Note: Please read the warnings in the paragraph 1. The ignition must be off at all times.
Mass air flow sensor (DMRV)
Withdrawal
1. DMR8 is installed on the top cover of the air filter housing. Unhook the latches and remove the top cover from the case.
2. Loosen the clamp and disconnect the air duct from the DMRV.
3. Disconnect the wiring connector from the sensor.
4. Turn away screws of fastening and remove the gauge. Remove the gasket.
Installation
5. Installation is the reverse procedure. Install a new gasket or o-ring (what is provided).
Throttle position sensor (TPS or throttle potentiometer)
Note: TPS is fitted to the throttle body at the factory, and is not available for spare parts. A defective TPS requires replacement of the entire throttle body.
Withdrawal
6. Disconnect the wiring connector from the sensor.
7. Turn away screws of fastening and remove the gauge from the throttle case. Remove the sealing ring.
Installation
8. Installation is the reverse procedure. Pay attention to the following.
- A) If necessary, replace the O-ring.
- b) Correctly align the sensor with the damper axis.
- V) On models with automatic transmission, the sensor must be coordinated with the automatic transmission control unit - this requires the use of specialized equipment. Please contact your dealer.
Intake air temperature sensor
Withdrawal
9. If equipped, the sensor is screwed into the intake manifold near the throttle body.
10. Disconnect the wiring connector from the sensor.
11. Turn away bolts and remove the gauge from a collector.
Installation
12. Installation is the reverse procedure. Be sure to check the correct tightening torque of the threaded connection.
Idle speed controller
Removal and installation
13. The idle speed controller is built into the multi-functional throttle body, including the throttle potentiometer and the idle sensor/switch. In addition to controlling the idle speed of the engine, the governor acts as a damper when the throttle is closed.
14. The removal and installation procedures are the same as for the throttle potentiometer above. Please note that when power is removed from the regulator, the throttle automatically moves to the base position.
15. After installing the regulator, it is necessary to perform the activation procedure, which requires the use of specialized equipment VAG 1551 or 1552. Contact your Audi / VAG dealer for help.
Vehicle speed sensor
Removal and installation
16. If provided, the sensor is built into the speedometer and its signal is processed by the Motronic control unit. The signal is used to stabilize idle speed and to minimize jolts when shifting gears. Sensor malfunctions can be identified using the Audi / VA diagnostic equipment: If necessary, replace the entire speedometer unit on the front panel - see chapter 12.
Coolant temperature sensor
Withdrawal
17. The sensor is installed on all engines in the rear of the cylinder head.
18. Drain about a quarter of the coolant from the engine as described chapter 1A.
19. Disconnect the wiring from the sensor.
20. Carefully unscrew the sensor or remove the retainer and then the sensor. Take off the sealing washer.
Installation
21. Installation is the reverse procedure. Install a new sealing washer. If provided, securely tighten sensor. Add coolant as described in chapter 1A.
Engine speed sensor
Withdrawal
22. 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 1 to improve access.
23. Disconnect the electrical connector from the sensor.
24. Turn away a bolt of fastening and take out the gauge from the block of cylinders.
Installation
25. Installation - reverse procedure.
Throttle body
Withdrawal
26. On models with an accelerator cable, disconnect it from the throttle control lever as described in paragraph 3.
27. Loosen the clamps and disconnect the intake duct from the throttle body.
28. Disconnect the wiring connector from the TPS housing.
29. Disconnect the vacuum hose from the inlet to the throttle body and, if necessary, release the wiring from the fasteners.
30. Turn out through bolts and remove the case of a throttle from an inlet collector. Remove and discard gasket.
31. If necessary, remove the throttle potentiometer - see the appropriate subparagraph.
Installation
32. Installation - reverse procedure, please note the following:
- A) Install a new gasket between the housing and the intake manifold.
- b) Be convinced of reliability at connections of vacuum hoses and electric sockets.
- V) If necessary, adjust the accelerator cable - see paragraph 3.
