permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ... List of Workshop Manual Repair Groups. Repair Group ...
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Workshop Manual
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr.
4-valve turbo)
Engine ID
AXX BPY BWA
Edition 11.2005
Service
Service Department. Technical Information
Page 2
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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.
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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2005 Audi AG, Ingolstadt
A0050442920
Page 3
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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.
Contents
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
Servicing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
General notes on self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.2
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.3
Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1.4
Procedure to be followed prior to opening high-pressure injection system - take note of the
following: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1.5
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1.6
Overview - fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
1.7
Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.8
Exploded view - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.9
Exploded view - air cleaner / engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.10 Removing and installing engine cover panel with air filter element . . . . . . . . . . . . . . . . . . 16
1.11 Removing and installing intake manifold with fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.12 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.13 Checking initial fuel pressure (up to high-pressure pump) . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.14 Checking fuel pressure and residual pressure (up to high-pressure pump) . . . . . . . . . . . . 28
1.15 Exploded view - high-pressure fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.16 Removing and installing high-pressure fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.17 Wiring and component check with test box V.A.G 1598/42 . . . . . . . . . . . . . . . . . . . . . . . . 34
1.18 Renewing Motronic control unit J220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.19 Removing and installing Lambda probe G39 and Lambda probe heater Z19 before catalytic
converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.20 Removing and installing Lambda probe after catalytic converter G130 and Lambda probe 1
heater, after catalytic converter Z29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1
Checking ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.1
General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.2
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.3
Technical data for ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2
Ignition system - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3
Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 11.2005
Contents i
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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.
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 11.2005
ii Contents
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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.
24 – Mixture preparation - injection
1
Servicing injection system
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. Clamping-type 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 driver's door is opened, the fuel
pump is activated for 2 seconds in order to build up pressure
in the fuel system → Chapter (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
→ Chapter (page 3).
The connection must be opened IMMEDIATELY after reduc‐
ing the pressure by wrapping a cloth around the connection
and allowing the residual pressure (approx. 6 bar) to dissi‐
pate.
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
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.
Audi A3 2004 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 11.2005
1. Servicing injection system 1
Page 6
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.
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 mea‐
sure 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.
♦ If the fault memory has been erased, you must generate the
readiness code again.
♦ 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- → Chapter (page 43). 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 the adjacent areas before
disconnecting.
♦ 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.
Do not move vehicle.
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