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Direct Petrol Injection and Ignition System

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Direct Petrol Injection and Ignition System

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zozo0424

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Service

Workshop Manual
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr.
4-valve)
Engine ID AXW BHD BMB BLX BLY BLR BVY BVZ

Edition 09.2009

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Service Department. Technical Information

Service
List of Workshop Manual Repair Groups

Repair Group
24 - Mixture preparation - injection
28 - Ignition system

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Audi AG, Ingolstadt A0050305220

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Contents

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety precautions and rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General notes on self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Important: Required procedure prior to opening high-pressure injection system . . . . . . . . 3
1.5 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Air cleaner - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Throttle
Protected valve Copying
by copyright. module, exhaust
for private gas recirculation
or commercial valve
purposes, in part or and
in whole, intake manifold - exploded view
is not
.with
. .respect
. . . .to. the
. . correctness
. . . . . . .of.information
. . . . . . in. this
. . .document.
. . . . . Copyright
. . . . . .by. AUDI
. . . AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
............................. 17
2.6 Fuel rail with intake manifold flap motor V157 - exploded view (for engine code letters AXW
and BHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.7 Fuel rail with intake manifold flap motor V157 - exploded view (for engine code letters BMB,
BLX, BLY, BLR, BVZ and BVY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.8 Intake manifold - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.9 Checking intake manifold change-over function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.10 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.11 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.12 Checking fuel pressure and residual pressure (up to high-pressure pump) . . . . . . . . . . . . 26
2.13 High-pressure pump - exploded view (for engine code letters AXW and BHD) . . . . . . . . . . 29
2.14 High-pressure pump - exploded view (for engine code letters BMB, BLX, BLY, BLR, BVZ and
BVY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.15 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.16 Removing and installing injectors, renewing combustion chamber (teflon) ring seal . . . . . . 34
2.17 Removing and installing Lambda probes (before catalytic converter) . . . . . . . . . . . . . . . . 39
2.18 Removing and installing Lambda probes (after catalytic converter) . . . . . . . . . . . . . . . . . . 40
2.19 Removing and installing NOx sensor control unit J583 and NOx sender G295 . . . . . . . . 41
2.20 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 43
2.21 Lambda probe 3 after catalytic converter G287 and Lambda probe heater 3 after catalytic
converter Z64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.1 Wiring and component check with test box V.A.G 1598/42 . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2 Renewing Motronic control unit J220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1 General notes and safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.1 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.2 Ignition system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.3 Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Contents i
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

ii Contents
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

24 – Mixture preparation - injection

1 Safety precautions and rules for
cleanliness

1.1 General notes on self-diagnosis

♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and fault finding the fault memory must be
interrogated. The vacuum hoses and connections must also
be checked (unmetered air).
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. O-type clips or screw-type clips must not be
used.
♦ A voltage of at least 11.5 V is required for proper operation of
the electrical components.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and will
damage the Lambda probe.
♦ The vehicles are fitted with a crash/fuel shut-off system. This
system is designed to reduce the risk of a vehicle fire after a
crash by deactivating the fuel pump via the fuel pump relay.
♦ At the same time, this system also improves the engine's start‐
ing performance. When the door is opened, the fuel pump is
activated for 2 seconds in order to build up pressure in the fuel
system. Observe safety precautions ⇒ page 1 .

1.2 Safety precautions

WARNING

The fuel system is pressurised. The fuel pressure in the high-

pressure part of the injection system must be reduced to a
residual pressure prior to opening; for procedure see
⇒ page 3 .
The connection must be opened immediately after reducing
the pressure; wrap a cloth around the connection and allow the
residual pressure (approx. 6 bar) to dissipate.

Note the following if testers and measuring instruments have to

be used during a road test:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
WARNING
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Test equipment must always be secured on the rear seat

and operated from that position by a second person.
♦ If test and measuring instruments are operated from front
passenger's seat and the vehicle is involved in an acci‐
dent, the person sitting in this seat could be seriously
injured when the airbag is triggered.

1. Safety precautions and rules for cleanliness 1

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

To avoid any risk of injuries to persons and/or damage to the fuel

injection and ignition system, always observe the following safety
precautions.
♦ If the battery is not disconnected, fuse No. 27 for fuel pump
control unit -J538- must be removed as a precautionary meas‐
ure before opening the fuel system, because the fuel pump will
otherwise be activated by the contact switch on the driver's
door.
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as the
ignition system and gas-discharge headlights.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off the ignition before connecting or discon‐
necting injection or ignition system wiring or tester cables.
♦ If engine is to be operated at cranking speed without it starting
(e.g. compression test), unplug connectors from ignition coils
and remove fuse for electric fuel pump.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. The fault memory should therefore be inter‐
rogated and (if necessary) erased after completing the tests
and any repair work that may be required.
♦ Always switch off the ignition before cleaning the engine.
♦ Always switch off the ignition before connecting or discon‐
necting the battery, otherwise the engine control unit may be
damaged.
♦ If the engine has to be operated at the starting
Protected speed
by copyright. without
Copying for private or commercial purposes, in part or in whole, is not
actually starting (e.g. to test compression
permittedpressure), detach
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
the four connectors from the ignition coils usingto the
with respect assembly
correctnesstool
of information in this document. Copyright by AUDI AG.
-T40039- ⇒ page 55 . Also remove fuse 27 from fuel pump
control unit -J538- .

Note

Removing fuse 27 will interrupt the voltage supply for the fuel
pump control unit -J538- .

1.3 Rules for cleanliness

When working on the fuel supply/injection system, pay careful at‐
tention to the following “6 rules”:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place parts that have been removed on a clean surface and
cover them over. Do not use fluffy cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).
♦ When the system is open: Do not work with compressed air if
this can be avoided. Do not move the vehicle unless absolutely
necessary.
♦ Unplugged electrical connectors must be kept clean and dry.
Make sure connections are dry when attaching.

2 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

1.4 Important: Required procedure prior to

opening high-pressure injection system

Caution

The injection system consists of a high-pressure section (max‐

imum approx. 120 bar) and a low-pressure section (approx. 6
bar).
Prior to opening the high-pressure section (e.g. when removing
the high-pressure pump, fuel rail, injectors, fuel pipes or fuel
pressure sender
Protected -G247-
by copyright. ), the
Copying fuel orpressure
for private in the high-pres‐
commercial purposes, in part or in whole, is not
sure section
permittedmust
unless be reduced
authorised toAG.
by AUDI a residual
AUDI AG does pressure of approx.
not guarantee or accept any liability
6 bar. Thewithprocedure is described
respect to the correctness below.
of information in this document. Copyright by AUDI AG.

Reducing fuel pressure in high-pressure section

Special tools and workshop equipment required
♦ Assembly tool -T10118-

1. Safety precautions and rules for cleanliness 3

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

– Using assembly tool -T10118- , detach electrical connector

from fuel pressure regulating valve -N276- -5-.
– Allow engine to idle for about 10 seconds.

Note

♦ Fuel pressure will be reduced from approx. 50 bar to approx.

6 bar when electrical connector is detached from fuel pressure
regulating valve -N276- while engine is idling.
♦ You can watch the fuel pressure dropping by connecting a ve‐
hicle diagnosis and service information system -VAS 5052-
and selecting the engine control unit. Select function “Read
measured value block” and display group 140.
♦ The fuel pressure (actual value) is displayed in zone 3.

– Switch off ignition.

WARNING

The fuel lines are still filled with fuel, however the fuel is no
longer under high pressure. Wear safety goggles and protec‐
tive clothing when opening the fuel system to avoid possible
injury and skin contact.
Before opening the high-pressure section, wrap a cloth around
the connection.

– The high-pressure system must be opened IMMEDIATELY

after reducing the pressure by wrapping a clean cloth around
the connection and allowing the residual pressure (approx. 6
bar) to dissipate. Catch the escaping fuel.

Note

The pressure may increase again slightly if a high-pressure line

is not opened immediately.

– Connect vehicle
Protected by copyright.diagnosis andorservice
Copying for private commercialinformation
purposes, in partsystem
or in whole,-is not
VAS 5052-
permitted and
unless generate
authorised readiness
by AUDI AG. AUDI AGcode inguarantee
does not engineorcontrol unit
accept any liability
using
with“Guided Fault
respect to the Finding”
correctness mode.
of information in this document. Copyright by AUDI AG.

