D3E800A4762-Fuel Injection and Ignition

Service
Repair Manual
Audi R8 2007 ➤
Audi R8 Spyder 2010 ➤
Fuel Injection and Ignition
Engine ID BYH CND
A
Edition 03.2013
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 GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
24 - Multiport Fuel Injection
28 - Ignition/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 © 2014 Audi AG, Ingolstadt D3E800A4762

Audi R8 2007 ➤ , Audi R8 Spyder 2010 ➤
Fuel Injection and Ignition - Edition 03.2013
Contents
24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 On Board Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Air Filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Fuel Injection System Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 High
Protected Pressure
by copyright. CopyingPump Overview
for private or commercial .purposes,
. . . . . in. part
. . .or.in. whole,
. . . .is. not
............................. 22
2.4 with Intake
respect to Manifold Overview
of information in. this
. . .document.
. . . . . Copyright
. . . . . by . .AUDI
. . . AG.
............................... 25
the correctness
2.5 Fuel Injectors and Fuel Rail Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.6 Oxygen Sensors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.7 Engine Control Module Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.8 Releasing Pressure in High Pressure Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.9 Protective Body Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.1 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2 Wiring and Components, Checking with Test Box VAG 1598/42 . . . . . . . . . . . . . . . . . . . . 40
4.3 Leak Test on Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1 Air Filters and Mass Airflow Sensor G70 / Mass Airflow Sensor 2 G246 . . . . . . . . . . . . . . 43
5.2 Air Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3 Engine Compartment Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.4 Engine Control Module J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.5 Engine Control Module 2 J624 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.6 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.7 Fuel Pressure Sensor G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.8 High Pressure Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.9 Intake Flap Vacuum Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.10 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.11 Oxygen Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.12 Throttle Valve Control Module J338/J544 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.2 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.1 Ignition Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.2 Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.1 Camshaft Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.2 Engine Speed Sensor G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.3 Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.4 Knock Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Contents i
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
ii Contents
24 – Multiport Fuel Injection

1 General Information
(Edition 03.2013)
⇒ “1.1 Safety Precautions”, page 1
⇒ “1.2 Clean Working Conditions”, page 3
⇒ “1.3 On Board Diagnostics”, page 4
1.1 Safety Precautions

⇒ “1.1.1 Fuel System”, page 1
⇒ “1.1.2 Ignition System”, page 1
⇒ “1.1.3 Test and Measuring Instruments during Test Drive”, page
3
1.1.1 Fuel System
WARNING
There is a risk of injury because the fuel is under very high

pressure.
♦ Fuel system is under pressure! Fuel pressure must be re‐
duced to a residual pressure before opening high pressure
area of the injection system. Refer to
⇒ “2.8 Releasing Pressure in High Pressure Area”,
page 34 .
♦ After reducing high pressure, connection should be
opened immediately. To do this, place a cloth around the
connection to reduce residual pressure (approximately 7
bar).
Burn risk due to escaping fuel.
♦ Because the Transfer Fuel Pump - G6- runs briefly when
the battery is connected and the driver's door is opened,
the voltage supply to the
Protected by -G6- must
copyright. befordisconnected
Copying private or commercial be‐
purposes, in part or in whole, is not
fore opening the permitted
fuel system.
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Caution
Risk of destroying electronic components when disconnecting

the battery.
♦ Observe measures for disconnecting battery.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27 ; Removal and Installation .
1.1.2 Ignition System

To reduce the risk of personal injury and/or damage to the fuel
injection and ignition system, always observe the following:
♦ For safety reasons, if the battery is not disconnected, the fuel
pump control module - J538- fuse must be removed before
opening fuel system. Otherwise, the fuel pump will be activa‐
ted by the driver door contact switch.
1. General Information 1
♦ Individuals with a pacemaker must not stay in the danger area

of high voltage systems, for example ignition systems, xenon
light.
♦ Only disconnect and reconnect wires for injection and ignition
system, including test leads, when ignition is switched off.
♦ Delete any DTC memory entries that occurred during testing
or assembly Vehicle Diagnostic Tester, Guided Functions ,
Check DTC memory , and then Generate readiness code .
♦ Cleaning the engine should only be performed with ignition

switched off.
♦ The battery must only be disconnected and connected with the
ignition switched off, since the Engine Control Module (ECM)
can otherwise be damaged.
♦ If engine is to be cranked at starting RPM without starting (for
example, for compression testing), disconnect the four ignition
coil connectors using the Ignition Coil Puller - T40039- . Refer
to ⇒ “4.3 Ignition Coils”, page 87 .
♦ Also remove fuse for the Fuel Pump Control Module - J538- .
♦ The Fuel Pump Fuse - S81- is located inside the “9-pin relay
and fuse panel”.
– R8 Coupe and R8 GT: Remove theunless
permitted rearauthorised
shelf. Refer
by AUDI toAG.⇒ Body
AUDI AG does not guarantee or accept any liability
Interior; Rep. Gr. 70 ; Removal and Installation
with respect to the correctness. of information in this document. Copyright by AUDI AG.
– R8 Spyder: Remove the right rear connector station and move

the connected ground wire and sockets to the side. Refer to
⇒ Electrical Equipment; Rep. Gr. 97 ; Removal and Installa‐
tion .
Note
♦ By removing fuse fuel pump fuse - S81- , the voltage supply

to »terminal 30« for the fuel pump control module - J538- is
interrupted.
♦ “9-pin relay and fuse panel” Wiring diagrams, Troubleshooting
& Component locations current routing.
2 Rep. Gr.24 - Multiport Fuel Injection