Fuel injectors and fuel rail
Withdrawal
33. Disconnect the wire from the battery "masses", as described in chapter 5A.
34. Disconnect the vacuum hose from the fuel pressure regulator on the fuel rail (pic. 4.34).
35. Temporarily remove the fuel filler cap and install it back to relieve any pressure in the tank.
36. Lay a rag around the connection of the fuel supply line to the fuel rail (pic. 4.36). Place 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.
37. Turn away connection of a returnable highway and disconnect its tube from a ramp.
38. Disconnect wiring from all injectors. Attach tags to the wiring so as not to mix up during installation.
39. On ADP and AEB engines, disconnect the wiring from the Hall sensor.
40. Remove the mounting bolts, then carefully remove the fuel rail along with the injectors from the intake manifold (Figure 4.40, a, b).
41. Having installed the assembly on a workbench, pull off the fasteners and remove the nozzles from the fuel rail. Remove O-rings (pic. 4.41, a, b).
Installation
42. 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. When installing the front sealing ring, do not remove the plastic cover from the nozzle, leave it in place and put the ring through it.
- b) Make sure the injector mountings are secure.
- V) Connect fuel lines correctly. Check the condition of the sealing washers and, if necessary, replace them.
- 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
43. If necessary, remove the engine top cover and depressurize the fuel system - see paragraph 9.
44. Disconnect the vacuum hose from the pressure regulator (pic. 4.44).
45. Lay a rag under the regulator to collect fuel.
46. Pull out the spring clip and remove the regulator from the fuel rail. Remove sealing rings.
Installation
47. Installation - reverse procedure, install new o-rings.
Hall Sensor
Note: This paragraph does not cover the removal of the Hall sensor on the ADP engine, as it is located in the distributor there.
Withdrawal
48. Remove the outer timing belt cover as described in paragraph 4 of chapter 2A.
49. Release the retainer and disconnect the wiring connector from the Hall sensor (pic. 4.49).
50. Turn away bolts of fastening and remove the gauge in front of a head of cylinders. Remove the gasket.
Installation
51. Installation - reverse procedure. Replace gasket. Tighten the mounting bolts securely.
Oxygen sensor (Lambda probe)
Withdrawal
52. On all engines except AEB and AJL (turbocharged) the sensor is installed in the exhaust manifold to the right of the engine (pic. 4.52). On AEB and AJL engines, the sensor is mounted on top of the catalytic converter mounted at the rear of the turbocharger to the right of the engine.
53. The sensor wiring connector is located on the left side of the engine shield, under the expansion tank of the cooling system. Loosen the tank mounting screws and disconnect the wiring, move the tank to the side. Do not disconnect hoses. Disconnect the sensor wiring from all mountings.
54. Unscrew the sensor and carefully remove without damaging the tip.
Note: If there is a special head with a slot, when unscrewing the wire from the sensor, you can not disconnect it.
Installation
55. Apply non-stick lubricant to the threads, but do not smear the sensor tip with it.
Note: A new sensor may already have grease applied to its threads.
56. Screw on the sensor and tighten it to the prescribed torque.
57. Attach the wiring and secure with plastic clamps.
Electronic control unit (BEU)
Warning: Wait at least a few seconds after turning off the ignition before disconnecting the connector. When the connector is disconnected, all set data are erased, but the codes of possible malfunctions are stored in the memory. Once the connector is connected, the basic settings must be programmed, which requires specialized Audi/VAG equipment. When starting the BEU, you must also enter the identification code on the block into the immobilizer memory. Contact your dealer for help.
Withdrawal
58. BEU is installed on the engine shield at the rear of the engine compartment. On right-hand drive models, it is on the right, with left-hand drive it is on the left.
59. Disconnect the wire "masses" from the fan as described in chapter 5A.
60. Loosen the screws and remove the cover (pic. 4.60).
Note: On early left hand drive models there is a hole to access the mounting bolt in the cover panel in front of the windshield, on later models there are no holes - the panel must be removed.
61. Release the spring clip with a screwdriver and lift the BEU up (pic. 4.61).
62. Release the retainer and disconnect the wiring connector from the block.
Warning: After turning off the ignition, wait at least 30 seconds before disconnecting the connector.
63. Remove the block from the motor shield.
Installation
64. Installation - reverse procedure. Press the latch until it clicks (pic. 4.64). Connect battery - see chapter 5A.
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