A0059007420-TDI Injection and Glow Plug System (6-Cyl)

Service
Workshop Manual
Audi A4 2001 ➤
Audi A4 Cabriolet 2003 ➤
TDI injection and glow plug system (6-cyl.)
Engine ID AKE AYM BFC BCZ BDG BDH BAU
Edition 12.2006
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
23 - Mixture preparation - injection
28 - Glow plug 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 A0059007420

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
TDI injection and glow plug system (6-cyl.) - Edition 12.2006
Contents
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Servicing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Air cleaner - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.8 Removing and installing intake manifold (front section) - engine code letters AKE, AYM, BAU,
BCZ, BFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.9 Removing and installing intake manifold (front section) - engine code letters BDG, BDH . . 9
1.10 Removing and installing intake manifold (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.11 Removing and installing intake manifold (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.12 Removing and installing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.13 Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.14 Draining fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.15 Dynamically checking and adjusting commencement of injection . . . . . . . . . . . . . . . . . . . . 22
1.16 Dynamic check of injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.17 Checking spray pattern of injectors and checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . 25
1.18 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.19 Removing and installing injector with needle lift sender G80 . . . . . . . . . . . . . . . . . . . . . . 27
1.20 Wiring and component check with adapter cable, 121-pin V.A.G 1598/31 (test box) . . . . 29
1.21 Renewing diesel direct injection system control unit J248 . . . . . . . . . . . . . . . . . . . . . . . . 31
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.1 Checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2 Checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Contents i
ii Contents
23 – Mixture preparation - injection

1 Servicing diesel direct injection sys‐
tem
1.1 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

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.
To avoid injury and/or damage to the injection and glow plug sys‐
tem, note the following:
♦ Switch off the ignition before connecting or disconnecting in‐
jection or glow plug system wiring or tester cables.
♦ If the engine is to be turned at starter speed without starting,
e.g. when checking compression, detach connector from in‐
jection pump.
WARNING
Before disconnecting battery,

Protected obtain
by copyright. Copyingradio code
for private for radios
or commercial purposes, in part or in whole, is not
equipped with anti-theft coding.
Always switch off the ignition before connecting or disconnect‐

ing the battery, otherwise the engine control unit may be dam‐
aged.
1.2 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. Use only lint-free 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 stored loose (e.g. in tool boxes 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.
1. Servicing diesel direct injection system 1

♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
1.3 Overview of fitting locations

Components A and B are not shown in the illustration.
1 - Air mass meter -G70- with

intake air temperature sender -
G42-
❑ Removing and installing
⇒ page 7
2 - Solenoid valve for charge
pressure control -N75-
3 - Electrical connector for ter‐
minal 50
❑ Between ignition/starter
switch and starter
4 - Electrical connector for nee‐
dle liftProtected
senderby-G80-
copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Needle lifttosender
with respect -G80-
the correctness of information in this document. Copyright by AUDI AG.
is not fitted on engines
with code letters BCZ
5 - Electrical connector for en‐
gine speed sender -G28-
6 - Oil pressure sender -G10-
7 - Oil temperature sender -
G8-
8 - Vacuum unit for charge
pressure
9 - Mechanical exhaust gas re‐
circulation valve
10 - Electronics box in plenum
chamber
❑ Diesel direct injection
system control unit -
J248- with altitude sen‐
sor -F96-
❑ Diesel direct injection
system relay -J322-
❑ Fuel pump relay -J17-
❑ Glow plug relay -J52-
❑ Glow plug fuse
11 - Engine speed sender -G28-
2 Rep. Gr.23 - Mixture preparation - injection

12 - Throttle butterfly valve -

N211-
❑ Only fitted on vehicles
with the following en‐
gine code letters: AKE,
AYM, BFC, BCZ, BAU
❑ Intake manifold flap mo‐
tor -V157- is fitted on en‐
gines with code letters
BDG and BDH, for this
reason, these engines
have no throttle butterfly
valve -N211-
13 - Exhaust gas recirculation
valve -N18-
14 - Intake manifold pressure
sender -G71-
❑ In charge air cooler
15 - Vacuum unit with intake
manifold flap
❑ Only fitted on vehicles
with the following en‐
gine code letters: AKE,
AYM, BFC, BCZ, BAU
❑ Intake manifold flap mo‐
tor -V157- is fitted on en‐
gines with code letters
BDG and BDH, for this
reason, these engines
have no vacuum unit
with intake manifold flap
16 - Injection pump
❑ With injection pump
control unit
❑ With metering adjuster
solenoid valve
❑ With injection pump speed sender
❑ With commencement of injection valve
❑ With fuel temperature sender
❑ Removing and installing ⇒ page 14
17 - Coolant temperature sender -G62-
18 - Injector with needle lift sender -G80-
❑ Injector for No. 3 cylinder
❑ Needle lift sender -G80- is not fitted on engines with code letters BCZ
A - Brake light switch -F- and brake pedal switch -F47-
❑ permitted
In footwell on brake
unless authorised pedal
by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Combined in one unit
B - Accelerator position sender -G79-