1.1.3 Test and Measuring Instruments during

Test Drive
If special testing equipment is required during road test, note the
following:
WARNING
Improperly secured testing and measuring equipment and dis‐

traction during a road test increase the risk of an accident.
The passenger airbag could pose a risk if it deploys in a colli‐
sion.
• Operating testing equipment while driving causes it to shift
position.
• There is an increased risk of injury due to unsecured test‐
ing equipment. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Position passenger's seat as far back as possible.

♦ Do NOT use the following vehicle diagnosis testers: VAS
5051 , VAS 5051A and VAS 5051B .
♦ Testing and measuring instruments -1- must lay flat on the
passenger's thighs and be operated by him or her, as
shown in the illustration.
1.2 Clean Working Conditions

Even a little contamination can lead to faults. When working on
the fuel supply and on the fuel injection system, observe the fol‐
lowing guidelines for a clean working environment:
♦ Before loosening, connections and surrounding areas must be
cleaned thoroughly with engine or brake cleaner, and then
cleaned area must be dried completely.
♦ Plug open lines and connections immediately with appropriate
protective caps.
♦ Place removed parts on a clean surface and cover them. Use
lint-free cloths.
♦ Only install clean components: Remove the replacement parts
from their packaging just prior to installing them. Do not use
parts that have been stored loose (for example in tool boxes
etc.).
♦ When the system is open: Do not work with compressed air.
Do not move vehicle unless absolutely necessary.
♦ Protect the disconnected connectors from dirt and moisture
and only connect when they are dry.
1.3 On Board Diagnostics

♦ The Engine Control Module (ECM) is equipped with On Board
Diagnostics (OBD). Before repairs such as fault finding, check
the Diagnostic Trouble Code (DTC) memory first. Also the
vacuum hoses and connections must be checked (unmetered
air).
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. The use of clamp or screw type clips is not
permissible.
♦ For the electric components to work properly, a voltage of at
least 11.5 Volts is required.
♦ Do notpermitted
use sealants containing
unless authorised silicone.
by AUDI AG. AUDI AG Particles of silicone
does not guarantee or accept any liability
drawn into
with the engine,
respect will notofbe
to the correctness burnt ininthis
information the engine
document. and dam‐
Copyright by AUDI AG.
age the oxygen sensor.
♦ The vehicles have a crash fuel shut-off. It reduces the risk of
fire in an accident because the fuel pump relay switches the
fuel pump off.
♦ This setup also makes it easier to start the engine. When the
driver-side door is opened, the fuel pump is activated for 2
seconds so that pressure builds in the fuel system, observe
safety measures. Refer to
⇒ “1.1.3 Test and Measuring Instruments during Test Drive”,
page 3 .

2 Description and Operation

⇒ “2.1 Air Filter Overview”, page 5
⇒ “2.2 Fuel Injection System Component Location”, page 9
⇒ “2.3 High Pressure Pump Overview”, page 22
⇒ “2.4 Intake Manifold Overview”, page 25
⇒ “2.5 Fuel Injectors and Fuel Rail Overview”, page 27
⇒ “2.6 Oxygen Sensors Overview”, page 33
⇒ “2.7 Engine Control Module Overview”, page 34
⇒ “2.8 Releasing Pressure in High Pressure Area”, page 34
⇒ “2.9 Protective Body Covers”, page 36
2.1 Air Filter Overview

⇒ “2.1.1 Vehicles with Manual/R tronic Transmission 086”,
page 5
⇒ “2.1.2 Vehicles with DSG Transmission 0BZ”, page 7
2.1.1 Vehicles with Manual/R tronic Transmission 086
1 - Air Guide Hose

2 - Mass Airflow Sensor
❑ Cylinder bank 1 (right)
Mass Airflow Sensor -
G70-
❑ Cylinder bank 2 (left)
Mass Airflow Sensor 2 -
G246-
❑ Removing and instal‐
ling. Refer to
⇒ “5.1 Air Filters and
Mass Airflow Sensor
G70 / Mass Airflow Sen‐
sor 2 G246 ”, page 43
3 - O-Ring
❑ Replace if damaged
4 - Air Filter
❑ Always use an Original
air filter
❑ Removing and instal‐permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ling. Refer to with respect to the correctness of information in this document. Copyright by AUDI AG.
Mass Airflow Sensor
sor 2 G246 ”, page 43
❑ Follow the replacement
intervals, refer to Main‐
tenance Manual
5 - Bolt
❑ 3 Nm
6 - Adapter
❑ 4 Nm
2. Description and Operation 5

