SAFETY PRECAUTIONS
Note the following when working on the fuel system
| WARNING | There is a risk of injury because the fuel is under very high pressure. Reduce the fuel pressure down to residual pressure before opening high pressure area of the fuel injection system. To reduce remaining residual pressure, place a clean cloth around the connector and carefully loosen connector. |
Procedures before opening high pressure fuel injection system. Refer to General Information .
To prevent personal injury and damage to the injection and ignition system, observe the following
- The ignition must be switched off before connecting or disconnecting injection and ignition system wiring or tester cables.
- 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", refer to vehicle diagnosis tester.
| CAUTION | Danger of causing damage to electrical components when disconnecting the battery. Complete the steps for disconnecting the battery. Turn off the ignition and disconnect the battery. |
Disconnect the battery. Refer to [For transmission(s) 02E] Removal and Installation .
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 high pressure area, fuel pressure must be reduced to a residual pressure of approximately 6 bar. Refer to General Information . |
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. |
| CAUTION | The vehicle could overheat if the cap is installed incorrectly. The cap must engage noticeably when sealing. |
If it is necessary to use testing and measuring devices on road tests, observe the following
| WARNING | Distraction and improperly secured test equipment can lead to accidents. There is a risk that the passenger airbag could deploy in a collision. Operating testing and measuring equipment while driving creates a distraction. There is an increased risk of injury due to unsecured testing and measuring equipment. Always secure testers on the rear seat with a strap and have a second person on the rear seat to operate them. |
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. |
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: Only unpack replacement parts immediately prior to installation. 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. Replace any corroded fuel hoses.
- Protect disconnected electrical connectors from dirt and moisture and only connect if dry.
ENGINE NUMBER
The engine number ("engine code" and "serial number") is located at left on the engine/transmission partition.
The engine code is also stamped on the right side on the cylinder head and on the cylinder block.
Scheme 54
The engine number consists of up to nine characters (alphanumeric). The first part (maximum 3 letters) represents the "engine code", the second (six digit) is the "serial number". If more than 999, 999 engines with the same engine code are produced, the first of the six characters is replaced with a letter.
In addition, a sticker with "engine code" and "serial number" is affixed to the toothed belt guard.
The engine code is also on the vehicle data plate.
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.
CONTACT CORROSION
Contact corrosion can occur if incorrect fasteners (bolts, nuts, washers, etc.) are used.
For this reason, only install connecting elements that are treated with a special coating.
Also, rubber or plastic parts and adhesive consist of non-conductive materials.
If there are doubts about the suitability of parts, generally use new parts. .
Note. Only original replacement parts are recommended, they are checked and compatible with aluminum. Audi accessories are recommended. Damage due to contact corrosion is not covered by warranty.
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.
COOLERS, CONDENSERS AND CHARGE AIR COOLERS
When assembled correctly, the radiator, condenser and turbocharger may have slight impressions on their fins. This is not damage. Do no replace the cooler, condenser or turbocharger because of impressions like that.
ENGINE DATA
| Code letters | BWA | BPY | |
|---|---|---|---|
| Displacement | Liter | 1.984 | 1.984 |
| Output | KW at RPM | 147/5100 | 147/5700 |
| Torque | Nm at RPM | 280/1800 | 280/2000 |
| Bore | Diameter mm | 82.5 | 82.5 |
| Stroke | Mm | 92.8 | 92.8 |
| Compression ratio | 10.3 | 10.5 | |
| RON | 98 1) | 98 1) | |
| 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 Research Octane Number (RON) 95 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 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.
If using the VAS 6213 and 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.
SPECIAL TOOLS
Special tools and workshop equipment required
Scheme 55
- Hand Vacuum Pump VAS 6213