❑ In footwell on accelerator pedal

1.4 Air cleaner - exploded view
1 - Cover
2 - Air duct
❑ Air duct from lock carrier
to air cleaner housing
❑ Clean dirt and leaves
out of air duct
3 - Airpermitted
mass unless
meter -G70-by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
❑ Removing andcorrectness
with respect to the installing
of information in this document. Copyright by AUDI AG.
⇒ page 7
4 - 10 Nm
5 - Air hose
❑ Check air intake hose
for dirt and leaves
6 - O-ring
❑ Renew if damaged
7 - Air cleaner housing (top
section)
❑ Clean any salt deposits
or leaves and dirt out of
air cleaner housing (top
section)
8 - Rubber grommet
9 - Air filter element
❑ Always use genuine
part for air filter element
❑ Removing and installing
⇒ page 5
❑ Observe change inter‐
vals ⇒ Maintenance ;
Booklet 803
❑ Also clean snow screen
(if fitted)
10 - Air cleaner housing (bottom section)
❑ Clean any salt deposits or leaves and dirt out of air cleaner housing (bottom section)
❑ Check for dirt in water drain and clean as required
❑ Water drain must function properly
1.5 Removing and installing engine cover

panel
Removing
– There are two different types: a bolted version and a push-
fitted version

• Procedure on bolted version: remove cover caps and unscrew

nuts -arrows-. Then pull off engine cover panel carefully from
above.
• Push-fitted version: Pull engine cover panel carefully off re‐
taining pins. Do not jerk the cover panel away, and do not try
to pull on one side only.
Illustration shows bolted version
Installing
– To avoid damage, do not strike the engine cover panel with
your fist or with any kind of tool.
– Press engine cover panel with both hands onto retaining pins.
If bolted versionProtected
is installed: also
by copyright. secure
Copying withornuts.
for private commercial purposes, in part or in whole, is not
1.6 Removing and installing air filter ele‐
ment
Removing
– Remove air cleaner cover -2-.
– Unscrew two bolts securing air duct at lock carrier.
– Disconnect air duct -1- from air cleaner housing.
– Release hose clip -3-.
– Unplug electrical connector -4- at air mass meter -G70- .

– Pull hose -2- off air cleaner housing.

– Release 4 retaining clips on top section of air cleaner and lift
off top section of air cleaner.
– Take out old air filter element.
Installing
To ensure the proper function of the air mass meter -G70- it is
important to observe the following notes and instructions.
Note
♦ If the air filter element is very dirty or wet, dirt or water could
reach the air mass meter -G70- and affect the air mass value.
This would lead to loss of power, since a smaller injection
quantity is calculated.
♦ Always use genuine part for air filter element. Observe change
intervals ⇒ Maintenance ; Booklet 803 .
♦ 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.
♦ Both sections of the air cleaner housing must be clean (inspect
water drain).
♦ Also clean snow screen (if fitted).
♦ 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 water drain
permitted in authorised
unless bottom by section
AUDI AG.of airAG
AUDI cleaner for dirt or
does not guarantee and
accept any liability
clean if necessary
with respect(small hole). of information in this document. Copyright by AUDI AG.
to the correctness
– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections); use a vacuum cleaner if necessary.
– Check for salt residue, dirt and leaves in air mass meter and
air intake hose (engine intake side).
– Check for dirt and leaves in air duct going from lock carrier to
air cleaner housing.
– 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).
– Ensure secure fit of intake hose at air mass meter -G70- .
The remaining installation steps are carried out in the reverse se‐
quence.

1.7 Removing and installing air mass meter

-G70-
Removing
– Unplug electrical connector -4- at air mass meter -G70- .
– Open hose clip -3- and disconnect air intake hose from air
mass meter -G70- .
– Unscrew both bolts from air mass meterProtected
-G70- by . copyright. Copying for private or commercial purposes, in part or in whole, is not
– Then carefully pull air mass meter -G70- out
withof guide
respect to theon air
correctness of information in this document. Copyright by AUDI AG.
cleaner housing.
Installing
To ensure the proper function of the air mass meter -G70- it is
important to observe the following notes and instructions.
Note
♦ If the air filter element is very dirty or wet, dirt or water could
reach the air mass meter -G70- and affect the air mass value.
This would lead to loss of power, since a smaller injection
quantity is calculated.
♦ Always use genuine part for air filter element.
♦ Always renew seal of air mass meter -G70- if damaged (air
leaks in intake system).
♦ Use a silicone-free lubricant when installing the intake hose
and seal.
(same as original equipment): ⇒ Parts catalogue
– Check for salt residue, dirt and leaves in air mass meter and
air intake hose (engine intake side).
– Check for dirt in air duct leading to air filter element. If neces‐
sary, clean salt residue, dirt and leaves out of air cleaner
housing (top and bottom sections); wash out or use a vacuum
cleaner as required. Removing and installing air cleaner
⇒ page 5 .
– Align seal in slot on air cleaner housing and carefully push air
mass meter -G70- into air cleaner housing.
The remaining installation steps are carried out in the reverse se‐
quence.