7 - Grommet
8 - Sleeves
9 - Bolt
❑ 8 Nm
10 - Bolt
❑ 8 Nm
11 - Air Guide
❑ Clean dirt and leaves from the air duct
12 - Air Guide permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
13 - Bolt
❑ 8 Nm
14 - Sleeves
15 - Bolt
❑ 8 Nm
16 - Air Guide
17 - Bolt
❑ 8 Nm
18 - Sleeve
19 - Grommet
20 - Boot
❑ Be careful of the catch when installing
21 - Grommet
22 - Grommet
23 - Bolt
❑ If the air filter upper section is made of carbon, only tighten it when a rubber washer is inserted between
❑ 8 Nm
24 - Air Filter Housing Upper Section
❑ Clean salt, dirt and leaves from the upper section of the air filter
25 - Bolt
❑ 1.2 Nm
26 - Strainer
27 - Bolt
❑ 8 Nm
28 - Sleeve
29 - Grommet
30 - Air Filter Housing Lower Section
❑ Clean the lower section of the air filter from salt, dirt and leaves
❑ Clean the water drain hose
❑ Removing and installing. Refer to ⇒ “5.2 Air Filter Housing”, page 47
❑ Tighten to 8 Nm

31 - Water Drain Valve

32 - Heat Shield
33 - Bolt
❑ 1.5 Nm
2.1.2 Vehicles with DSG Transmission 0BZ
1 - Air Guide Hose

2 - Mass Airflow Sensor
❑ Cylinder bank 1 (right)
Mass Airflow Sensor -
G70-
❑ Cylinder bank 2 (left)
Mass Airflow Sensor 2 -
G246- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing
permittedand instal‐
ling. Refer to

Mass Airflow Sensor
sor 2 G246 ”, page 43
3 - O-Ring
4 - Air Filter
❑ Use an Original air filter,
refer to the Parts Cata‐
log
ling, refer to
Mass Airflow Sensor
sor 2 G246 ”, page 43
❑ Follow the replacement
intervals, refer to Main‐
tenance Manual
5 - Bolt
❑ 3 Nm
6 - Adapter
❑ 4 Nm
7 - Grommet
8 - Sleeves
9 - Bolt
❑ 8 Nm
10 - Bolt
❑ 8 Nm
11 - Air Guide
12 - Air Guide

13 - Bolt
❑ 8 Nm
14 - Sleeves
15 - Bolt
❑ 8 Nm
16 - Air Guide
17 - Bolt
❑ 8 Nm
18 - Sleeve
19 - Grommet
20 - Boot
❑ Be careful of the catch when installing
21 - Grommet
22 - Grommet
23 - Bolt
❑ If the air filter upper section is made of carbon, only tighten it when a rubber washer is inserted between
❑ 8 Nm
24 - Ball Pin
❑ 2.5 Nm
25 - Air Filter Housing Upper Section
❑ Clean salt, dirt and leaves from the upper section of the air filter
26 - Air Filter Housing Lower Section
❑ Clean the lower section of the air filter from salt, dirt and leaves
❑ Clean the water drain opening
❑ Removing and installing, refer to ⇒ “5.2 Air Filter Housing”, page 47
❑ Tighten to 8 Nm
27 - Bolt
❑ 8 Nm
28 - Sleeve
29 - Grommet
30 - Bolt
❑ 1.2 Nm
31 - Heat Shield
32 - Bolt
❑ 1.5 Nm

Install air guides with screw-type clamps
Note
♦ The hose connections as well as the air guide pipes and hoses
must be free of oil and grease before installing.
♦ Secure all hose connections with hose clamps of the same
type as those equipped by the factory. Refer to the Parts Cat‐
alog.
♦ In order to be able to securely mount the air guide hoses on
their connectors, spray the screws on the previously used
clamps with a rust remover.
Tightening specification for:

1- Clamp -a- = 13 mm wide: 5.5 Nm
2- Clamp -b- = 9 mm wide: 3 Nm
2.2 Fuel Injection System Component Location

On the Left Side of the Engine Compartment
1 - Engine Control Module

(ECM) 2 - J624-
❑ Installed location:
Coupe, refer to
⇒ Fig. ““ Engine Control
Module (ECM) 2 -J624-
Component Location -
R8 Coupe”“ ,
page 16 , Spyder
⇒ Fig. ““ Engine Control
Module (ECM) 2 -J624-
Component Location -
R8 Spyder”“ ,
page 16
ling, refer to
⇒ “5.5 Engine Control
Module 2 J624 ”,
page 54
2 - Camshaft Position (CMP)
Sensor 4 - G301-
❑ 10 Nm
❑ Installed location, refer
to
⇒ Fig. ““Component Lo‐
cation Cylinder Bank
2”“ , page 20
ling, refer to
⇒ “4.1 Camshaft Posi‐
tion Sensor”, page 84
3 - Secondary Air Injection
(AIR) Pump Motor
❑ AIR system assembly
overview, installed loca‐
tions, refer to ⇒ Engine
Mechanical; Rep. Gr.
26 ; Removal and Installation

