Fuel tank for vehicles with front wheel drive — general assembly diagram 1. Fuel line: vehicles with auxiliary heater, from auxiliary heater metering pump; do not go too far 2. Fuel supply line: to the engine; fastened to the fuel tank with clamps; do not go too far 3. Vent line: to canister...
Ground connection for fuel filler neck Lay the earth cable as shown in the figure. Check the correct position of the connector. Connector -2- of the ground cable on the threaded ring -3- of the filler neck. First insert the contact tongue -1- of the earth...
Removal and installation of the fuel tank For vehicles with front wheel drive Remove rear seat. Release retainers of cover -1- of connecting flange from retainer using wedge -3409-arrows-. Disconnect connector -1- from fuel pump. Vehicles with auxiliary heater...
Removing and installing fuel delivery unit with fuel level sender -G- For vehicles with front wheel drive The fuel tank must be filled no more than 3/4 full. Remove rear seat. Release cover -1- of connecting flange from retainer using wedge -3409- -arrows-. Disconnect connector -1- from...
Removing and installing fuel level sender -G- For vehicles with front wheel drive Remove the fuel delivery module. Disconnect the connectors -1- of the connecting flange by releasing the latches. Remove electrical wires from bracket -arrow- and lay them aside....
Removing and installing fuel gauge sender 2 -G169- For vehicles with all-wheel drive The fuel tank must be filled no more than 3/4 full. Remove rear seat. Release cover -1- of left connecting flange from retainer using wedge -3409- -arrows-. Disconnect connectors -1 and...
Removing and installing fuel pump control unit -J538- Remove rear seat. Release cover -1- of right connecting flange from retainer using wedge -3409- -arrows-. Press mounting -2- upwards in -direction of arrow A- by placing your finger between the body support and fuel...
Disengagement of couplings Note: The quick connectors for the fuel vacuum and breather lines are color coded. There is a dot of the desired color on the quick connector, or the release button is painted in this color. Attention! The pressure fuel...
Accelerator Pedal Module — General Wiring Diagram 1. 6 Nm 2. Connector: Check for secure fit by pulling in the opposite direction 3. Accelerator pedal module: with accelerator position sender -G79- and accelerator position sender 2 -G185-; for vehicles with DSG...
Removing and installing the gas pedal module Carefully! During these works, the surface of the knee airbag may be damaged due to mechanical impact. After completing the inspection, check the surface of the knee airbag for damage. Tilt floor trim -1- forwards in...
Disconnecting and Connecting the Accelerator Pedal Module Connector Note: The accelerator pedal module uses connectors that can be disconnected and connected in different ways. Disconnecting connector 1KQ 973 706 Lightly press the gate -A- (grey) in -direction of arrow 1- and slide as...
Activated carbon filter system — general installation diagram 1. Vent line: to canister solenoid valve 1 -N80-; fastened to the fuel tank with clamps 2. 20 Nm 3. Adsorber; installation location: in the right rear wheel arch, under the fender liner 4. Vent line: to fuel tank
Removal and installation of an adsorber Observe safety regulations. Follow the rules for maintaining cleanliness. Remove the right rear wheel. Remove the rear right fender liner. Detach vent hoses -1 and 2- from canister. Disconnect ventilation hoses from...
Removal and installation of a turbocharger Carefully! If mechanical defects of the turbocharger are detected, for example, the destruction of the compressor impeller, it is not enough just to replace the turbocharger. To avoid subsequent damage, the following...
Removing and installing charge pressure regulator -V465-, adjusting Remove exhaust pipe with catalytic converter. Unscrew bolts -arrows- and remove heat shield for right drive shaft. Remove screw -arrow- and detach oil return line. Disconnect connector -1 Loosen lock nut -2- and unscrew...
Parts and components of the intercooler Note: Before checking or repairing, check all air connections and air hoses as well as vacuum hoses for firm seating and tightness. If properly assembled, the radiator, condenser or intercooler fins may be slightly...
Removal and installation of the intercooler Remove coolant radiator. Loosen clamps -1 and 2- and remove air duct hose. Close open openings of pipelines and fittings with clean plugs. Using a second mechanic, release clips -1- on left and right in -direction of...
Removing and installing charge pressure sender -G31- Remove soundproof cover. Disconnect connector -2-. Remove screws -1- and remove charge pressure sender -G31- from air duct connection. Installation Installation in reverse order. Note: Replace sealing ring.
Installation locations of fuel injection system components Modules A to H are not shown in the general view. 1. Valve 1 for camshaft adjuster -N205- 2. Exhaust camshaft adjuster valve 1 -N318- 3. Lambda probe after catalytic converter -G130- 4. Camshaft adjuster actuators...
Accelerator and clutch pedal position sensors Accelerator position sender -G73- and accelerator position sender 2 -G185- 2. Accelerator pedal module connector Note: Accelerator position sender -G79- and accelerator position sender 2 -G185- are integrated in the...
High pressure pump and hall sensor 1. Hall sender 3 -G300- 2. Fuel pressure regulator -N276- 3. Pressure fuel line to the fuel rail of MPI injectors 4. Pressure fuel line to the fuel rail of the FSI injectors 5. Pressure fuel line from the fuel tank...