1.8 Removing and installing intake manifold

(front section) - engine code letters AKE,
AYM, BAU, BCZ, BFC
Removing
Note
All cable ties which are released or cut open when removing must
be fitted in the same position when installing.

– Remove air intake duct -1- leading to air cleaner.
– Pull off engine cover panel -arrows-.

– Pull off bonnet seal at lock carrier.
– Detach vacuum line -arrow- at connection for cut-off flap.

– Unplug electrical connector at injection pump.

– Remove intake manifold (front section) -arrows-.

Installing
Installation is carried out in the reverse order; note the following:
Note
♦ Renew gaskets and seals.

(same as original equipment) ⇒ Parts catalogue.
♦ Fit all cable ties in the original positions when installing.
Tightening torques
Component Nm
Front section of intake manifold to left and right 10
section of intake manifold
EGR connecting pipe to intake manifold (front 10
section)
EGR cooler to intake manifold (front section) 10
Hose clips (9 mm wide) 3
Hose clips (13 mm wide) 5.5

(front
permittedsection) - by
engine code
AUDI AG. AUDI AG doesletters
unless authorised not guarantee or accept any liability
BDG, BDH
Removing
– Pull off engine cover panel -arrows-.
– Pull off bonnet seal at lock carrier.
– Release fasteners -arrows- and remove toothed belt cover

(left-side).
– Move coolant line clear at intake manifold (front section).
– Detach electrical connector -3- at intake manifold flap motor -
V157- .
– Detach air intake hose -4- going to charge air cooler from in‐
take manifold (front section).

– Unscrew nuts -1- and -2- and bolts -5- and -6-.
– Unscrew both bolts as shown in illustration.
Note
The bolts are accessible through an opening in toothed belt cover

(rear) for injection pump.
– Detach intake manifold (front section).

Installing
Note
♦ Renew seals and gaskets.

Tightening torques
Component Nm
Intake manifold Intake manifold (left and 10
(front section) to: right)
Exhaust gas recirculation 10
cooler

(left-side)
Special tools and workshop equipment required
♦ Ring spanner -3035-
♦ Torque wrench -V.A.G 1331- with 17 mm attachment (com‐

mercially available)

♦ Open ring spanner or open-end spanner
Removing
Note
– Remove intake manifold (front section):

♦ Vehicles with engine code letters AKE, AYM, BAU, BCZ, BFC
⇒ page 8 .
♦ Vehicles with engine code letters BDG, BDH ⇒ page 9 .
– Disconnect vacuum hose at mechanical exhaust gas recircu‐
lation valve -arrow-.
– Remove heat shield above turbocharger -arrows-.

– Mark position of retaining clips on injector pipes (e.g. with felt-
tip pen).
– Mark injector pipes according to cylinder (e.g. with felt-tip pen).
– Disconnect injector pipes one by one with ring spanner
-3035- .
– Move wiring harness near intake manifold (left-side) clear to
the side.

– Remove intake manifold (left-side) -arrows-.

– Watch the two dowel sleeves when removing intake manifold.
– Block off intake ports in cylinder head with clean rags.
Installing
Note

– Watch the two dowel sleeves when installing intake manifold.

– Fit injector pipes one at a time, working from bottom to top and
secure using torque wrench -V.A.G 1331- and 17 mm attach‐
ment (commercially available).
Note
♦ Ensure stress-free installation of injector pipes.

♦ The injector pipes must always be re-installed on the same
cylinder. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Make sure that retaining clips are positioned correctly.
– Install intake manifold (front section):

⇒ page 8 .
Tightening torques
Component Nm
Intake manifold (left-side) to cylinder head 10
Mechanical EGR valve to intake manifold (left- 22
side)
EGR pipe to intermediate flange 22
Injector pipes to: Injectors 30
Injection pump 30
Heat shield to turbocharger 10

(right-side)

♦ Torque wrench -V.A.G 1331- with 17 mm attachment (com‐

mercially available)
♦ Open ring spanner or open-end spanner
Removing
Note
– Remove intake manifold (front section):

♦ Vehicles with engine code letters AKE, AYM, BAU, BCZ,unless
permitted BFC authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 8 . with respect to the correctness of information in this document. Copyright by AUDI AG.

– Disconnect vacuum hoses -arrows- from turbocharger and
mechanical exhaust gas recirculation valve.
– Mark position of retaining clips on injector pipes (e.g. with felt-
tip pen).
– Mark injector pipes according to cylinder (e.g. with felt-tip pen).
– Disconnect injector pipes one by one with ring spanner
-3035- .
– Move wiring harness and fuel pipes near intake manifold
(right-side) clear to the side.