❑ AIR system, checking, refer to ⇒ Engine Mechanical; Rep. Gr. 26 ; Diagnosis and Testing
❑ Secondary Air Injection (AIR) pump motors - V101- / -V189- , Removing and installing, refer to ⇒ Engine
Mechanical; Rep. Gr. 26 ; Removal and Installation
❑ Secondary Air Injection (AIR) pump relay - J299- . Refer to Wiring diagrams, Troubleshooting & Com‐
ponent locations
4 - Ignition Coils, Cylinder Bank 2
❑ Ignition Coil 5 with Power Output Stage - N323-
❑ Installed location, refer to ⇒ Fig. ““Component Location, Inside Cylinder Bank 2”“ , page 21
5 - High Pressure Pump Cylinder Bank 2
❑ Removing and installing, refer to ⇒ “5.8 High Pressure Pumps”, page 63
6 - Camshaft Position (CMP) Sensor 2 - G163-
❑ 10 Nm
❑ Removing and installing, refer to ⇒ “4.1 Camshaft Position Sensor”, page 84
7 - Fuel Metering Valve 2 - N402-
❑ Installed location, refer to ⇒ Fig. ““Component Location Cylinder Bank 2”“ , page 20
8 - Electrical Connectors on Knock Sensor (KS) 3 - G198- and Knock Sensor (KS) 4 - G199-
❑ Installed location, refer to ⇒ Fig. ““Component Locations, Engine from Front”“ , page 21
9 - Knock Sensor (KS) 3 - G198-
❑ 20 Nm
❑ Connector location, refer to ⇒ Fig. ““Component Locations, Engine from Front”“ , page 21
❑ Removing and installing, refer to ⇒ “4.4 Knock Sensors”, page 89
10 - Engine Viewed From Front
❑ Installed location, refer to ⇒ Fig. ““Component Locations, Engine from Front”“ , page 21
❑ Adapt the intake manifold runner position sensor - G336- in the “Guided Functions” operating mode under
“Adapting intake manifold runner position sensor” after replacing it.
❑ Intake Manifold Runner Control (IMRC) valve - N316-
❑ Protected
Oil pressure switch - F1- for checking removing and installing, refer to ⇒ Engine Mechanical; Rep. Gr.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
17 ; Removal
permitted andbyInstallation
unless authorised AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Knock Sensor (KS) 1 - G61- connector

11 - Oxygen Sensor Connectors
❑ Installed location:
♦ Refer to
⇒ Fig. ““Heated Oxygen Sensor connector bracket, Vehicles with manual/R tronic transmission 086”“ , page
21
♦ Refer to
⇒ Fig. ““Heated Oxygen Sensor connector bracket, vehicles with DSG transmission 0BZ”“ , page 22
❑ 20 Nm

13 - Intake Manifold Runner Position Sensor 2 - G512-

❑ After replacement, adapt in “Guided Functions” operating mode in “Adapting intake manifold runner po‐
sition sensor”
❑ Installed on the rear of the intake manifold, refer to
⇒ Fig. ““ Intake Manifold Runner Position Sensor 2 -G512- -2- ”“ , page 17
14 - Mass Airflow (MAF) Sensor 2 - G246-
❑ Installed location, refer to ⇒ Fig. ““Throttle Valves and Mass Airflow (MAF) Sensor”“ , page 17
❑ Removing and installing, refer to
⇒ “5.1 Air Filters and Mass Airflow Sensor G70 / Mass Airflow Sensor 2 G246 ”, page 43
15 - Throttle Valve Control Module 2 - J544-
❑ 9 Nm
❑ Adapt the throttle valve control module 2 in the “Guided Functions” operating mode after replacing.
16 - Low Fuel Pressure Sensor - G410-
❑ 15 Nm
❑ Installed location, refer to ⇒ Fig. ““High Pressure Pump, Cylinder Bank 2 -3- ”“ , page 18
17 - Camshaft Adjustment Valve 2 - N208-
18 - Exhaust Camshaft Adjustment Valve 2 - N319-
On the Right Side of the Engine Compartment

Components A through L are not shown in the exploded view il‐
lustration.

1 - Fuel Pressure Sensor -

G247-
❑ 22 Nm
to
cation, Inside Cylinder
Bank 1”“ , page 20
ling, refer to
⇒ “5.7 Fuel Pressure
Sensor G247 ”,
page 62
❑ 20 Nm
to
cation, Inside Cylinder
Bank 1”“ , page 20
❑ Connector location, re‐
fer to
cations, Engine from
Front”“ , page 21
ling, refer to
⇒ “4.4 Knock Sensors”,
page 89
3 - Electrical Connectors on
Knock Sensor (KS) 1 - G61-
and Knock Sensor (KS) 2 -
G66-
❑ Connector location, re‐
fer to