1.5 Checking vacuum system

Special tools and workshop equipment required
♦ Hand vacuum pump -VAS 6213-

4 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites
♦ Kinked or crushed lines
♦ Lines porous or leaking
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
– If a fault is stored in the fault memory, check the vacuum lines
leading to the corresponding component and also check the
remaining vacuum lines leading to other components.
– If it is not possible to build up pressure with hand vacuum pump
-VAS 6213- or if the pressure drops again immediately, check
hand vacuum pumpbyandAUDI connecting hoses for leaks.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Safety precautions and rules for cleanliness 5

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

2 Injection system

2.1 Technical data

Engine data 2.0 ltr. / 110 kW FSI engine
Bosch Motronic
Idling speed is not adjustable; controlled by the 640 ... 800 rpm
idling speed stabilisation
Maximum rpm governed by deactivation of fuel 6500 rpm
injectors
Fuel pressure Initial fuel pressure up to approx. 6.0 bar (identical for all
high-pressure pump operating conditions)
(generated by electric
fuel pump in fuel tank)
Fuel high-pressure (gen‐ approx. 50 bar at idling speed
erated by mechanical sin‐ up to 110...120 bar in certain
gle-plunger pump) parts of operating range.

2.2 Overview of fitting locations

Components A to Y are not shown in the exploded view.

6 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

1 - Activated charcoal filter sol‐

enoid valve 1 -N80-
2 - Motronic control unit -J220-
❑ Removing and installing
⇒ page 47
3 - Exhaust gas recirculation
valve -N18- with exhaust gas
recirculation potentiometer -
G212-
❑ Not fitted on engines
with code letters BHD,
BMB, BLY and BVZ
❑ ⇒ page 12
4 - Camshaft control valve 1 -
N205-
❑ ⇒ page 12
❑ Removing and installing
⇒ Rep. Gr. 15
5 - 6-pin connector
❑ For Lambda probe -
G39- and Lambda
probe heater -Z19-
(black)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For Lambda probe 2 -permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
G108- and Lambda with respect to the correctness of information in this document. Copyright by AUDI AG.
probe heater 2 -Z28-
(brown); “not fitted on
engines with code let‐
ters BHD, BLY, BMB,

2. Injection system 7
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

BVY and BVZ”

❑ ⇒ page 10
6 - Coolant temperature sender -G62- (4-pin)
❑ ⇒ page 12
7 - Fuel pressure regulating valve -N276-
❑ ⇒ page 12
8 - Single-plunger high-pressure pump
9 - Radiator outlet coolant temperature sender -G83-
❑ ⇒ page 13
10 - Intake air temperature sender 2 -G299-
❑ ⇒ page 12
11 - Intake manifold pressure sender -G71- with intake air temperature sender -G42-
❑ ⇒ page 13
12 - Throttle valve module -J338- , throttle valve drive for electric throttle -G186-
❑ Throttle valve drive angle sender 1 for electric throttle -G187- and throttle valve drive angle sender 2 for
electric throttle -G188-
❑ Perform adaption after renewing throttle valve module -J338-
Protected . Copying for private or commercial purposes, in part or in whole, is not
by copyright.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
13 - 8-pin connector for injectors with respect to the correctness of information in this document. Copyright by AUDI AG.

14 - Vacuum pump
15 - Ignition coils with output stages
❑ Ignition coil 1 with output stage -N70-
❑ Ignition coil 2 with output stage -N127-
❑ Ignition coil 3 with output stage -N291-
❑ Ignition coil 4 with output stage -N292-
16 - Fuel pressure sender -G247-
❑ ⇒ page 13
❑ 15 Nm
17 - Variable intake manifold change-over valve -N156-
❑ ⇒ page 12
18 - Right-side of engine (in direction of travel)
❑ ⇒ page 12
❑ Fuel pressure sender for low pressure -G410- (not fitted on engines with code letters BVZ and BVY)
❑ Activated charcoal filter solenoid valve -N80-
❑ Variable intake manifold change-over valve -N156-
❑ 3-pin electrical connector for engine speed sender -G28-
❑ Map-controlled engine cooling system thermostat -F265-
❑ 3-pin connector for knock sensor 1 -G61-
❑ Hall sender -G40- (camshaft position sensor)
19 - Hall sender -G40- (camshaft position sensor)
❑ ⇒ page 12
A - Diagnostic connector
❑ In driver's knee restraint
B - Fuel pump control unit -J538-
❑ Adaption must be performed after renewing fuel pump control unit -J538- . Basic setting, measured value
block 243, refer to ⇒ Rep. Gr. 20
❑ Beneath rear seat bench ⇒ page 10

8 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

C - “EPC” warning lamp

❑ In instrument cluster
D - “MIL” exhaust emissions warning lamp
❑ In instrument cluster
E - Lambda probe -G39- and Lambda probe heater -Z19-
❑ ⇒ page 10
❑ Removing and installing ⇒ page 39
F - Lambda probe 2 -G108- and Lambda probe heater 2 - Z28 -
❑ Not fitted on engines with code letter BVZ
❑ ⇒ page 10
❑ Removing and installing ⇒ page 39
G - Lambda probe, after catalytic converter -G130- and Lambda probe heater 1, after catalytic converter -Z29-
❑ ⇒ page 11
❑ Removing and installing ⇒ page 40
H - Lambda probe 2, after catalytic converter -G131- and Lambda probe heater 2, after catalytic converter -
Z30-
❑ Not fitted on engines with code letters BLY, BHD, BMB and BVZ
❑ ⇒ page 11
❑ Removing and installing ⇒ page 40
I - NOx sender -G295- and NOx sender heater -Z44-
❑ ⇒ page 11
❑ Not fitted on engines with code letters BHD, BMB, BLY, BLR, BVZ and BVY
❑ Removing and installing ⇒ page 41
J - Lambda probe 3 after catalytic converter -G287- and Lambda probe heater 3 after catalytic converter -Z64-
❑ On engines with code letters BLR and BVY a Lambda probe 3 after catalytic converter -G287- is fitted
in place of the NOx sender -G295- .
❑ Removing and installing ⇒ page 44
K - Exhaust gas temperature sender 1 -G235-
❑ ⇒ page 11
❑ Not fitted on engines with code letters BHD, BMB, BLY, BLR, BVZ and BVY
❑ Removing and installing ⇒ page 43
L - NOx sensor control unit -J583-
❑ ⇒ page 10
❑ Not fitted on engines with code letters BHD, BMB, BLY, BLR, BVZ and BVY
❑ Removing and installing ⇒ page 41
M - Brake light switchProtected
- F- and brake pedal
by copyright. switch
Copying for -F63-
private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ In footwell on brake pedalto the correctness of information in this document. Copyright by AUDI AG.
with respect

❑ ⇒ page 14
N - Accelerator position sender -G79- and accelerator position sender 2 -G185-
❑ In footwell on accelerator pedal (both senders are accommodated in one housing)
❑ ⇒ page 14
O - Clutch position sender -G476-
❑ ⇒ page 14
P - Motronic current supply relay -J271-
❑ ⇒ page 14
Q - Radiator fan control unit -J293-
❑ Installed in left-side radiator fan (in direction of travel)

2. Injection system 9
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

R - Injectors
❑ In fuel rail
❑ Injector, cylinder 1 -N30-
❑ Injector, cylinder 2 -N31-
❑ Injector, cylinder 3 -N32-
❑ Injector, cylinder 4 -N33-
The fuel injectors are high-pressure injectors. They inject fuel at high pressure (maximum approx. 110 bar)
directly into the cylinder.

S - 3-pin connector for knock sensor 2 -G66-

❑ ⇒ page 14
T - Oil pressure switch -F1-
❑ ⇒ page 14
V - Engine speed sender -G28-
❑ ⇒ page 14
W - Knock sensor 1 -G61-
❑ ⇒ page 15
❑ Tightening torque: 20 Nm
X - Knock sensor 2 -G66-
❑ ⇒ page 15
❑ Tightening torque: 20 Nm
Y - Intake manifold flap motor -V157- and intake manifold flap potentiometer -G336-
❑ ⇒ page 15
❑ After the intake manifold has been renewed, intake manifold flap potentiometer -G336- must be adapted
to engine control unit -J623- . For this purpose, use vehicle diagnosis and service information system -
VAS 5052- , “Guided Functions”.