– Remove intake manifold (right-side) -arrows-.

– Watch the two dowel sleeves when removing intake manifold.
– Block off intake ports in cylinder head with clean rags.
Installing
Note

– Watch the two dowel sleeves when installing intake manifold.

– Fit injector pipes one at a time, working from bottom to top and
secure using torque wrench -V.A.G 1331- and 17 mm attach‐
ment (commercially available).
Note
♦ Ensure stress-free installation of injector pipes.

♦ The injector pipes must always be re-installed on the same
cylinder.
♦ Make sure that retaining clips are positioned correctly.
– Install intake manifold (front section):

⇒ page 8 .
Tightening torques
Component Nm
Intake manifold (right-side) to cylinder head 10with respect to the correctness of information in this document. Copyright by AUDI AG.
Oil pipe to intake manifold 22

Injector pipes to: Injectors 30
Injection pump 30
1.12 Removing and installing injection pump

♦ Torque wrench -V.A.G 1331-

♦ Locking pin -3242-

♦ Diesel injection pump locking pin -3359-
Note
♦ For security reasons, in all vehicles as from the 2002 model

year the injection pump is integrated in the immobiliser sys‐
tem.
♦ When an injection pump has been renewed, it must be re-
adapted to the immobiliser.
♦ The adaption of the injection pump is described in the Guided
Fault Finding or Guided Functions.
Removing
– Remove engine cover panel ⇒ page 4 .
– Remove viscous fan.
– Remove toothed belt covers (front left and right).
– Remove front section of intake manifold ⇒ page 9 .

– Open oil filler cap.

– Turn engine until the marking “- OT -” (TDC) is visible on cam‐

shaft.
Note
Turn over the engine at the central bolt on the crankshaft.
– Unscrew plug for TDC marking from crankcase. The crank‐

shaft is provided with a TDC drilling, which can be felt directly
below the plug.
– Screw locking pin -3242-permitted
into threaded holebywhere
unless authorised plug
AUDI AG. AUDI has
AG does not guarantee or accept any liability
been removed, and tightenwith
locking
respect topin -3242- . of information in this document. Copyright by AUDI AG.
the correctness
– Remove vibration damper on injection pump sprocket (bolts

-1-).
Note
Do NOT loosen nut - 2 - for injection pump sprocket. Otherwise

this would alter the basic setting of the injection pump. The setting
cannot be re-adjusted with workshop equipment.
– Mark direction of rotation of toothed belt. The belt can break if

it rotates in the opposite direction when refitted.
– Slacken toothed belt tensioner and take off toothed belt.

– Unplug electrical connector from injection pump.
– Disconnect fuel supply and return pipes from injection pump.
– Cover open connections with a clean cloth.
– Disconnect injector pipes from injectors using open ring span‐
ner -3035- .

– Unscrew injection pump mountings.

– Lift out injection pump together with injector pipes.
– Mark injector pipes according to cylinders.
– Disconnect injector pipes from injection pump using ring span‐
ner -3035- .
Installing injection pump
– Mount injection pump on engine and bolt it in place.
– Bolts on crankcase: 20 Nm
– Bolts on toothed belt cover: 10 Nm

– After tightening injection pump mountings, fit injector pipes
one at a time, working from bottom to top and secure using
torque wrench -V.A.G 1331- and 17 mm open ring spanner
attachment (commercially available).
Tightening torque for injection pipes: 30 Nm
Note
♦ When tightening the connections, make sure the injector pipes

are not twisted or under tension.
♦ Incorrect assembly will distort the taper sets of the pipe unions.
♦ Secure the retaining clips on the injector pipes in their original
positions and without tension.
– Lock injection pump sprocket with diesel injection pump lock‐

ing pin -3359- .
– Slacken camshaft sprocket -1- and align centrally in longitu‐

dinal holes.
– Fit toothed belt. Pay attention to the direction of rotation as
marked upon removal.
– Tension toothed belt. To do so, turn Allen key anti-clockwise
until markings -1- are in line, then tighten securing nut.

– Tightening torque: 36 Nm
– Tighten bolts at camshaft sprocket.
– Remove diesel injection pump locking pin -3359- .
– Protected
Remove locking
by copyright. pin for
Copying -3242- . commercial purposes, in part or in whole, is not
private or
– Turn crankshaft
with respect two rotations
to the correctness of informationin
in normal direction
this document. Copyright of rotation
by AUDI AG.
until it is set to TDC of No. 3 cylinder again.
– Recheck markings at toothed belt tensioner. Correct toothed
belt tension as necessary.
– Install vibration damper on injection pump sprocket (bolts
-1-).

– Install front section of intake manifold ⇒ page 9 .