cations, Engine from

Front”“ , page 21
4 - Camshaft Position (CMP) Sensor - G40-
❑ 10 Nm
5 - Fuel Metering Valve - N290-
6 - Ignition Coils, Cylinder Bank 1
7 - Camshaft Position (CMP) Sensor 3 - G300-
❑permitted
10 Nm unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
9 - Engine Control Module (ECM) - J623-
❑ Installed location, refer to Coupe
⇒ Fig. ““ Engine Control Module (ECM) -J623- Component Location - R8 Coupe”“ , page 16 , Spyder
⇒ Fig. ““ Engine Control Module (ECM) -J623- Component Location - R8 Spyder”“ , page 16
❑ Removing and installing, refer to ⇒ “5.4 Engine Control Module J623 ”, page 51
10 - Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 - N80-
❑ Installed location, refer to
⇒ Fig. ““ Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80- -1- ”“ , page 18
11 - High Pressure Pump
❑ With fuel metering valve - N290-
❑ Installed location; refer to ⇒ Fig. ““High Pressure Pump, Cylinder Bank 1 -2- ”“ , page 18
❑ Removing and installing, refer to ⇒ “5.8 High Pressure Pumps”, page 63
12 - Coolant Temperature Sensor - G62-
❑ Installed location; refer to ⇒ Fig. ““ Engine Coolant Temperature (ECT) Sensor -G62- -1- ”“ , page 18
❑ Removing and installing, refer to ⇒ Engine Mechanical; Rep. Gr. 19 ; Removal and Installation
13 - Camshaft Adjustment Valve 1 - N205-
14 - Mass Airflow (MAF) Sensor - G70- / Intake Air Temperature (IAT) Sensor - G42-
❑ Removing and installing, refer to
⇒ “5.1 Air Filters and Mass Airflow Sensor G70 / Mass Airflow Sensor 2 G246 ”, page 43
15 - Throttle Valve Control Module - J338-
❑ 9 Nm
❑ Adapt the throttle valve control module in the “Guided Functions” operating mode after replacing.

16 - Knock Sensor 2 - G66-

❑ 20 Nm
17 - Secondary Air Injection (AIR) Solenoid Valve - N112-
❑ The secondary Air Injection (AIR) solenoid valve 2 - N320-
❑ Installed location, refer to unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
⇒ Fig. ““Installed Location of the
with respect Secondary
to the correctness of Air Injection
information (AIR) Solenoid
in this document. Copyright byValve”“
AUDI AG. , page 20
A - Fuel Injectors, Cylinder Bank 1

❑ Cylinder 1 Fuel Injector - N30-
❑ Removing and installing, refer to ⇒ “5.6 Fuel Injectors”, page 56
B - Fuel Injectors, Cylinder Bank 2
C - Engine Speed (RPM) Sensor - G28-
❑ Component location
♦ Refer to
⇒ Fig. ““ Engine Speed Sensor -G28- , Vehicles with manual/R tronic transmission 086”“ , page 17

♦ Refer to ⇒ Fig. ““ Engine Speed Sensor -G28- , vehicles with DSG transmission 0BZ”“ , page 17
❑ Removing and installing. Refer to ⇒ “4.2 Engine Speed Sensor G28 ”, page 86
❑ 9 Nm
D - Heated Oxygen Sensor (HO2S) - G39- (before catalytic converter)
⇒ Fig. ““Component Location, Oxygen Sensors, Cylinder Bank 1”“ , page 22
❑ Component location: connector, refer to
⇒ Fig. ““Heated Oxygen Sensor connector bracket, Vehicles with manual/R tronic transmission 086”“ ,
page 21
❑ Removing and installing, refer to ⇒ “5.11 Oxygen Sensors”, page 72
E - Heated
permitted Oxygen
unless authorised Sensor
by AUDI (HO2S)
AG. AUDI AG does2not - guarantee
G108- or (inaccept
converter) frontanyof catalytic
liability

❑ Component location: connector , refer to
page 21
F - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) - G130-
page 21
G - Oxygen Sensor (O2S) 2 after Catalytic Converter - G131-
page 21
H - 9-Pin Relay and Fuse Carrier Under the Rear Shelf (on the right side)
❑ Motronic Engine Control Module (ECM) power supply relay - J271-
❑ Auxiliary Engine Coolant (EC) pump relay - J496-
❑ Starter Relay - J53-
❑ Relay 2 for Starter - J695-
❑ Secondary Air Injection (AIR) Pump Relay - J299-
❑ Engine Component Power Supply Relay - J757-
❑ Component locations Wiring diagrams, Troubleshooting & Component locations
I - Accelerator Pedal Position Sensor - G79- / Accelerator Pedal Position Sensor 2 - G185-
❑ Removing and installing, refer to ⇒ Fuel Supply System; Rep. Gr. 20 ; Removal and Installation
J - Brake Lamp Switch - F- / Brake Pedal Switch - F47-
❑ Removing and installing, see brake system, refer to ⇒ Brake System; Rep. Gr. 45 ; Removal and
Installation
K - Clutch Pedal Starter Interlock Switch - F194- and Clutch Pedal Switch - F36-
❑ Only for vehicles with manual transmission
❑ Removing and installing, see transmission - clutch, refer to ⇒ R-Tronic Transmission; Rep. Gr. 30 ;
Removal and Installation
L - Clutch Position Sensor - G476-
❑ Only with R-tronic
❑ Removing and installing, refer to ⇒ R-Tronic Transmission; Rep. Gr. 30 ; Removal and Installation