Fuel pump control unit -J538-

• Adaption must be performed after renewing fuel pump control
unit -J538- . Basic setting, measured value block 243, refer to
⇒ Rep. Gr. 20

Lambda probes before catalytic converter

1 - Lambda probe -G39- and Lambda probe heater -Z19- “engines
with code letters BLY and BVZ,Protected
see next illustration”
by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Lambda probe 2 -G108- andpermitted
Lambda probe heater 2 -Z28-
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

(not fitted on vehicles with engine codes BVY, BLY, BHD, BMB
with respect to the correctness of information in this document. Copyright by AUDI AG.

and BVZ)

10 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Lambda probes after catalytic converter

1 - Lambda probe 2, after catalytic converter -G131- and Lambda
probe heater 2, after catalytic converter -Z30- “not fitted on en‐
gines with code letters BLY, BHD, BMB and BVZ”
2 - Lambda probe, after catalytic converter -G130- and Lambda
probe heater 1, after catalytic converter -Z29-

NOx sender -G295- and exhaust gas temperature sender 1 -

G235-
1 - NOx sender -G295- and NOx sender heater -Z44- (“NOx”
stands for oxides of nitrogen) “not fitted on engines with code let‐
ters BHD, BMB, BLY, BLR, BVY and BVZ”; tightening torque
63 Nm.
2 - Exhaust gas temperature sender 1 -G235- (tightening torque
for union nut: 45 Nm) not fitted on engines with code letters “BHD,
BMB, BLY, BLR, BVZ and BVY”

Note

On engines with code letters BLR and BVY a Lambda probe 3

after catalytic converter -G287- is fitted in place of the NOx sender
-G295- .

Connectors located on right-side underbody beneath the under‐

body cover (arrow faces direction of travel)
1 - NOx sensor control unit -J583- (cable for control unit cannot
be disconnected from NOx sender -G295- ) not fitted on engines
with code letters “BHD, BMB, BLY, BLR, BVZ and BVY”
2 - Connector for exhaust gas temperature sender 1 -G235- not
fitted on engines with code letters “BHD, BMB, BLY, BLR, BVZ
and BVY”
3 - Connector (black) for Lambda probe after catalytic converter
-G130- (right-side) and Lambda probe 1 heater after catalytic
converter -Z29-
4 - Connector (brown) for Lambda probe 2 after catalytic convert‐
er -G131- (left-side) and Lambda probe heater 2 after catalytic
converter -Z30- “not fitted on engines with code letters BLY, BHD,
BMB and BVZ”

Connectors for Lambda probes before catalytic converter

1 - Connector for Lambda probe 2 -G108- and Lambda probe 2
heater -Z28- (for cylinders 2 and 3) “not fitted on engines with
code letters BHD, BLY, BMB, BVZ and BVY”
2 - Connector for Lambda probe -G39- and Lambda probe heater
-Z19- (for cylinders 1 and 4)

2. Injection system 11
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Intake air temperature sender 2 -G299-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Left-side of engine (in direction of travel)

with respect to the correctness of information in this document. Copyright by AUDI AG.

1 - Throttle valve module -J338- , including throttle valve drive for

electric throttle -G186- , throttle valve drive angle sender 1 for
electric throttle -G187- and throttle valve drive angle sender 2 for
electric throttle -G188-
2 - Camshaft control valve 1 -N205-
3 - Exhaust gas recirculation valve -N18- with exhaust gas recir‐
culation potentiometer -G212- “not fitted on engines with code
letters BHD, BMB, BLY and BVZ”
4 - Coolant temperature sender -G62-
5 - Fuel pressure regulating valve -N276-

Right-side of engine (in direction of travel)

1 - Activated charcoal filter solenoid valve -N80-
2 - Fuel pressure sender for low pressure -G410- “not fitted on
engines with code letters BVZ and BVY”
3 - Variable intake manifold change-over valve -N156-

Right-side of engine (in direction of travel)

1 - Fuel pressure sender for low pressure -G410- “not fitted on
engines with code letters BVZ and BVY”
2 - Activated charcoal filter solenoid valve -N80-
3 - Variable intake manifold change-over valve -N156-
4 - 3-pin electrical connector for engine speed sender -G28-
5 - Map-controlled engine cooling system thermostat -F265-
6 - 3-pin connector for knock sensor 1 -G61-
7 - Hall sender -G40- (camshaft position sensor)

12 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Intake manifold pressure sender -G71- with intake air tempera‐

ture sender -G42-
1 - Intake manifold pressure sender -G71- with intake air temper‐
ature sender -G42-

Knock sensor 1 -G61- and fuel pressure sender -G247-

1 - 3-pin connector for knock sensor 1 -G61-
2 - Fuel pressure sender -G247-

Radiator outlet coolant temperature sender -G83-

1 - Radiator outlet coolant temperature sender -G83-

Clutch position sender -G476-

4 - Connector

2. Injection system 13
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Fitting location of brake light switch -F- and brake pedal switch -
F63- (in driver's footwell)
1 - Brake light switch -F- and cruise control system brake pedal
switch (diesel direct injection system) -F47-

Fitting location of accelerator pedal position sender -G79- and

accelerator pedal position sender 2 -G185- (in driver's footwell)

Motronic current supply relay -J271-

- R1 - Terminal 15 voltage supply relay -J329-
- R2 - Terminal 50 voltage supply relay -J682-
- R3 - Fuel pump relay -J17-
- R4 - Motronic current supply relay -J271-

Fitting locations
1 - 3-pin connector for knock sensor 2 -G66-
2 - Oil pressure switch -F1-
3 - Engine speed sender -G28-

14 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Knock sensors (beneath fuel rail)

1 - Knock sensor 1 -G61-
2 - Knock sensor 2 -G66-
Tightening torque for knock sensors: 20 Nm

Intake manifold flap for air distribution

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4 - Connector with
forrespect
intake manifold flap motor -V157
to the correctness of information in this document. Copyright by AUDI AG.

A - Intake manifold flap motor -V157- with intake manifold flap

potentiometer -G336-

Note

Intake manifold flaps are the same as air flow control flaps.

2.3 Air cleaner - exploded view

2. Injection system 15
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

1 - Panel bolt
❑ 5 Nm
2 - Air channel
❑ Clean any leaves and
dirt out of air channel
3 - Air funnel
4 - Intake air temperature
sender 2 -G299-
❑ Tighten to 2 Nm
❑ Renew O-ring if dam‐
aged
5 - Spring clamp
6 - Intake air duct
7 - Vacuum connection for vac‐
uum booster
8 - Panel bolt
❑ 8 Nm
9 - Panel bolt
❑ 3 Nm
10 - Air cleaner housing
❑ Clean any salt deposits
or leaves and dirt out of
air cleaner housing
11 - Air filter element
❑ Always use genuine
part for air filter element
❑ Observe change inter‐
vals ⇒ Maintenance ;
Booklet 808
❑ When installing the air
filter element, check that it is properly centred in the retainer in the air cleaner (bottom section).
❑ Fit the top section of the air cleaner carefully on the bottom section, without using force. Make sure the
top section of the air cleaner is fitted straight on the air filter element (note position of sealing lip on air
filter element).
❑ Removing and installing ⇒ page 16
12 - Hexagon flange nut
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 20 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
13 - Intake air duct
❑ Damping chamber
❑ Check intake air duct for dirt and leaves
14 - Spring clamp
15 - Intake air duct
❑ Check intake air duct for dirt and leaves

2.4 Removing and installing air filter ele‐

ment
Removing air filter element
– Slacken bolts and detach top section of air cleaner.

16 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

– Pull out air filter element.

Installing air filter element

Note

♦ Always use genuine part for air filter element.

♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. Do not use any lubri‐
cants containing silicone when assembling.
♦ The air cleaner housing must be clean.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue
♦ To prevent malfunctions, cover all critical parts of the engine
air intake tract (air mass meter, intake pipes, etc.) with a clean
cloth when blowing out the air cleaner housing with com‐
pressed air.
♦ Please observe requirements for disposal.