– Attach electrical connector on injection pump (make sure con‐
nector engages properly).
– Connect fuel supply and return pipes.
After installing the injection pump, the following steps must be
performed:
• Bleed fuel system, otherwise engine will not start
⇒ page 19 .
• Dynamically check and adjust commencement of injection
⇒ page 22 .
Additional step for vehicles as from model year 2002:
• The new injection pump must be adapted to the immobiliser
(otherwise engine will not start).
The procedure required after installing the new injection pump is
described in the Guided Fault Finding or Guided functions.
– Install toothed belt cover.
1.13 Bleeding fuel system

♦ Hose clamps for hoses up to 25 mm Ø -3094-
♦ Remote control -V.A.G 1348/3A- for V.A.G 1348 with adapter
cable -V.A.G 1348/3-2-
WARNING
♦ When bleeding the fuel system, make sure the inner sec‐
tion of the baffle housing (capacity approx. 0.5 litres) is
permanently filled with fuel.
♦ When the engine is not running (electric fuel pump off), the
inner section of the baffle housing will only stay full if the
tank is more than 1/3 full.
♦ So if the fuel tank is less than 1/3 full, follow the procedure
outlined below.
The following steps are only required if the fuel tank is less than
1/ full (check fuel gauge in instrument cluster). If the tank is more
3
than 1/3 full, you can start the bleeding procedure.
If you do not want to put more fuel in the tank because of tests
that will be required later, the following method can be used to fill
the inner section of the baffle housing with fuel:
– Open fuse box lid on left-hand side of dash panel.
– Pull out fuse No. 28 from fuse holder.

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

adapter cable -V.A.G 1348/3-2- to right-hand terminal of fuse
socket No. 28 -arrow-.
– Connect crocodile clamp to vehicle battery (positive).
– Using hose clamps up to Ø 25 mm -3094- clamp off fuel supply

hose leading to fuel filter. (Rear left hose)
– Operate remote control switch for about 30 seconds to fill baf‐
fle housing (fuel pump should run audibly).
– Then remove hose clamps up to Ø 25 mm -3094- from fuel
supply hose to fuel filter.
Bleeding
– Open fuse box lid on left-hand side of dash panel.
– Pull out fuse No. 28 from fuse holder.
– Connect remote control -V.A.G 1348/3A- for V.A.G 1348 with

adapter cable -V.A.G 1348/3-2- to right-hand terminal of fuse
socket No. 28 -arrow-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Connect crocodile clamp to vehicle battery (positive).

– Using hose clamps up to Ø 25 mm -3094- , clamp off fuel return

line at the following points:
♦ Between filter and fuel tank
♦ Between filter and injection pump
– Detach fuel return line for injectors of right-side cylinder bank
at injection pump.

– Fit a suitable length of transparent hose onto the free connec‐

tion at the injection pump and run the hose into a suitable
container (fuel canister or similar).
– Operate remote control switch until fuel comes out of hose free
of bubbles; fuel pump should run audibly.
– Reconnect fuel return line to injection pump.
– Remove hose clamps up to Ø 25 mm -3094- from fuel return
hose.
When starting the engine for the first time after bleeding the fuel
system, you must activate the electric fuel pump with the remote
control switch.
– Operate remote control -V.A.G 1348/3A- for V.A.G 1348 with
adapter cable -V.A.G 1348/3-2- (fuse socket No. 28) while
starting engine.
WARNING
Do not prolong attempted starting for more than 15 seconds.

If engine does not start, repeat bleeding procedure.
– Continue to press remote control switch for approx. 30 sec‐

onds after engine has started.
– Then stop engine and remove remote control.
– Re-fit fuse No. 28.
– Start engine again and inspect fuel system for leaks (visual
check).
– Leave engine idling under no load for at least 5 minutes (to
fully bleed fuel system).
Note
If fuel system is leaking, check entire fuel system for leaks ⇒ Fuel
supply system, diesel engines; Rep. Gr. 20 .
1.14 Draining fuel filter

♦ Hand-operated vacuum pump -VAS 6213- or hand-operated
vacuum pump with attachments -V.A.G 1390-

♦ Water drain container -V.A.G 1390/1-
Draining
– Unscrew bleeder screw -2- at fuel filter completely.
– Connect hand-operated vacuum pump -VAS 6213- (or hand-
operated vacuum pump -V.A.G 1390- ) together with water
drain container -V.A.G 1390/1- to bleeder connection at fuel
filter.
– Operate hand pump until approx. 100 cm3 of fluid is drawn out
of fuel filter.
WARNING
No fluid must be allowed to enter the hand-operated vacuum

pump.
– Start engine and inspect fuel system for leaks (visual check).
Note
If fuel system is leaking, check entire fuel system for leaks ⇒ Fuel
supply system, diesel engines; Rep. Gr. 20 .
1.15 Dynamically checking and adjusting