Engine Control Module (ECM) - J623- Component Location - R8

Coupe
1 - Connector
2 - Protective housing
3 - Engine Control Module (ECM) - J623-
♦ Under the right engine compartment trim
♦ ECM, removing and installing
⇒ “5.4 Engine Control Module J623 ”, page 51
Engine Control Module (ECM) 2 - J624- Component Location -

R8 Coupe
1 - Connector
2 - Protective housing
3 - ECM 2
♦ Under the left engine compartment trim
♦ ECM 2, removing and installing, refer to
⇒ “5.5 Engine Control Module 2 J624 ”, page 54
Engine Control Module (ECM) - J623- Component Location - R8

Spyder
1- Connector
2- Metal Retainer
3- ECM
♦ In the right side of the engine compartment
Removing and installing, refer to
⇒ “5.4 Engine Control Module J623 ”, page 51 .
Engine Control Module (ECM) 2 - J624- Component Location -

R8 Spyder
1- Engine Control Module 2 - J624-
2- Metal retainer
3- Connector
♦ In the left side of the engine compartment
⇒ “5.5 Engine Control Module 2 J624 ”, page 54 .

Engine Speed Sensor - G28- , Vehicles with manual/R tronic

transmission 086
⇒ “4.2 Engine Speed Sensor G28 ”, page 86
Engine Speed Sensor - G28- , vehicles with DSG transmission

0BZ
♦ Component location: on the left or right of the transmission
housing, depending on equipment
1- Connector
2- Bolt
3- Engine Speed Sensor - G28-
Intake Manifold Runner Position Sensor 2 - G512- -2-

Note
♦ Installed on the rear of the intake manifold.

♦ The throttle valve control module 2 must be removed to re‐
move and install the intake manifold runner position sensor 2
-2-.
Throttle Valves and Mass Airflow (MAF) Sensor

1 - Throttle valve control module
permitted unless 2 - J544-
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2 - Throttle valve control module - J338-
3 - MAF) sensor and intake air temperature sensor - G42-
4 - MAF sensor 2
Note
A vehicle with a manual/R tronic transmission 086 is shown in the

illustration.

High Pressure Pump, Cylinder Bank 1 -2-

1 - Fuel metering valve - N290-
High Pressure Pump, Cylinder Bank 2 -3-

1 - Fuel metering valve 2 - N402-
2 - Low fuel pressure sensor - G410-
Engine Coolant Temperature (ECT) Sensor - G62- -1-

2 - MAF sensor
Removing and installing, refer to ⇒ Engine Mechanical; Rep. Gr.
19 ; Removal and Installation
Evaporative Emission (EVAP) Canister Purge Regulator Valve 1

- N80- -1-

Oil Temperature Sensor 2 - G664-

1- Oil Temperature Sensor 2 - G664- on the oil filter housing.
Component Location Cylinder Bank 1

1 - Camshaft adjustment valve 1 - N205-
2 - High pressure pump cylinder bank 1
3 - Fuel metering valve - N290-
4 - Camshaft position sensor - G40-
5 - Ignition coil 1 with power output stage - N70-
9 - Camshaft position sensor 3 - G300- , removing and installing,
refer to ⇒ “4.1 Camshaft Position Sensor”, page 84
Note
The throttle valve control module - J338- must be removed to re‐

move and install the camshaft adjustment valve 1 - N205- .

Component Location Cylinder Bank 2

1 - Camshaft position sensor 2 - G163-
2 - Fuel metering valve 2 - N402-
3 - Low fuel pressure sensor - G410-
4 - High pressure pump cylinder bank 2
5 - Camshaft adjustment valve 2 - N208-
6 - Exhaust camshaft adjustment valve 2 - N319-
11 - Camshaft position sensor 4 - G301- , removing and installing,
refer to ⇒ “4.1 Camshaft Position Sensor”, page 84
Note
The throttle valve control module 2 - J544- must be removed to

remove and install the camshaft adjustment valve 2 - N208- .
Component Location, Inside Cylinder Bank 1

♦ Under intake manifold
1 - Camshaft position sensor - G40-
2 - Cylinder 1 fuel injector - N30-
6 - Knock sensor 2 - G66-
7 - Secondary air injection solenoid valve - N112- , refer to
⇒ Fig. ““Installed Location of the Secondary Air Injection (AIR)
Solenoid Valve”“ , page 20 )
8 - Camshaft Position (CMP) sensor 2 - G163-
9 - Fuel pressure sensor - G247-
Installed Location of the Secondary Air Injection (AIR) Solenoid