– Check for salt residue, dirt and leaves in air intake hose (en‐
gine intake side).
– Check for dirt in air intake hose from air duct.
– When installing the air filter element, check that it is properly
centred in the retainer in the air cleaner (bottom section).
– Fit the top section of the air cleaner carefully on the bottom
section, without using force. Make sure the top section of the
air cleaner is fitted straight on the air filter element (note posi‐
tion of sealing lip on air filter element).
The remaining installation steps are carried out in the reverse se‐
quence.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2.5 Throttle valve module, exhaust
permitted gasbyrecirculation
unless authorised AUDI AG. AUDI AG doesvalve and
not guarantee intake
or accept manifold
any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
- exploded view

2. Injection system 17
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

1 - Activated charcoal filter sol‐

enoid valve 1 -N80-
2 - Bracket for activated char‐
coal filter solenoid valve 1 -
N80-
3 - Connecting hose
❑ Between activated char‐
coal filter solenoid valve
1 -N80- and activated
charcoal filter
4 - Hexagon socket head
flange bolt
5 - Connecting pipe for exhaust
gas recirculation
6 - Hexagon socket head
flange bolt
7 - Gasket
8 - Exhaust gas recirculation
valve -N18- with exhaust gas
recirculation potentiometer -
G212-
❑ Not fitted on engines
with code letters BHD,
BMB and BLY
❑ Adaption to engine con‐
trol unit is required after
replacement (Basic set‐
ting, Display group 74,
with ignition switched
on); see “Guided Fault

18 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Finding”.
9 - Coolant hoses
10 - Hexagon socket head
flange bolt
11 - Hexagon bolt
12 - Hexagon socket head flange bolt
13 - Connecting pipe for exhaust gas recirculation
14 - Hexagon socket head flange bolt
❑ 5 Nm
15 - Fuel rail
16 - Vent hose
17 - Intake manifold
18 - Intake manifold pressure sender -G71- with intake air temperature sender -G42-
❑ ⇒ page 13
❑ Tighten to 3 Nm
19 - Throttle valve module
❑ Adaption to engine control unit required after replacement (Basic setting, Display group 60; see “Guided
fault finding”).
20 - Hexagon socket head flange bolt
21 - Securing nut for intake manifold (2x), 10 Nm
22 - Rubber bush (2x)
23 - Change-over barrel for intake manifold change-over
24 - Variable intake manifold change-over valve -N156-
25 - Connecting hose
❑ Between vacuum unit and air cleaner (top section)
26 - Hexagon socket head flange bolt
27 - Spring clamp (8x)
28 - Connection piece (4x)

2.6 Fuel rail with intake manifold flap motor

-V157- - exploded view (for engine code
letters AXW and BHD)

WARNING Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
The fuel system is pressurised. The fuel pressure in the high-
pressure part of the injection system must be reduced to a
residual pressure prior to opening; for procedure see
⇒ page 3 .

2. Injection system 19
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

1 - Fuel pressure sender for

low pressure -G410-
2 - Fuel pipes
❑ Install so that parts are
free of tension
3 - Bolts
❑ 15 Nm
❑ With tapered sealing
seat
❑ Ensure parts are kept
clean
4 - Hexagon socket head bolt,
10 Nm
5 - Clip
6 - Connection piece
7 - 25 Nm
❑ With tapered sealing
seat
❑ Ensure parts are kept
clean
8 - Fuel pipe (high-pressure)
❑ Install so that parts are
free of tension
9 - Fuel pressure sender -
G247-
❑ 15 Nm
10 - Bolt
❑ 10 Nm
11 - Cable retainer
12 - Connector
❑ For injectors
13 - Bracket
14 - Nut and washer assembly (2x)
❑ 10 Nm
15 - Fuel rail with intake manifold flap motor -V157- and intake manifold flap potentiometer -G336-
16 - Gasket
❑ Renew
17 - Injector, cylinder 1 -N30- ... injector, cylinder 4 -N33-
❑ Removing and installing ⇒ page 34
18 - Air guide plates
❑ Removable
❑ Check for damage and correct fitting

20 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

2.7 Fuel rail with intake manifold flap motor

-V157- - exploded view (for engine code
letters BMB, BLX, BLY, BLR, BVZ and
BVY)

WARNING

The fuel system is pressurised. The fuel pressure in the high-

pressure part of the injection system must be reduced to a
residual pressure prior to opening; for procedure see
⇒ page 3 .

1 - Fuel pressure sender for Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
low pressure -G410- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Not fitted on engines
with code letters BVZ
and BVY
2 - Fuel pipes
❑ Install so that parts are
free of tension
3 - Hexagon socket head bolt,
10 Nm
4 - Gasket
❑ Renew
5 - Fuel rail with intake mani‐
fold flap motor -V157- and in‐
take manifold flap potentiome‐
ter -G336-
6 - Clip
7 - Connection piece
8 - Fuel pipe
❑ Install so that parts are
free of tension
9 - 17 Nm
❑ With tapered sealing
seat
❑ Ensure parts are kept
clean
10 - 10 Nm
11 - Connector
❑ For injectors
12 - Pressure limiting valve
❑ 30 Nm
13 - Fuel pressure sender -G247-
❑ 15 Nm
14 - Cable retainer
15 - Injector, cylinder 1 -N30- ... injector, cylinder 4 -N33-
❑ Removing and installing ⇒ page 34

2. Injection system 21
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

16 - Air guide plate

❑ Removable
❑ Check for damage and correct fitting

2.8 Intake manifold - exploded view

WARNING

The fuel system is pressurised. The fuel pressure in the high-

pressure part of the injection system must be reduced to a
residual pressure prior to opening; for procedure see
⇒ page 3 .

1 - Vacuum hose
2 - Vacuum reservoir
3 - 5 Nm
4 - Pipe for exhaust gas recir‐
culation
5 - Vacuum hose
❑ With non-return valve
6 - Crankcase breather hose
7 - Seal
❑ Renew if damaged
8 - Cable retainer
9 - 8 Nm
10 - Throttle valve module -
J338- , throttle valve drive for
electric throttle -G186-
❑ Throttle valve drive an‐
gle sender 1 for electric Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

throttle -G187- and

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
throttle valve drive angle
sender 2 for electric
throttle -G188-
❑ Perform adaption after
renewing throttle valve
module -J338- .
11 - Connection for vacuum
booster
12 - Seal
❑ Renew if damaged
13 - Intake manifold pressure
sender -G71- with intake air
temperature sender -G42-
14 - 3 Nm
15 - O-ring
❑ Renew if damaged

22 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

16 - 10 Nm
17 - Bonded rubber mounting
18 - Intake manifold support
19 - 15 Nm
20 - 25 Nm
21 - Seal
❑ Renew if damaged
22 - Seal
❑ Renew if damaged
23 - Change-over barrel
24 - 7 Nm
25 - Cover
26 - Variable intake manifold change-over valve -N156-
27 - Vacuum unit
❑ Checking ⇒ page 23
28 - Intake manifold
29 - Connection for activated charcoal filter solenoid valve 1 -N80-

2.9 Checking intake manifold change-over

function
Only perform this test if there is a loss of engine torque (poor
flexibility or lack of pulling power).
Special tools and workshop equipment required
♦ Hand vacuum pump with attachments -V.A.G 1390- or hand
vacuum pump -VAS 6213-

• Variable intake manifold change-over valve -N156- has been

tested via “Guided Fault Finding” using vehicle diagnosis, test‐
ing and information system -VAS 5051B- .
Perform the following tests if the variable intake manifold change-
over valve -N156- is OK.
– Remove cover from vacuum unit.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Start
permitted engine
unless and
authorised runAG.
by AUDI at AUDI
idlingAGspeed.
does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Injection system 23
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

– Have a second mechanic rev up engine quickly (short burst of

throttle) and observe vacuum unit for intake manifold change-
over. Vacuum unit should pick up.
If the change-over does not operate as described:
– Check vacuum system for leaks (including vacuum reservoir
on intake manifold).
– Check that change-over mechanism moves freely by operat‐
ing linkage manually.
– Check proper connection of vacuum lines.
– Check vacuum hoses for damage and leaks.

– Detach vacuum hose going to vacuum unit for intake manifold

change-over -arrow- at variable intake manifold change-over
valve -1-.
– Connect hand vacuum pump -V.A.G 1390- to vacuum unit for
intake manifold change-over.

– Operate the hand vacuum pump -V.A.G 1390- several times.

The vacuum unit should move.
– Renew vacuum unit if the intake manifold change-over does
not move.

2.10 Removing and installing intake manifold

Removing intake manifold
Perform adaption after renewing throttle valve module -J338- .

WARNING

The fuel system is pressurised. The fuel pressure in the high-

pressure part of the injection system must be reduced to a
residual pressure prior to opening; for procedure see
⇒ page 3 .

24 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Note

♦ Use the exploded views on the previous pages.

♦ The combustion chamber (teflon) ring seal and the injector O-
ring must always be renewed.
♦ The injectors can only be accessed after removal of the intake
manifold and fuel rail with air flow control flap. (Additional or
fewer steps may be required depending on the model.)

– Pull off vacuum hose for intake manifold change-over from

vacuum unit.