commencement of injection

♦ Socket -T10023-
♦ Fault reader
♦ Torque wrench -V.A.G 1331- (5...50 Nm)
Note
The commencement of injection must always be checked after

renewing the toothed belt or loosening the injection pump bolts or
toothed belt sprockets, and adjusted if necessary.
– Start engine.
– Read measured value block “function 08” display group 07.
– Check readout in display zone 4 (coolant temperature).
• Specification: at least 85 °C
Do not continue the test until the coolant has reached the speci‐
fied temperature.
– Start basic setting “function 04”, Display group 04, engine run‐
ning at idling speed.
– Check display in display zone 4.
• Specification: 100%
– Observe display in display zone 2.
• Specification: “retarded”
– Check display in display zone 3.
• Specification: 2° ATDC ± 2°
If the specifications are not obtained:
– Switch off ignition.
– Remove toothed belt covers (front left and right).

– Check toothed belt tension.

• The marks -1- should be aligned.
If the marks are not aligned:
– Tension toothed belt.
– Slacken nut on belt tensioner using special tool.
– Turn Allen key anti-clockwise until markings -1- are in line,

then tighten nut.
If the toothed belt tension is OK (markings are in line):
– Slacken camshaft sprocket securing bolts -1-.

– Apply ring spanner (22 mm) to pump shaft and turn slightly:
• In direction A ⇒ to retard commencement of injection
• In direction B ⇒ to advance commencement
permitted unless authorised by AUDIof injection
AG. AUDI AG does not guarantee or accept any liability
Note
Do NOT loosen nut - 2 - for injection pump sprocket. Otherwise

this would alter the basic setting of the injection pump. The setting
cannot be re-adjusted with workshop equipment.
– Re-tighten camshaft sprocket securing bolts -1-.

– Check commencement of injection again and compare with
the specification ⇒ page 22 .
If commencement of injection is outside specified range:
– Correct setting at injection pump sprocket (re-position toothed
belt).
– Install toothed belt cover.
1.16 Dynamic check of injectors

Dynamic check
– Start engine.
– Read measured value block “function 08” display group 07.
– Check readout in display zone 4 (coolant temperature).

• Specification: at least 85 °C
Do not continue the test until the coolant has reached the speci‐
fied temperature.
– Read measured value block, Display group 13 (cylinders 3 and
1), engine running at idling speed.
• Specification: -1.50 mg/H ... +1.50 mg/H (milligrams per
stroke)
– Read measured value block, Display group 14 (cylinders 6, 4,
5), engine running at idling speed.
• Specification: -1.50 mg/H ... +1.50 mg/H (milligrams per
stroke)
– If the values for all the cylinders of one cylinder bank are no‐
ticeably outside the tolerance range, check the toothed belt
tension and tensioning roller ⇒ Rep. Gr. 15
– If one or more of the values is outside the tolerance, swap
round the injectors (except the injectors for cylinders 2 and 3).
– If the fault moves along with the injector, fit a new injector
⇒ page 26 .
– If the fault remains on the same cylinder, check the compres‐
sion ⇒ Rep. Gr. 15 .
1.17 Checking spray pattern of injectors and

checking for leaks
♦ Injector tester -V.A.G 1322- and pressure pipe -V.A.G 1322/2-
Use injector tester -V.A.G 1322- and pressure pipe -V.A.G

1322/2- for checking the injectors.
WARNING
When testing injectors, ensure that the jet of fuel does not con‐
tact the hands as the high pressure will cause the fuel to
penetrate the skin and may cause severe injuries.
• Pressure gauge switched on

– Move pump lever down slowly. Read off injection pressure
when injector opens. If the pressure does not match the spec‐
ification, fit a new injector.
New injectors 200 ... 235 bar
Wear limit 170 bar
• Pressure gauge switched on

– Move pump lever down slowly and maintain a pressure of ap‐

prox. 150 bar for 10 seconds. There should be no fuel leakage
from the injector nozzle.
Note
This test is only able to check the injection pressure of the first
stage.
– Renew the injector if leakage occurs.
1.18 Removing and installing injectors
Note
Removing injector together with needle lift sender -G80-

⇒ page 27
Removing injectors
– Remove relevant cylinder head cover ⇒ Rep. Gr. 15 .