Valves for adjusting the valve timing 1. Connector for exhaust camshaft adjuster valve 1 -N318- 2. Exhaust camshaft adjuster valve 1 -N318- 3. Connector for camshaft adjuster valve 1 -N205- 4. Valve 1 for camshaft adjuster -N205-
Temperature sensors Coolant temperature sender -G62- 1. Connector for coolant temperature sender -G62- 2. Screw 3. Coolant temperature sender -G62- Radiator outlet coolant temperature sender -G83-
Air filter parts and assemblies 1. Air intake bottom: on the front carrier 2. Air intake top: on the front carrier 3. Cover: air duct 4. 2 Nm 5. O-ring 6. Air hose 7. Screw clamp 8. Air hose 9. Spring clamp 10.2 Nm 11. Upper part of the air filter...
Removing and installing the air filter housing Release screws -1 and 3-. Release catch -arrow- and remove cover -2-. Release coolant hose -2-. Unlock catches -arrows- and remove top section of air duct -1-. Detach vacuum hose -1-. Loosen clamp -2- and remove air...
Details and components of the intake manifold 1. Intake manifold 2. 9 Nm 3. Intake manifold flap valve -N316- 4. Vacuum intake manifold flap actuator 5. High pressure pump bolts: replacement; 1.8 l engine: 8 Nm + turn 90° (¼ vol.); 2.0 l engine: 20 Nm 6. Connector:...
FSI fuel rail parts and assemblies 1. Nozzle: always replace together with the O-ring and the Teflon sealing ring of the combustion chamber; replace sealing rings; observe the correct mounting position 2. Support ring: replace 3. Fuel rail FSI injectors...
MPI fuel rail parts and assemblies 1. 9 Nm: to fuel rail MPI injectors 2. Fuel rail MPI injectors 3. O-ring: replace 4. Nozzle: replace O-rings; observe the correct mounting position 5. O-ring: replace 6. Mounting bracket 7. Spring clamp 8. High pressure...
Removal and installation of an inlet collector Note: After replacing the fuel rail, the intake duct flap potentiometer -G336- must be adapted to the engine control unit -J623-. Remove engine cover. Remove screws -arrows- securing coolant pipe to intake manifold....
Removing and installing throttle valve control unit -J338- Remove engine cover. Release screws -1 and 3-. Release catch -arrow- and remove cover -2-. Release coolant hose -2-. Unlock catches -arrows- and remove top section of air duct -1-. Unscrew left and right screws -arrow-....
Removing and installing FSI injectors 1. Intermediate ring: replace 2. Mount: replace 3. Combustion chamber sealing ring (teflon): replace; during installation, it must not be lubricated or treated with other means to improve sliding - replace 4. Nozzle 5....
Removing and installing MPI injectors Detach fuel supply line -1- from intake manifold. Remove connector -3- from bracket. Disconnect connectors -4 and 5-. Disconnect wiring harness -1- from fuel rail. Remove screws -arrows- from fuel rail. Carefully pull...
Removing and installing fuel pressure sender -G247- If the fuel pressure sender -G247- fails, the fuel pressure regulator -N276- is switched off, the fuel delivery unit switches to full load operation and the engine runs at the existing fuel pressure. As a result, there...
Parts and components of the high pressure pump Attention! The fuel system is under pressure! Be sure to depressurize the high pressure area before opening the system. 1. Connector: fuel pressure regulator-N276- 2. High pressure pump screw: replacement; 1.8 l engine:...
Removal and installation of the high pressure fuel pump Note: The high pressure fuel pump may only be removed and installed when the engine is cold. When installing the high pressure pump, make sure that no impurities enter the fuel system. Collect escaping fuel with a rag....
Removing and installing lambda probes -G39- and -G130- Removing and installing lambda probe -G39- Disconnect connector -2- from lambda probe -G39-. Unscrew lambda probe -G39- -1- using tool from lambda probe spanner set -3337-. Installation Note: The threads of new lambda...
Removing and installing engine control unit -J623- Removing and installing engine control unit -J623- (without protective housing) Switch on the ignition and select Tester. Press the following buttons in turn on the display: 01 - Engine electronics, 01 - Guided...
Front part of the exhaust system — general installation diagram 1. 20 Nm 2. Bracket: replace if damaged 3. Screw 4. Nut 5. Converter bracket 6. Downpipe with neutralizer: the bellows must not be bent more than 101, due to the possibility of damage; do not subject the bellows to...
Removal and installation of a reception pipe Note: The catalytic converter is removed complete with downpipe. All cable ties must be put back into place during installation. Remove connector -2- for lambda probe in front of catalytic converter -G39- from bracket,...
Ignition system — design description 1. 10 Nm 2. Ignition coil with power output stage: Ignition coil 1 with power output stage -N70-. Ignition coil 2 with power output stage -N127-. Ignition coil 3 with power output stage -N291-. Ignition coil 4 with...
Removal and installation of ignition coils with power output stages Remove engine cover. Unlock and disconnect all connectors from the ignition coils. Unscrew the screws of the ignition coil to be removed. Carefully pull out the ignition coil towards the top. Installation Press the...
Removing knock sensor 1 -G61- Unplug connector -2- from knock sensor 1 -G61-. Remove the coolant pump with thermostat. Note: The knock sensor 1 -G61- is located under the intake manifold behind the coolant pump. Unscrew knock sensor 1 -G61- -arrow-....
Removal and installation of Hall sensors Removing and installing Hall sender -G40- Remove engine cover. Remove intake manifold, unplug connector -1-. Remove screw -arrow- and remove Hall sender. Installation Installation in reverse order. Replace sealing ring....