Valve
1- Secondary Air Injection (AIR) solenoid valve - N112-
2- Secondary Air Injection (AIR) solenoid valve 2 - N320-
Note
Installed location: under the intake manifold. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Component Location, Inside Cylinder Bank 2

♦ Under intake manifold
2 - Cylinder 8 Fuel Injector - N86-
6 - Oil pressure switch - F1-
8 - Camshaft Position (CMP) sensor - G40-
9 - Secondary Air Injection (AIR) solenoid valve - N112- , refer to
⇒ Fig. ““Installed Location of the Secondary Air Injection (AIR)
Solenoid Valve”“ , page 20 )
Component
with respectLocations, Engine
to the correctness frominFront
of information this document. Copyright by AUDI AG.
1 - High pressure pump cylinder bank 1 with fuel metering valve

- N290-
2 - Camshaft Position (CMP) sensor - G40-
3 - Intake Manifold Runner Position Sensor - G336-
4 - Intake Manifold Runner Control (IMRC) valve - N316-
6 - High pressure pump cylinder bank 2 with fuel metering valve
2 - N402-
7 - Knock Sensor (KS) 4 - G199- connector
9 - Oil pressure switch - F1-
Heated Oxygen Sensor connector bracket, Vehicles with manual/

R tronic transmission 086
1- Oxygen Sensor 2 After Catalytic Converter - G131-
2- Oxygen Sensor 2 before Catalytic Converter - G108-
3- Heated Oxygen Sensor - G39- (before catalytic converter)
4- Oxygen Sensor after Three Way Catalytic Converter -
G130-

Heated Oxygen Sensor connector bracket, vehicles with DSG

transmission 0BZ
1- Oxygen Sensor (O2S) 2 after catalytic converter - G131-
2- Heated Oxygen Sensor (HO2S) 2 - G108- (in front of cata‐
lytic converter)
3- Heated Oxygen Sensor (HO2S) - G39- (before catalytic
converter)
4- Oxygen Sensor (O2S) after Three Way Catalytic Converter
(TWC) - G130-
Component Location, Oxygen Sensors, Cylinder Bank 1

1- Oxygen Sensor (O2S) after Three Way Catalytic Converter
(TWC) - G130-
2- Heated Oxygen Sensor (HO2S) - G39- (before catalytic
converter)
⇒ “5.11 Oxygen Sensors”, page 72
Component Location, Oxygen Sensors, Cylinder Bank 2

1- Heated Oxygen Sensor (HO2S) 2 - G108- (in front of cata‐
lytic converter)
2- Oxygen Sensor (O2S) 2 after catalytic converter - G131-
2.3 High Pressure Pump Overview

⇒ “2.3.1 High Pressure Pump with Fuel Supply
permitted Hose”,
page 22 with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ “2.3.2 High Pressure Pump with Fuel Supply Line”, page 24
2.3.1 High Pressure Pump with Fuel Supply Hose


ling. Refer to
⇒ “5.8.1 High Pressure
Pump with Fuel Supply
Hose”, page 63 .
2 - Bolt
❑ Quantity: 3
❑ 10 Nm
3 - High Pressure Line
WARNING
Fuel
♦ system is under high
pressure! Before opening
high pressure compo‐
nents of the fuel injection
system, pressure must
be relieved to residual
pressure. Refer to
⇒ “2.8 Releasing Pres‐
sure in High Pressure
Area”, page 34 .
Then
♦ wrap a clean cloth
around the connection
and relieve residual pres‐
sure by carefully loosen‐
ing the connection.
❑Protected
Before loosening,
by copyright. Copyingturn
for private or commercial purposes, in part or in whole, is not
off the
permitted ignition
unless and
authorised dis‐ AG. AUDI AG does not guarantee or accept any liability
by AUDI
connect
with the
respect to the ground
correctnessca‐
of information in this document. Copyright by AUDI AG.
ble from the battery.
❑ Tighten the connection
to 40 Nm. Check the line
torque every time before
installing the fuel line.
❑ Connectors should not show any signs of damage
❑ Do not change the shape of the line
❑ Coat the thread on the union nut with clean engine oil.
❑ Tighten the high pressure line ⇒ Fig. ““High Pressure Line Tightening Method”“ , page 25
4 - Fuel Supply Hose
❑ Make sure it is secure
5 - O-Ring
❑ Replace
❑ Coat with clean engine oil
6 - Roller Tappet
❑ Coat with clean engine oil when installing.