– Remove retainers (to do so, unscrew nuts -arrows-) from in‐

jectors and pull out injectors upwards.
If a cam on the camshaft prevents the injector from being with‐
drawn (vehicles with manual gearbox):
– Engage 4th gear and push the vehicle forwards slightly.
If a cam on the camshaft prevents the injector from being with‐
drawn (vehicles with automatic gearbox):
– Refit all the retainers onto the injectors that are still inside the
cylinder head, and tighten the nuts by hand.
WARNING
Before operating the starter, make sure that all the injectors
are secured with their retainers and that the injection pump
connector is detached.
– Operate starter briefly and check whether injectors can now

be removed.
Installing injectors
– Remove copper seal (between injector and cylinder head)
from cylinder head.
Note
Always renew copper seals between cylinder head and injectors.
– Protected
Install byinjectors. Ensure
copyright. Copying that orinjectors
for private commercialare seated
purposes, in partcorrectly.
or in whole, is not
– Fitwith
retainers.
respect to the correctness of information in this document. Copyright by AUDI AG.
– Secure retainers.
• Tightening torque: 10 Nm
– Re-install cylinder head cover ⇒ Rep. Gr. 15 .
1.19 Removing and installing injector with

needle lift sender -G80-
Needle lift sender -G80- is not fitted on engines with code letters
BCZ. Commencement of injection is determined and controlled
by engine control unit.
Removing
– Remove cylinder head cover (right-side) ⇒ Rep. Gr. 15 .
– Unplug connector for needle lift sender -G80- (brown connec‐
tor on bulkhead).

– Slacken the two nuts -arrows- on retainer for injector in No. 3

cylinder.
– Pull out injector together with needle lift sender -G80- .
If one of the cams prevents the injector from being withdrawn
(vehicles with manual gearbox):
– Engage 4th gear and push the vehicle forwards slightly.
If one of the cams prevents the injector from being withdrawn
(vehicles with automatic gearbox):
– Screw retainer back onto injector again.
WARNING
Before operating the starter, make sure that all the injectors
are secured with their retainers and that the injection pump
connector is detached.
– Operate starter briefly and check whether injector with needle

lift sender -G80- can now be removed.
Installing
– Remove copper seal (between injector and cylinder head)
from cylinder head.
Note
The copper seal must always be renewed.
– Install new injector with collar -2- and new copper seal -1-.
– When installing injector, make sure that locating pin -3- fits into
groove in cylinder head.
– Secure retainer.
• Tightening torque: 10 Nm
– Run electrical wire along metal channel in camshaft bearing

-arrow-.
– Fit semi-circular rubber seal on wire into cut-out provided in
cylinder head.
Note
Do not slide the semi-circular rubber seal along the wire (the seal
is bonded to the wire to ensure proper sealing).
– Re-install cylinder head cover (right-side) ⇒ Rep. Gr. 15 .

1.20 Wiring and component check with

adapter cable, 121-pin -V.A.G 1598/31-
(test box)
Note
♦ The adapter cable, 121-pin -V.A.G 1598/31- (test box) is de‐

signed for simultaneous connection to the wiring harness
leading to the engine control unit and to the engine control unit
itself.
♦ 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.
♦ Always use auxiliary measuring set -V.A.G 1594 C- to connect
test equipment (e.g. voltage tester -V.A.G 1527 B- , hand-held
multimeter -V.A.G 1526C- etc.).
– Switch off ignition and remove ignition key.

– Detach rubber seal from plenum chamber cover in direction of
-arrow-.
– Detach plenum chamber cover -1- towards the front.

– Lever off both cover caps -3- with a screwdriver.
– Loosen hexagon nuts -4- several turns.
– Loosen wiper arms -2- from wiper shafts by tilting slightly.

– Completely remove hexagon nuts and take off wiper arms.

– Pull off retaining clips -1- and detach cowl panel grille -5-.
– Remove cover of protective housing for control units

-arrows-.
– Carefully lever out retaining strap from engine control unit us‐
ing a screwdriver -arrow-.
– Release retaining tabs -arrows- and unplug connectors -1-

and -2- from engine control unit.
– Remove engine control unit.
Caution
To prevent damage to electronic components, select appro‐

priate measuring range before connecting measuring leads
and observe test requirements.

– Connect adapter cable, 121-pin -V.A.G 1598/31- (test box) to

wiring harness connector. Earth clip on test box must be con‐
nected to battery earth. The instructions for performing the
individual tests indicate whether or not the engine control unit
itself also needs to be connected to the test box.
– Carry out test as described in appropriate repair procedures.
Perform the following after reconnecting engine control unit:
– Interrogate and, if necessary, erase fault memory ⇒ vehicle
diagnostic, testing and information system VAS 5051 .
1.21 Renewing diesel direct injection system

control unit -J248-
Removing
Note
When the engine control unit is disconnected, the learnt values

are erased but the contents of the fault memory remain intact.
– Connect fault reader and select engine electronics control unit

with “address word” 01. When doing this, the ignition must be
switched on.
The fault reader display shows the control unit identification and
the coding -2-.
– Always start by displaying the control unit identification and
printing it out.
– Switch off ignition and remove ignition key.
– Detach rubber seal from plenum chamber cover in direction of
-arrow-.
– Detach plenum chamber cover -1- towards the front.

– Lever off both cover caps -3- with a screwdriver.
– Loosen hexagon nuts -4- several turns.

– Loosen wiper arms -2- from wiper shafts by tilting slightly.