Note

The vacuum unit is integrated in the intake manifold cover.

– Pull off both vacuum hoses between vacuum unit and throttle
valve module.
– Pull off vacuum unit upwards from intake manifold.
– Disconnect the two hoses from cylinder head cover.
– Unplug all connectors.
– Detach connecting pipe for exhaust gas recirculation at the
connection.
– Disconnect fuel supply pipe and fuel return pipe (collect es‐
caping fuel).
– Disconnect coolant hose from throttle valve (collect any dis‐
charged water).
– Pull out oil dipstick.
– Release the four hose clips on intake manifold.
– Unscrew nuts securing intake manifold (2x).
– Remove intake manifold.
Installing intake manifold
Install in reverse order.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.11 Removing and installing fuel rail

Removing fuel rail
Intake manifold must be removed. Removing intake manifold
⇒ page 24

2. Injection system 25
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

– Disconnect fuel pipes from high-pressure pump -1- (pipes

have “ridge” at the connection point to ensure proper sealing
and correct attachment of pipe).
– Unscrew the four securing bolts for fuel pipes.
– Unplug connector -2-.
– Remove hose -3- from oil separator for crankcase breather.
– Unplug connector at intake manifold flap motor -V157- .
– Unplug connector -5- at fuel pressure sender -G247- .
– Unplug connector -6- from fuel pressure sender for low pres‐
sure -G410- (not fitted on engines with code letters BVZ and
BVY).

– Loosen securing screws for fuel rail: 6 Allen screws and 2 nuts
with washers.
– Pull fuel rail with air flow control flaps off injectors.
– Detach connectors from injectors.
Installing fuel rail

Note

♦ Renew seals and O-ring.

♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.

– Lift air flow control flaps slightly when fitting fuel rail (lower
section of intake manifold) on cylinder head.

Note

If this is neglected, the air flow control flaps can become stuck
between the fuel rail and cylinder head so they will not function
when assembly has been completed.

The remaining installation steps are carried out in the reverse se‐
quence.

2.12 Checking fuel pressure and residual pressure (up to high-pressure pump)

26 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Special tools and workshop

equipment required
♦ Pressure tester -
V.A.G 1318-
♦ Adapter -V.A.G 1318/11-
♦ Adapter -V.A.G 1318/17-1-
from adapter set -V.A.G
1318/17-
♦ Connector -V.A.G 1318/23-
♦ Remote control -V.A.G
1348/3 A- with adapter ca‐
ble -V.A.G 1348/3-3-
♦ Auxiliary measuring set -
V.A.G 1594 C- or -V.A.G
1594 A-
♦ Fuel-resistant measuring
container

Test conditions
• Batteryunless
voltage at least
by AUDI12.5 V AG does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted authorised AG. AUDI
with respect to the correctness of information in this document. Copyright by AUDI AG.
• Fuel filter OK
• Fuel tank at least 1/4 full.
• Fuel pump control unit -J538- OK (check)
• Ignition off.
Test sequence
– Remove rear seat ⇒ General body repairs, interior; Rep. Gr.
72 .
– Unclip retaining tabs -arrows- for flange cover.

2. Injection system 27
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

– Unplug electrical connector -arrow- at flange.

– Connect remote control -V.A.G 1348/3 A- with adapter cable

-V.A.G 1348/3-3- to contact -1- using a test lead from auxiliary
measuring set -V.A.G 1594 C- .
– Tape off 2nd connector contact of the adapter cable -
V.A.G 1348/3-3- with insulating tape -arrow- to prevent short
circuits.
– Connect contact -5- to the body (earth) using a test lead from
auxiliary measuring set -V.A.G 1594 C- .
– Connect crocodile clip to positive (+) terminal of battery.
– Remove filler cap from fuel filler neck.

WARNING
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Fuel system is pressurised (low pressure). Wear safety gog‐
with respect to the correctness of information in this document. Copyright by AUDI AG.
gles and protective clothing to avoid possible injury and skin
contact. Before opening the fuel system, wrap a cloth around
the connection. Then dissipate pressure by carefully detaching
the connection.

– Disconnect fuel supply pipe -3- by pulling release tab.

Note

The fuel return pipe -2- and vacuum pipe -1- remain connected
(if fitted).

– Screw connector -V.A.G 1318/23- and adapter -

V.A.G 1318/17-1- onto pressure gauge -V.A.G 1318- .
– Fit adapter -V.A.G 1318/17-1- onto the disconnected fuel sup‐
ply pipe.
– Screw the adapter -V.A.G 1318/11- onto the pressure gauge
-V.A.G 1318- . Attach test hose -arrow- and hold end of hose
in measuring container.
– Open cut-off tap on pressure tester -V.A.G 1318- . Lever must
point in direction of flow.
– Bleed fuel system by pressing remote control switch briefly.

28 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

– Close cut-off tap on pressure tester -V.A.G 1318- . Lever is at

right angle to direction of flow -arrow-.
– Press and hold remote control switch until pressure tester -
V.A.G 1318- shows no further increase in pressure.
• Specification: approx. 6 bar (5 ... 7 bar).
If specification is not obtained:
– Check delivery rate of fuel pump ⇒ Fuel supply system, petrol
engines; Rep. Gr. 20 .
Checking residual pressure
– Check for leaks and check residual pressure by watching drop
in pressure on pressure tester -V.A.G 1318- .
• After 10 minutes pressure should still be at least 3.75 bar.
If the residual pressure drops below 3.75 bar:
♦ Check union between pressure tester -V.A.G 1318- and fuel
supply line for leaks.
♦ Check pressure tester -V.A.G 1318- for leaks.
♦ Check fuel lines and their connections for leaks.
♦ Renew fuel filter with integrated fuel pressure regulator ⇒ Fuel
supply system, petrol engines; Rep. Gr. 20 . Then repeat the
test.
♦ If fuel filter is OK, renew fuel pump ⇒ Fuel supply system,
petrol engines; Rep. Gr. 20 .
Assembly is carried out in the reverse order; note the following:

– Switch off ignition.

Note

Before removing the pressure tester, release the fuel pressure by

opening the cut-off valve. Hold end of test hose in a container.

– Re-install fuel supply line (make sure that all parts are clean).

2.13 High-pressure pump - exploded view (for engine code letters AXW and
BHD)

2. Injection system 29
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

❑ Install fuel pipe so it is

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
free of tension (all parts
must be clean)
6 - Banjo bolt with tapered
sealing seat
❑ Connection for high-
pressure fuel pipe lead‐
ing to fuel rail
❑ Counterhold connection
on high-pressure pump when loosening
❑ Renew banjo bolt
❑ 25 Nm
❑ Install fuel pipe so it is free of tension (all parts must be clean)
7 - High-pressure fuel pipe
❑ Fuel pressure in high-pressure pipe can be up to 120 bar! Wear safety goggles and protective clothing
to avoid possible injury and skin contact. Wrap a cloth around the connection before loosening the fuel
pipes. Then dissipate pressure by carefully slackening banjo bolts
8 - Fuel pipes

30 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

2.14 High-pressure pump - exploded view (for engine code letters BMB, BLX,
BLY, BLR, BVZ and BVY)

1 - Roller tappet
❑ Can possibly stick in‐
side cylinder head after
removal of high-pres‐
sure pump
2 - O-ring
❑ Renew
❑ Before installing, lubri‐
cate lightly with clean
engine oil
3 - Mechanical single-plunger
high-pressure pump with fuel
pressure regulating valve -
N276-
4 - Dust cap for bleeder valve
5 - Bolts
❑ 10 Nm
6 - Banjo bolt with tapered
sealing seat
❑ 17 Nm
❑ Counterhold connection
on high-pressure pump
when loosening
7 - High-pressure fuel pipe
❑ Connection for high-
pressure fuel pipe lead‐
ing to fuel rail
❑ Fuel pressure in high-
pressure pipe can be up
to 120 bar! Wear safety
goggles and protective
clothing to avoid possi‐
ble injury and skin con‐
tact. Wrap a cloth
around the connection before loosening the fuel pipes. Then dissipate pressure by carefully slackening
banjo bolts
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
8 - Banjo bolt with tapered sealing
permitted unless seatby AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
❑ 17 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Counterhold connection on high-pressure pump when loosening

❑ Renew banjo bolt
9 - Fuel line from tank

2. Injection system 31
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

2.15 Removing and installing high-pressure

pump

Note

♦ The high-pressure fuel pump should only be removed and in‐

stalled when the engine is cold.
♦ When installing the high-pressure fuel pump, it is essential to
ensure that no dirt enters the fuel system.
♦ Use a cloth to catch escaping fuel.
♦ The high-pressure pump must not be dismantled.

