lines and connections immediately with clean plugs, for example, from the engine bung set VAS 6122.
- Place removed parts on a clean surface and cover them with lint-free cloths.
- Carefully cover over opened components or seal, if repairs are not performed immediately.
- Only install clean components: Remove the replacement parts from their packaging just prior to installing them. Do not use parts that have been stored out of their original packaging (for example in tool boxes etc.).
- If system is open, do not work with compressed air and do not move the vehicle.
- Make sure no fuel gets onto the fuel hoses. If necessary, wipe off the fuel hoses immediately.
- Protect the disconnected connectors from dirt and moisture and only connect when they are dry.
CONTACT CORROSION
Contact corrosion can occur if incorrect fasteners (bolts, nuts, washers, etc.) are used.
For this reason, only connecting elements with a special surface coating are installed.
In addition, rubber or plastic parts and adhesive are made of materials that do not conduct electricity.
If you are not sure about the suitability of parts, install new parts.
Note. Only original replacement parts are recommended, they are checked and compatible with aluminum. It is recommended to use Audi accessories. Damage resulting from contact corrosion is not covered by the warranty.
COOLERS, CONDENSERS AND CHARGE AIR COOLERS
When assembled correctly, the radiator, condenser and turbocharger may have slight impressions on their fins. It is not damage. Do no replace the cooler, condenser or turbocharger because of impressions like that.
ENGINE CONTAMINANTS
- To prevent foreign objects from entering when working on the engine, seal open intake and exhaust channels with suitable plugs, for example from the engine bung set VAS 6122.
ENGINE NUMBER
The engine number ("engine code" and "serial number") are located at the front of the engine/transmission joint.
In addition, a sticker with "engine code" and "serial number" is affixed to the toothed belt guard.
The engine code is also included on the vehicle data plates.
LINES, ROUTING AND SECURING
- Mark the individual fuel, hydraulic and vacuum lines for the EVAP canister system as well as the electrical wires before disconnecting and/or removing them. This will prevent a mix-up when reconnecting them. If necessary, draw sketches or take pictures.
- Due to the limited space inside the engine compartment, be especially careful when working near moving or hot parts. This will also prevent damaging the lines.
COOLING SYSTEM
Note the following when working on the cooling system
| WARNING | Risk of scalding due to hot steam and hot coolant. The coolant system is under pressure when the engine is warm. Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system. Risk of injury through fan turning on automatically. Disconnect the connectors before working near the fan shroud. |
| CAUTION | The vehicle could overheat if the cap is installed incorrectly. The cap must engage noticeably when sealing. |
EXHAUST SYSTEM
Note the following when working on the exhaust system
| CAUTION | Danger of damaging the decoupling element. Decoupling element must not be bent more than 10°. Do not load decoupling element on cable. Do not damage wire mesh at decoupling element. |
FUEL SYSTEM
Note the following when working on the fuel system
| WARNING | There is a risk of injury because the fuel is under very high pressure. Let the fuel pressure come down before opening any high pressure components in the fuel injection system. To reduce any remaining pressure, place a clean cloth over the connections and carefully loosen the connections. |
Procedures before opening the high pressure fuel injection system. Refer to General Information .
To prevent personal injury and damage to the injection and ignition system, observe the following
- Turn off the ignition before disconnecting and connecting the wiring for the injection and ignition system. This includes tester cables as well.
- Only clean engine with ignition switched off.
- If electrical connectors were disconnected and the engine was started, then malfunctions have been stored in the engine control modules. "Generate readiness code" in "Guided Functions" using the vehicle diagnosis tester.
| CAUTION | Risk of destroying electronic components when disconnecting the battery. Observe measures for disconnecting battery. Only disconnect the battery with ignition switched off. |
Disconnect the battery. Refer to [For transmission(s) 02E] Removal and Installation .
TEST DRIVES WITH THE USE OF TEST AND MEASURING DEVICES
If testing equipment must be used during a road test, observe the following
Scheme 139
| WARNING | Distraction and testing equipment that is not secured properly can cause accidents. The passenger airbag could pose a risk if it deploys in a collision. Operating testing equipment while driving causes it to shift position. There is an increased risk of injury due to unsecured testing equipment. Position passenger's seat as far back as possible. Only use the vehicle diagnosis and service system VAS 5052 A or diagnostic system VAS 5053. Testing and measuring instruments -1- must lay flat on the passenger's thighs and be operated by him or her, as shown in the illustration. |
ENGINE DATA
| Identification Codes | CCTA | CETA | |
|---|---|---|---|
| Displacement | Liter | 1.984 | 1.984 |
| Output | KW at RPM | 147/5100 | 155/4200 |
| Torque | Nm at RPM | 280/1700 | 350/1500 |
| Bore | Diameter mm | 82.5 | 82.5 |
| Stroke | Mm | 92.8 | 92.8 |
| Compression ratio | 9.6 | 9, 6 | |
| RON | 98 1) | 95 2) | |
| Fuel injection and ignition system | FSI | FSI | |
| Ignition sequence | 1-3-4-2 | 1-3-4-2 | |
| Knock control | Yes | Yes | |
| Turbocharger | Yes | Yes | |
| Exhaust Gas Recirculation (EGR) | No | No | |
| Variable intake manifold | No | No | |
| Variable valve timing | Yes | Yes | |
| Secondary Air Injection (AIR) | No | No | |
| 1) Unleaded RON 95 is also permissible, although with reduced power. 2) Unleaded RON 91 is also permissible, although with reduced power. | |||
FUEL SYSTEM, CHECKING FOR LEAKS
Let the engine run a few minutes at a moderate speed.
Turn off the ignition.
Check the entire fuel system for leaks.
If there are leaks in spite of correct tightening specifications, the corresponding component must be replaced.
Then perform a road test and depress the accelerator pedal all the way at least one time.
Then check the high pressure area again for leaks.
VACUUM SYSTEM, CHECKING
Special tools and workshop equipment required
- Hand Vacuum Pump VAS 6213
Procedure
Check all vacuum lines in the vacuum system for
- Cracks
- Damage caused by animals
- Crimps
- Leaks
Check the vacuum line leading to and from the solenoid valve.
If there is a fault stored in the DTC memory, check the vacuum lines for the named component, but also check all the vacuum lines.
If using the VAS 6213 does not produce any vacuum or if the vacuum drops again right away, then check the hand vacuum pump and the connection hoses for leaks.
SPECIAL TOOLS
Special tools and workshop equipment required
Scheme 140
- Hand Vacuum Pump VAS 6213