– Completely remove hexagon nuts and take off wiper arms.
– Pull off retaining clips -1- and detach cowl panel grille -5-.
– Remove cover of protective housing for control units

-arrows-.
– Carefully lever out retaining strap from engine control unit us‐
ing a screwdriver -arrow-.

– Release retaining tabs -arrows- and unplug connectors -1-

and -2- from engine control unit.
– Remove engine control unit.
– Release catches and unplug control unit connectors.
After installing a new engine control unit, the following operations
must be performed:
Installation is performed in the reverse sequence.
– Activate engine control unit in “Guided Functions” mode, “Re‐
new engine control unit” ⇒ Vehicle diagnosis, testing and
information system VAS 5051.

28 – Glow plug system

1 Checking glow plug system
1.1 Checking operation

– Detach glow plug connectors from glow plugs.
– Connect hand-held multimeter (voltage test range) between
engine earth and one of the glow plug connectors.
– Start final control diagnosis and activate glow plug relay.
Specification: approx. battery voltage (every 5 seconds)
If specification is not obtained:
– Rectify open circuit or short circuit in wiring as necessary
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
1.2 Checking glow plugs

• Battery voltage at least 11.5 Volt
– Connect diode test lamp -V.A.G 1527- to battery (+) and check
all glow plugs one after the other.
If diode lights up: glow plug is OK.
If diode does not light up: renew glow plug ⇒ page 34 .
1.3 Removing and installing glow plugs

♦ U/J extension and socket, 10 mm -3220-
Removing
– Clean glow plug openings in cylinder head; make sure no dirt
gets into cylinder.
34 Rep. Gr.28 - Glow plug system

Note
♦ Cleaning procedure:
♦ Use a vacuum cleaner to remove coarse dirt.
♦ Spray brake cleaner or suitable cleaning agent into glow plug
openings, let it work in briefly, and blow out with compressed
air.
♦ Then clean the glow plug openings using a cloth moistened
with oil.
– To slacken the glow plugs use special tool U/J extension and
socket, 10 mm -3220-
Installing
Note
Before installing, coat threads of glow plugs with high-tempera‐

ture paste ⇒ Parts catalogue , servicing materials.
– To tighten the glow plugs use special tool U/J extension and
socket, 10 mm -3220- with a suitable torque wrench.
Tightening torque: 18 Nm
– Attach glow plug connectors correctly and make sure they are
securely fitted.
1. Checking glow plug system 35

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Copyright © 2015 Audi AG, Ingolstadt A0059007420

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

23 – Mixture preparation - injection

1.1 Safety precautions

♦ Test equipment must always be secured on the rear seat

Before disconnecting battery,

Always switch off the ignition before connecting or disconnect‐

1.2 Rules for cleanliness

1. Servicing diesel direct injection system 1

1.3 Overview of fitting locations

1 - Air mass meter -G70- with

2 Rep. Gr.23 - Mixture preparation - injection

12 - Throttle butterfly valve -

B - Accelerator position sender -G79-

1. Servicing diesel direct injection system 3

1.4 Air cleaner - exploded view

1.5 Removing and installing engine cover

4 Rep. Gr.23 - Mixture preparation - injection

• Procedure on bolted version: remove cover caps and unscrew

1. Servicing diesel direct injection system 5

– Pull hose -2- off air cleaner housing.

6 Rep. Gr.23 - Mixture preparation - injection

1.7 Removing and installing air mass meter

1. Servicing diesel direct injection system 7

1.8 Removing and installing intake manifold

– Remove air cleaner cover -2-.

– Pull off engine cover panel -arrows-.

– Detach vacuum line -arrow- at connection for cut-off flap.

8 Rep. Gr.23 - Mixture preparation - injection

– Remove intake manifold (front section) -arrows-.

♦ Renew gaskets and seals.

1.9 Removing and installing intake manifold

– Release fasteners -arrows- and remove toothed belt cover

1. Servicing diesel direct injection system 9

– Unscrew both bolts as shown in illustration.

The bolts are accessible through an opening in toothed belt cover

– Detach intake manifold (front section).

♦ Renew seals and gaskets.

1.10 Removing and installing intake manifold

♦ Torque wrench -V.A.G 1331- with 17 mm attachment (com‐

10 Rep. Gr.23 - Mixture preparation - injection

♦ Open ring spanner or open-end spanner

– Remove intake manifold (front section):

– Remove heat shield above turbocharger -arrows-.

1. Servicing diesel direct injection system 11

– Remove intake manifold (left-side) -arrows-.

♦ Renew gaskets and seals.

– Watch the two dowel sleeves when installing intake manifold.

♦ Ensure stress-free installation of injector pipes.

– Install intake manifold (front section):

1.11 Removing and installing intake manifold

12 Rep. Gr.23 - Mixture preparation - injection

♦ Ring spanner -3035-

♦ Torque wrench -V.A.G 1331- with 17 mm attachment (com‐