Removing

WARNING

Fuel system operates under high pressure. Always dissipate

fuel pressure prior to opening fuel system. For procedure, refer
to ⇒ page 3

Note

♦ If the battery is not disconnected, fuse No. 27 for fuel pump

control unit -J538- must be removed as a precautionary meas‐
ure before opening the fuel system, because the fuel pump will
otherwise be activated by the contact switch on the driver's
door.
♦ The high-pressure fuel pump should only be removed and in‐
stalled when the engine is cold.
♦ When installing the high-pressure fuel pump, it is essential to
ensure that no dirt enters the fuel system.
♦ Use a cloth to catch escaping fuel.
♦ The O-ring must always be renewed.
♦ Banjo bolt for fuel return line must always be renewed.
♦ Always ensure that the high-pressure fuel pipes are free of
tension when tightening the connections.

– Remove intake manifold ⇒ page 24 .

– Remove fuel pipes. Counterhold connections on high-pres‐
sure pump when loosening
– Remove retaining bracket for wiring harness -arrows-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove high-pressure pump -arrows- (depending on ver‐
with respect to the correctness of information in this document. Copyright by AUDI AG.
sion).

32 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Engine code letters AXW and BHD

Engine code letters BMB, BLX, BLY, BLR, BVZ and BVY
– Remove roller tappet ⇒ Item 1 (page 30) from camshaft hous‐
ing.
Installing

Note

♦ The securing bolts must be inserted before fitting the high-

pressure pump.
♦ Ensure stress-free installation of fuel pipes.
♦ Always renew banjo bolts.

– Renew O-ring for high-pressure pump (lubricate lightly with

clean engine oil before fitting)
– Check roller tappet ⇒ Item 1 (page 30) for damage and insert
in cylinder head
– Carefully locate high-pressure pump on cylinder head and
screw in bolts -arrows- hand-tight.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Engine code letters AXW and

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
BHDto the correctness of information in this document. Copyright by AUDI AG.
with respect

Engine code letters BMB, BLX, BLY, BLR, BVZ and BVY
– Install fuel pipes. Only tighten bolts hand-tight.
– Now tighten bolts as follows: (fit new banjo bolts)

2. Injection system 33
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Engine code letters AXW and BHD

1. - Tighten securing bolts for high-pressure pump to 10 Nm.
2. - Tighten banjo bolts -2- to 17 Nm
3. - Tighten banjo bolts -3- to 25 Nm
4. - Tighten securing bolts -1- to 10 Nm.

Engine code letters BMB, BLX, BLY, BLR, BVZ and BVY
1. - Tighten securing bolts for high-pressure pump to 10 Nm.
2. - Tighten banjo bolt -2- to 17 Nm
3. - Tighten banjo bolt -3- to 17 Nm
4. - Tighten banjo bolt -4- to 17 Nm
5. - Tighten union nut -5- to 27 Nm.
6. - Tighten securing bolts -1- to 10 Nm.
– Install intake manifold ⇒ page 24 .

2.16 Removing and installing injectors, re‐

newing combustion chamber (teflon)
ring seal
Special tools and workshop equipment required
♦ Puller -T10133-

Note

Special tool T10133/2 (puller) has been modified and now has the
designation puller T10133/2 A . If you have not yet received the
new tool you can make the modification yourself.

Modifying special tool T10133/2 (puller) to make it equivalent to

puller T10133/2 A
Special tools and workshop equipment required
♦ Round file, approx. 6 mm
– File out a semi-circular recess as shown in the illustration. The
recess allows the tool to be pushed further onto the injector so
the contact surface is increased.

34 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

– For identification purposes, mark the modified tool with the

letter “A” after the tool number.
Removing injectors

– Illustration shows injector when removed.

Note

The radial compensation element -Item 1- is clipped into the sup‐

port ring -Item 6- with the injector fitted. To remove the injector,
the support ring must be removed from the injector so that the
puller -T10133/2- can be inserted into the groove on the injector
-Item 3-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Use a screwdriver to bend retainer tabs of radial compensation

element to side, and pull support ring off injector.

2. Injection system 35
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

– Guide puller -T10133/2A- into groove on injector.

– Then attach removal tool -T10133/16- and pull out injector by
turning bolt -1-.

Note

The combustion chamber ring seal must always be renewed prior

to reinstalling the injector ⇒ page 36 .

2.16.1 Renewing combustion chamber ring

seal (teflon ring seal)
Special tools and workshop equipment required
♦ Puller -T10133-

36 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

– Illustration shows injector when removed.

1 - Radial compensation element, renew if damaged
2 - Combustion chamber ring seal (teflon ring seal) - renew; when
fitting, do not grease ring or use any other lubricant
3 - Groove on injector
4 - Spacer ring (renew if damaged)
5 - O-ring (renew; apply thin coating of clean engine oil prior to
installation)
6 - Support ring (via this support ring, fuel rail exerts force which
secures injector in cylinder head)
The combustion chamber ring seal must always be renewed prior
to reinstalling the injector.
– Carefully remove old teflon ring using suitable tools (e.g. cut
open ring using razor blade, or prise open ring with small
screwdriver and then pull off forwards). It is important to en‐
sure that the groove and the continuous ridge in the bottom of
Protectedthe groove
by copyright. are not
Copying damaged.
for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

The injector must be renewed if the groove is damaged.

– Before new teflon ring is fitted, any combustion residue must

be removed from ring groove and injector stem using a clean
cloth.

Note

The illustration shows an injector with “offset connector”. This can

be ignored since it is not relevant when replacing the combustion
chamber ring seal.

– Use assembly cone -T10133/5- and assembly sleeve -

T10133/6- to fit new teflon ring.

– Slide teflon ring onto assembly cone. Then use assembly

sleeve to push teflon ring evenly off assembly cone into injec‐
tor groove. Do not use any lubricants during this procedure.

Note

The teflon ring is widened as it is pushed onto the injector. The

teflon ring must therefore be compressed again after it has been
fitted. This is done in two steps. The procedure is described be‐
low.

Step 1 of teflon ring calibration (adaption) is done with special tool

-T10133/7- .

2. Injection system 37
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

– Turn special tool (approx. 180°) while simultaneously sliding it

over injector as far as it will go, applying moderate force. Then
pull back to the original position, once again turning it 180°.
Step 2 of teflon ring calibration (adaption) is done with special tool
-T10133/8- .

– Turn special tool (approx. 180°) while simultaneously sliding it

over injector as far as it will go, applying moderate force. Then
pull back to the original position, once again turning it 180°.

– Use supplied nylon brush (special tool -T10133/4- ) to thor‐

oughly clean holes for high-pressure injectors in cylinder head
prior to installing injector.

Note

An open inlet valve may prevent cleaning. If so, the engine must
be cranked by hand by rotating the crankshaft with a spanner.

– Refit support ring -1- on injector and clip radial compensation

element -2- onto support ring.

Note

♦ The teflon seal on the injector must not be oiled or greased.

♦ Make sure there is no cleaning fluid or oil in the cylinder head
bores when installing the injectors.

38 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

– Use assembly tool -T10133/9- to push injector as far as it will

go into hole in cylinder head (free of oil and grease). Ensure
that the injector is properly seated in the cylinder head.
Installation is performed in the reverse sequence.
Important: the following points must always be observed:
• The teflon seal on the injector must not be oiled or greased.
• Make sure there is no cleaning fluid or oil in the cylinder head
bores when installing the injectors.
• Coat O-rings of high-pressure injectors with clean engine oil
to facilitate insertion into fuel rail.
• Renew all seals.
• Fuel rail must be positioned on injectors and pressed in evenly.
• Installing fuel rail ⇒ page 25
• Installing intake manifold ⇒ page 24

2.17 Removing and installing Lambda

probes (before catalytic converter)
The components Lambda probe 2 -G108- and Lambda probe 2
heater -Z28- are not fitted on engines with code letter BVZ.
Special tools and work‐
shop equipment re‐
quired
♦ Lambda probe open
ring spanner set
-3337-

Fitting location of con‐

nectors for Lambda
probes before catalytic
converter
1 - Connector for Lamb‐
da probe 2 -G108- and
Lambda probe 2 heater -
Z28- (for cylinders 2 and
3) “not fitted on byengines
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised AUDI AG. AUDI AG does not guarantee or accept any liability
with
with code
respect to theletter BVZ”
correctness of information in this document. Copyright by AUDI AG.

