Note: Before starting work, read the warnings contained in paragraph 1. The ignition must be off at all times.
Mass air flow sensor (DMRV)
Withdrawal
1. Disconnect the wire from the battery "masses" - see chapter 5A. If necessary, remove the engine top cover.
2. As described in paragraph 2, loosen the clamps and disconnect the air duct from the sensor at the rear of the air filter housing.
3. Disconnect the wiring connector from the sensor.
4. Turn away screws of fastening and remove the gauge from the case of the air filter. Remove the sealing ring.
Warning: Handle the sensor with care - internal components are easily damaged.
Installation
5. Installation - reverse procedure. Replace damaged O-ring.
Throttle position sensor (TPS, throttle potentiometer)
6. TPS - an integral part of the throttle body. Please refer to the relevant subparagraph.
Intake air temperature sensor
Withdrawal
7. The sensor is installed on the left side of the intake manifold.
8. Disconnect the wiring from the sensor.
9. Turn out the gauge from an inlet collector. Remove the sealing ring.
Installation
10. Installation - reverse procedure. Install a new O-ring and tighten the sensor securely.
Vehicle speed sensor
11. The sensor is installed in the checkpoint - refer to the description chapter 7A.
Coolant temperature sensor
Withdrawal
12. The sensor is installed in the outlet flange of the cooling system at the rear of the cylinder head. Remove, if necessary, the engine top cover.
13. Disconnect the wiring from the sensor.
14. Drain about a quarter of the coolant from the engine - see chapter 1A.
15. Remove retainer and remove transducer from flange - be prepared for liquid spill. Remove the sealing ring.
Installation
16. Installation - reverse procedure. Use a new o-ring. Add coolant - see chapter 1A.
Engine speed sensor
Withdrawal
17. The sensor is installed in the rear left side of the cylinder block, closer to the docking plane with the bell, behind the oil filter. If necessary, drain the engine oil and remove the oil filter with oil cooler as described in chapter 1A, to improve access.
18. Disconnect from the gauge an electric socket.
19. Turn away a bolt of fastening and take out the gauge from the block of cylinders.
Installation
20. Installation - reverse procedure.
Throttle body
21. Disconnect the accelerator cable from the throttle control lever as described in paragraph 4.
22. Loosen the clamps and disconnect the intake duct from the throttle body.
23. Disconnect the wiring connector from the TPS housing.
24. Disconnect the vacuum hose from the inlet to the throttle body and, if necessary, release the wiring from the fasteners.
25. As described in chapter 3, drain about a quarter of the coolant from the engine. Loosen the clamps and disconnect the cooling hoses from the fittings on the throttle body, remembering their correct connection.
26. Disconnect the canister purge vacuum hose from the fitting on the throttle body.
27. Turn out bolts and remove the case of a throttle from an inlet collector. Remove and discard gasket.
Installation
28. Installation - reverse procedure, please note the following:
- A) Install a new gasket between the housing and the intake manifold.
- b) When tightening the throttle body mounting bolts, tighten them to the specified torque.
- V) Make sure that the vacuum hoses and electrical connectors are secure.
- G) As described in chapter 1A, add coolant.
- V) If necessary, adjust the accelerator cable.
Fuel injectors and fuel rail
Withdrawal
29. Disconnect the wire from the battery "masses" - see chapter 5A. If necessary, remove the engine top cover.
30. Disconnect the vacuum hose from the fuel pressure regulator on the fuel rail.
31. Remove the fuel filler cap and install it back to relieve any pressure in the tank.
32. Spread a rag around the connection of the supply fuel line to the fuel rail. Also provide a suitable container to collect the fuel. Loosen the connection nut while holding the bolt with another open end wrench and drain the fuel into a dish underneath. Remove the rag.
33. Turn away connection of a returnable highway and disconnect its tube from a stage.
34. Disconnect wiring from all injectors. Tag the wiring to avoid confusion during installation.
35. Remove the mounting bolts, then carefully remove the fuel rail along with the injectors from the intake manifold.
36. Having installed the assembly on the workbench, pull off the fasteners and remove the nozzles from the fuel rail. Remove sealing rings.
Installation
37. Installation - reverse procedure. Pay attention to the following.
- A) Replace the injector O-rings with new ones, lightly lubricate them with engine oil before installation to facilitate installation.
- b) Make sure the injector mountings are secure.
- V) Connect fuel lines correctly. Check the condition of the sealing washers and replace if necessary.
- G) Check the reliability of the vacuum and electrical connections
- d) Connect battery - see chapter 5A.
- e) Finally, start the engine and check for leaks.
Fuel pressure control
Withdrawal
38. If necessary, remove the engine top cover and depressurize the fuel system - see paragraph 9.
39. Disconnect the vacuum hose from the pressure regulator.
40. Lay a rag to collect fuel under the regulator.
41. Pull out the spring clip and remove the regulator from the fuel rail. Remove sealing rings.
Installation
42. Installation - reverse procedure, install new o-rings.
Hall Sensor
Withdrawal
43. Remove the camshaft sprocket as described in chapter 2A.
44. Remember the way the sensor is installed and mark its position relative to the cylinder head. Disconnect wiring from sensor.
45. Remove the rear timing belt cover from the cylinder head.
46. Turn away the remained bolts and remove the gauge from a head of cylinders.
Installation
47. Installation - reverse procedure. Center the sensor base plate before tightening the mounting bolts.
Oxygen sensor (Lambda probe)
Withdrawal
48. On all engines, the sensor is installed in the exhaust manifold to the right of the engine.
49. The sensor wiring connector is located on the left side of the engine shield, under the expansion tank of the cooling system.
50. Turn away screws of fastening of a tank and disconnect conducting, take a tank aside. Do not disconnect hoses. Disconnect the sensor wiring from all mountings.
51. Unscrew the sensor and remove without damaging the tip.
Application: If there is a special head with a slot, when unscrewing the wire from the sensor, you can not disconnect it.
Installation
52. Apply non-stick lubricant to the threads, but do not smear the sensor tip with it.
Note: A new sensor may already have lubricant applied to its threads.
53. Screw on the sensor and tighten it to the prescribed torque.
54. Attach the wiring and secure it with plastic ties.
Electronic control unit (BEU)
Warning: Before disconnecting the connector, wait at least 30 seconds after turning off the ignition. When the connector is disconnected, all data set will be erased. but codes of possible malfunctions are stored in memory. Once the connector is connected, the basic settings must be programmed, which requires specialized Audi/VAG equipment. When replacing the ECU, it is also necessary to enter the identification code of the new unit into the immobilizer memory. Contact your dealer for help.
Withdrawal
55. BEU is installed on the engine shield at the rear of the engine compartment. Not on right hand drive models it is on the right, on left hand drive models it is on the left.
56. Disconnect the wire "masses" battery as described in chapter 5A.
57. Loosen the screws and remove the cover (pic. 4.60).
Note: On early left hand drive models there are holes in the cover panel in front of the windshield to access the mounting bolt, on later models there is no hole - the panel must be removed.
58. Release the spring clip with a screwdriver and lift the BEU up.
59. Release the retainer and disconnect the wiring connector from the block.
Caution: After turning off the ignition, wait less than 30 seconds before disconnecting the connector.
60. Remove the block from the motor shield.
Installation
61. Installation - reverse procedure. Connect the battery as described in chapter 5A.
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