2 - Connector for Lamb‐

da probe -G39- and
Lambda probe heater -
Z19- (for cylinders 1 and
4)
– Unplug connector for
corresponding Lamb‐
da probe.

2. Injection system 39
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Fitting location of Lambda probes before catalytic converter

1 - Lambda probe -G39- and Lambda probe heater -Z19- before
catalytic converter “engines with code letters BLY and BVZ, see
next illustration”
2 - Lambda probe 2 -G108- and Lambda probe heater 2 -Z28-
before catalytic converter “not fitted on engines with code letter
BVZ”

Lambda probe -G39- -2- “engine code letters BLY and BVZ”
Removing
– Unplug electrical connector for Lambda probe -G39- and
Lambda probe heater -Z19- .
– Unscrew relevant Lambda probe using tool from Lambda
probe open ring spanner set -3337- .
Installing
When installing, note the following:

Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Threads of new Lambda probes are already coated with as‐
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.18 Removing and installing Lambda

probes (after catalytic converter)
The components Lambda probe 2 after catalytic converter -G131-
and Lambda probe 2 heater after catalytic converter -Z30- are not
fitted on engines with code letters BHD, BMB, BLY and BVZ.
Special tools and workshop equipment required
♦ Lambda probe open ring spanner set -3337-

40 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Removing
– Remove right-side cover from underbody.
Fitting location of connectors for Lambda probes after catalytic
converter (arrow faces direction of travel).
3 - Electrical connector (black) for right-side Lambda probe after
catalytic converter -G130- and Lambda probe 1 heater, after cat‐
alytic converter -Z29- (bank 1, probe 2)
4 - Electrical connector (brown) for left-side Lambda probe 2 after
catalytic converter -G131- and Lambda probe 2 heater after cat‐
alytic
Protected converter
by copyright. -Z30-
Copying (bank
for private 2, probe
or commercial 2) in part or in whole, is not
purposes,
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– respect
with Unplug connector
to the correctness for corresponding
of information in this document. Lambda probe.
Copyright by AUDI AG.

Lambda probes after catalytic converter

1 - Lambda probe 2, after catalytic converter -G131- and Lambda
probe heater 2, after catalytic converter -Z30- (bank 2, probe 2)
2 - Lambda probe after catalytic converter -G130- and Lambda
probe 1 heater after catalytic converter -Z29- (bank 1, probe 2)
– Unscrew relevant Lambda probe using tool from Lambda
probe open ring spanner set -3337- .
Installing
When installing, note the following:

Note

♦ Threads of new Lambda probes are already coated with as‐

2.19 Removing and installing NOx sensor

control unit -J583- and NOx sender -
G295-
The NOx sensor control unit -J583- and the NOx sender -G295-
are not fitted on vehicles with engine code letters BLY, BMB,
BHD, BLR, BVZ and BVY.

2. Injection system 41
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Special tools and work‐

shop equipment re‐
quired
♦ Lambda probe open
ring spanner set
-3337-

Fitting location of con‐

nectors (arrow faces di‐
rection of travel)
1 - NOx sensor control
unit -J583- (cable for
control unit cannot be
disconnected from NOx
sender -G295- )
2 - Connector for ex‐
haust gas temperature
sender 1 -G235-

Fitting location of NOx sender -G295- and exhaust gas tempera‐

ture sender 1 -G235-
1 - NOx sender -G295- and NOx sender heater -Z44- (“NOx”
stands for oxides of nitrogen)
2 - Exhaust gas temperature sender 1 -G235-
Removing
– Remove right-side cover from underbody.
– Unplug engine wiring harness connector at NOx sensor con‐
trol unit -J583- .
– Pull cable between NOx sensor control unit -J583- and NOx
sender -G295- out of retainers and detach NOx sensor control
unit -J583- .

– Unscrew NOx sender -G295- -item 1- using tool from Lambda

probe open ring spanner set -3337- .
Installing
When installing, note the following:

Note

♦ When installing, the cables must always be reattached at the

same locations to prevent them from coming into contact with
the exhaust pipe.
♦ Tightening torque for NOx sender -G295- is 63 Nm.

42 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

2.20 Removing and installing exhaust gas

temperature sender 1 -G235-
Exhaust gas temperature sender 1 -G235- is not fitted on engines
with code letters BLY, BMB, BHD, BLR, BVZ and BVY.
Special tools and work‐
shop equipment re‐
quired
♦ Lambda probe open
ring spanner set
-3337-

Fitting location of con‐

2. Injection system 43
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Fitting location of NOx sender and exhaust gas temperature

sender
1 - NOx sender -G295- and NOx sender heater - Z44 - (“NOx”
stands for oxides of nitrogen)
2 - Exhaust gas temperature sender 1 -G235-
Removing
– Remove right-side cover from underbody.
– Unscrew exhaust gas temperature sender 1 -G235- -item 2-
using tool from Lambda probe open ring spanner set -3337- .
Installing
When installing, note the following:

Note

♦ When installing, the cables must always be reattached at the

same locations to prevent them from coming into contact with
the exhaust pipe.
♦ Tightening torque for exhaust gas temperature sender 1 -
G235- is 45 Nm.

2.21 Lambda probe 3 after catalytic converter

-G287- and Lambda probe heater 3 after
catalytic converter -Z64-
On engines with code letters BLR and BVY a Lambda probe 3
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

after catalytic converter -G287- iswith

fitted in place of the NOx sender
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by AUDI AG.
-G295- .
Special tools and workshop equipment required
♦ Lambda probe open ring spanner set -3337-

Removing
– Remove right-side cover from underbody.

44 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

– Unplug electrical connector -2- for Lambda probe 3 after cat‐

alytic converter -G287- .

– Unscrew Lambda probe 3 after catalytic converter -G287-

-1- using tool from Lambda probe open ring spanner set
-3337- .
Installing
When installing, note the following:

Note

♦ Threads of new Lambda probes are already coated with as‐

sembly paste; the paste must not get into the slots on the probe
body.
♦ In the case of a used Lambda probe grease only the thread
with high-temperature paste. The paste must not get into the
slots on the probe body. High-temperature paste ⇒ Parts
catalogue
♦ When installing, the Lambda probe wire must always be reat‐
tached at the same locations to prevent it from coming into
contact with the exhaust pipe.
♦ Tightening torque: 55 Nm.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Injection system 45
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

3 Engine control unit

3.1 Wiring and component check with test

box -V.A.G 1598/42-

46 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Note

♦ The test box has 105 contacts. The connecting cable can be
disconnected from the test box. This means that only the cable
(and not the test box) has to be purchased for future engine
control units with different types of connectors.
♦ The smaller of the two connectors on the engine control unit
has the contacts 1 to 60. The larger of the two connectors has
the contacts 1 to 94.
♦ If you want to check a wiring connection to the engine control
unit, first refer to the current flow diagram to find out which
connector on the engine control unit the wiring connection
leads to. If this is a wire which leads to the 60-pin connector
(e.g. the activation wire for the intake manifold change-over
valve, T60/27), then attach the smaller of the two connectors
to connection “A” of the test box -V.A.G 1598/42- (using adapt‐
er cable -V.A.G 1598/39–1- ) and measure to pin 27.
♦ If a wiring connection leads to the 94-pin connector (according
to current flow diagram), then connect the larger of the two
connectors using adapter cable -V.A.G 1598/39–2- as follows:
The connector marked “A” must be attached to connection “A”
on the test box -V.A.G 1598/42- and the connector marked “B”
must be attached to connection “B” on the test box -V.A.G
1598/42- .
♦ The test box -V.A.G 1598/42- is designed so it can be con‐
nected both to the wiring harness for the engine control unit
and to the engine control unit itself at the same time.
♦ The advantage of this is that the electronic engine control sys‐
tem remains fully functional when the test box is connected
(for example, for measuring signals when the engine is run‐
ning).
♦ The relevant test procedure will state whether it is necessary
to also connect the engine control unit to the test box.

WARNING

To prevent damage to the electronic components, select ap‐

propriate measuring range before connecting the measuring
cables and observe the test requirements.

– Connect test box -V.A.G 1598/42- to wiring harness connec‐

tor. The earth clip on the test box must be connected to the
negative battery terminal.
– Remove engine control unit ⇒ page 47
– Carry out test as described in appropriate repair procedures.
Installing engine control unit
Installation is performed in the reverse sequence; the engine con‐
trol unit must be installed with the protective housing. New shear
bolts must be used.
Perform the following after by
Protected reconnecting
copyright. Copyingengine
for private control unit:
or commercial purposes, in part or in whole, is not

– Interrogate and, if necessary, erase faultofmemory

information ⇒ VAS 5051Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness in this document.
vehicle diagnostic, testing and information system .

3.2 Renewing Motronic control unit -J220-

Special tools and workshop equipment required

3. Engine control unit 47

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

♦ Hot air blower -VAS 1978/14A- -item 1- with nozzle attachment

-2- from wiring harness repair set -VAS 1978 B-

♦ Mole grips (commercially available type)

The engine control unit -1- is bolted to the locking plates
-2 and 5-. To make it more difficult to unscrew the shear bolts
-4- for locking plate -2-, their threads have been coated with lock‐
ing fluid.
The protective housing has to be removed before the connectors
can be unplugged from the engine control unit (e.g. to connect
the test box or renew the engine control unit).
To make it more difficult to unscrew the shear bolts, their threads
have been coated with locking fluid.
Removing engine control unit
– When renewing engine control unit, select diagnosis object
“Replace engine control unit” in “Guided Functions” ⇒ Vehicle
diagnosis, testing and information system VAS 5051.
– Switch off ignition.
– Lever off caps on windscreen wiper arms with a screwdriver.

– Loosen hexagon nuts -arrows- several turns.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– permitted
Loosen wiper
unless arms
authorised by from wiper
AUDI AG. shafts
AUDI AG byguarantee
does not tilting or
slightly.
accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Completely remove hexagon nuts and detach wiper arms from
wiper shafts.

– Unclip washer jets -arrow-.

– Push washer jets through assembly opening back into plenum
chamber, leaving hoses connected.

48 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

– Pull off rubber seal -1- from plenum chamber cover.

– Detach plenum chamber cover -2-.
The following steps are only required up to and including model
year 2006.
Set wiper shafts to service position (so that electrical connector
can be detached from engine control unit).
– First close bonnet.
– Switch ignition on and then off again. Within 10 seconds, press
wiper switch down once to brief wipe position.

Note

The wiper shafts will now run to the service position.

– Then open bonnet again.

Procedure for all vehicles:
– Remove ignition key.

WARNING

The following procedure must be followed exactly to prevent

any damage (scorching) to wiring, connectors, insulation and
control units. Observe operating instructions for hot air blower.

3. Engine control unit 49

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

– Select settings on hot air blower as shown in illustration, i.e.

set temperature potentiometer -2- to maximum heat output
and two-stage air flow switch -3- to position 3.

Note

♦ Then use hot air blower to heat shear bolts. This step reduces
inhibiting action of locking fluid on shear bolt threads and
makes it easier to unscrew these bolts.
♦ Cover up all painted parts to avoid any damage caused by hot
air blower or vice-grip pliers.

WARNING

Parts of the protective housing will become very hot as a result

of heating the shear bolts. Take care to avoid burns. Try to
ensure that only the shear bolt is heated and none of the near‐
by components. These should be covered if necessary.

– Place the hot air blower nozzle close to the shear bolt on the
protective housing.
– Switch on the hot air blower and heat the bolt for approximately
20Protected
to 25 seconds.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Thenwith
grasp
respectthe bolt
to the head ofwith
correctness the vice-grip
information pliers
in this document. and unscrew
Copyright by AUDI AG.
the shear bolt.
The procedure for the second shear bolt is exactly the same.
Engine control unit can now be separated from protective hous‐
ing.

Bracket for engine control unit: version 1

– Release clip “arrow” and remove engine control unit.

50 Rep. Gr.24 - Mixture preparation - injection

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Bracket for engine control unit: version 2

– Release front connector -1- from engine control unit and un‐
plug connector.
– Pull engine control unit out of retainer -arrow- (wiper shafts in
service position).
– Release rear connector on engine control unit and unplug
connector.
Installing engine control unit
Installation is performed in the reverse sequence.
– Make sure you fit protective housing back on engine control
unit.
– Clean threaded holes for shear bolts to remove any residue
from locking fluid. This can be done using a thread tap.
– Use new shear bolts.
– Return wiper arms to normal position.
– First close bonnet.
– Switch on ignition and press wiper switch down once to brief
wipe position. The wipers will then return to the normal posi‐
tion.
The following step must be performed after installing the new en‐
gine control unit:
– Activate engine control unit in “Guided Fault Finding” under
the test procedure / function “Replace engine control unit”.

3. Engine control unit 51

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

28 – Ignition system
1 General notes and safety precau‐
tions

1.1 General notes on ignition system

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ A voltage of unless
permitted at least 11.5byVAUDI
authorised is required
AG. AUDI AGfor doesproper operation
not guarantee or accept of
any liability
the electrical components.
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Certain tests may lead to a fault being detected by the control

unit and stored. The fault memory should therefore be inter‐
rogated and (if necessary) erased after completing the tests
and any repair work that may be required.
♦ If the engine starts, runs for a short period and then cuts out
after completing fault finding, repairs or component tests, this
may be due to the immobiliser disabling the engine control
unit. The fault memory must then be interrogated and, if nec‐
essary, the control unit must be adapted.

1.2 Safety precautions

Note the following if testers and measuring instruments have to
be used during a road test:

WARNING

♦ Test equipment must always be secured on the rear seat

To avoid any risk of injuries to persons and/or damage to the fuel

injection and ignition system, always observe the following safety
precautions.
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as the
ignition system and gas-discharge headlights.
♦ Do not touch or disconnect ignition wiring when the engine is
running or being turned at starter speed.
♦ Always switch off the ignition before connecting or discon‐
necting injection or ignition system wiring or tester cables.
♦ Always switch off the ignition before cleaning the engine.
♦ Always switch off the ignition before connecting or discon‐
necting the battery, otherwise the engine control unit may be
damaged.
♦ If the engine has to be operated at the starting speed without
actually starting (e.g. to test compression pressure), detach
the four connectors from the ignition coils using assembly tool
-T40039- ⇒ page 55 . Also remove fuse 27 from fuel pump
control unit -J538- .

52 Rep. Gr.28 - Ignition system

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Note

Removing fuse 27 will interrupt the voltage supply for the fuel
pump control unit -J538- .

1. General notes and safety precautions 53

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

2 Servicing ignition system

2.1 Test data

Engine data 2.0 ltr / 110 kW FSI engine
Idling speed: 640...800 rpm
Cannot be adjusted;
controlled by the idling
speed stabilisation
Speed governing: approx. 6,500 rpm
By deactivating injec‐
tors or closing throttle
valve
Ignition timing is deter‐
mined by the control
unit. Ignition timing
cannot be adjusted.
Ignition system Multi-coil ignition system with 4 ignition coils (integrated output stages) connected
directly to spark plugs via spark plug connectors; ignition coils can be pulled out
of cylinder head using puller - T40039 -
Firing order 1-3-4-2

2.2 Ignition system - exploded view

54 Rep. Gr.28 - Ignition system

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

1 - Knock sensor 1 -G61-

❑ Contacts gold-plated
2 - Knock sensor 2 -G66-
❑ Contacts gold-plated
3 - Ignition coil with output
stage -(N70, N127, N291,
N292)-
❑ Removing and installing
⇒ page 55
❑ Use puller -T40039- for
removal
4 - Spark plug
❑ 30 Nm
❑ Removing and installing
⇒ Maintenance ; Book‐
let 808
5 - Bolt
❑ 20 Nm
❑ Tightening torque influ‐
ences the function of the
knock sensor
6 - Bolt
❑ 10 Nm
7 - Hall sender -G40-
❑ Contacts gold-plated
8 - O-ring

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2.3 Removing and installing ignition coils
with respect to the correctness of information in this document. Copyright by AUDI AG.

with output stages

Special tools and workshop equipment required
♦ Puller -T40039-

2. Servicing ignition system 55

Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve) - Edition 09.2009

Removing:
– Unscrew two bolts -1- on connector rail.

– Pull all ignition coils approx. 30 mm out of spark plug holes

using puller -T40039- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Release connectors and pull all connectors off ignition coils.

Installing:
– Fit all ignition coils loosely into spark plug holes.

– Align ignition coils with connectors and attach all connectors

to ignition coils so they engage audibly.
– Press ignition coils onto spark plugs by hand with uniform
pressure (do not use tool).

56 Rep. Gr.28 - Ignition system

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