2.3.2 High Pressure Pump with Fuel Supply Line
1 - Roller Tappet
❑ Coat with clean engine
oil when installing.
2 - O-Ring
❑ Replace
oil when installing.
ling. Refer to
⇒ “5.8.2 High Pressure
Pump with Fuel Supply
Line”, page 65 .
4 - Bolt
❑ Quantity: 3
❑ 10 Nm
WARNING
Fuel
pressure. Refer to
Area”, page 34 .
Then
ing the connection.
❑ Tighten the connection
permitted to 40
unless authorised by Nm.
AUDI AG.Check
AUDI AG the line
does torque or
not guarantee every
accept time before installing the fuel line.
any liability
6 - Fuel Supply Line
❑ Low Pressure Line
❑ Tighten the connection to 40 Nm. Check the line torque every time before installing the fuel line.
❑ Tighten union nut to 22 Nm

High Pressure Line Tightening Method

– First tighten the high pressure line union nuts by hand.
– Make sure the high pressure line does not have tension.
– Use a torque wrench - V.A.G 1331- with 17 mm socket - V.A.G
1331/6- to tighten the high pressure line union nuts.
• 25 Nm
2.4 Intake Manifold Overview
1 - Intake Manifold Flap Vac‐

uum Actuator
❑ Right cylinder bank
❑ With bracket
ling, refer to
⇒ “5.9 Intake Flap Vac‐
uum Actuator”,
page 68
2 - Mounting Pin
❑ Replace
3 - Bolts
❑ 9 Nm
4 - Intake Manifold Runner Po‐
sition Sensor - G336-
❑ After replacing, perform
an “Adaptation” in “Gui‐
ded Functions”. Refer to
Vehicle Diagnostic
Tester
5 - Bolt
❑ 2.5 Nm
6 - Seal
❑ The open side faces the Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
intake manifold runner permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
position sensor - G336- with respect to the correctness of information in this document. Copyright by AUDI AG.
7 - Intake Manifold
ling. Refer to
⇒ “5.10 Intake Mani‐
fold”, page 68
8 - Seal
❑ Replace
9 - Throttle Valve Control Module - J338-
❑ After replacing, perform an “Adaptation” in “Guided Functions”. Refer to Vehicle Diagnostic Tester

10 - Bolt
❑ 9 Nm
11 - Clamp
12 - Bolt
❑ 9 Nm
13 - Seal
❑ Replace
14 - Bolt
❑ 9 Nm
❑ Left cylinder bank
16 - Intake Manifold Runner Position Sensor 2 - G512-
❑ Left cylinder bank
17 - Bolt
❑ 2.5 Nm
18 - Seal
❑ The open side faces intake manifold runner position sensor 2 - G512-
19 - Bolt
❑ Tightening specification, refer to ⇒ Fig. ““Intake manifold tightening specification”“ , page 27
20 - Intake Manifold Gasket
❑ Replace
21 - Bolt
❑ 9 Nm
22 - Fuel Filler Tubes
❑ With Low Fuel Pressure Sensor - G410-
23 - Mounting Pin
❑ Replace
24 - Bolts
❑ 9 Nm
25 - Intake Manifold Flap Vacuum Actuator
❑ Left cylinder bankby copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
❑ With bracketwith respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Removing and installing, refer to ⇒ “5.9 Intake Flap Vacuum Actuator”, page 68
26 - Intake Manifold Runner Control Valve - N316-

Intake manifold tightening specification

♦ First tightening: 8 Nm
♦ Then tighten the bolts -8 and 9- only to 11 Nm
♦ Second tightening for all other bolts: 9 Nm and the 90 degrees
2.5 Fuel Injectors and Fuel Rail Overview

⇒ “2.5.1 Fuel Rail with Fuel Return Hose”, page 27
⇒ “2.5.2 Fuel Rail with Fuel Return Line”, page 30
2.5.1 Fuel Rail with Fuel Return Hose
1 - Radial Adjustment
❑ Clip together with sup‐
port ring
⇒ Item 6 (page 27)
2 - Combustion Chamber Seal
❑ Do not grease ring or
treat with any other lu‐
bricant
❑ Replacing, refer to
⇒ page 59
3 - Fuel Injector
❑ Different versions. For
the correct allocation,
refer to the Parts Cata‐
log
ling, refer to
⇒ “5.6 Fuel Injectors”,
page 56
4 - Spacer Ring
5 - O-Ring
❑ Replace
oil
6 - Support Ring
❑ Replace
❑ The fuel rail wields force
via the support ring to
hold the fuel injector
tightly in the cylinder
head.

7 - Fuel Rail
WARNING
Fuel
pressure. Refer to
Area”, page 34 .
Then
ing the connection.
Observe
♦ procedures for
disconnecting battery.
Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ;
Removal and Installa‐
tion . with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Removing and installing. Refer to ⇒ “5.6 Fuel Injectors”, page 56 .
WARNING
Fuel
pressure. Refer to
Area”, page 34 .
Then
ing the connection.
Observe
♦ procedures for
disconnecting battery.
Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ;
Removal and Installa‐
tion .


9 - Return Hose
❑ lay clean cloths around the connection and loosen it carefully to reduce the residual pressure in the
injection system
10 - Pressure Relief Valve 125 bar
❑ For the high pressure line
❑ 30 Nm
11 - Bolt
❑ Replace
❑ Tighten diagonally in steps
❑ 8 Nm +90°
12 - Bolt
❑ Replace
❑ 8 Nm +90°
1 - From Fuel Railby copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
2 - Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Replace
❑ 7 Nm +90°
3 - Bolt
❑ Replace
❑ 7 Nm +90°
4 - To the High Pressure Pump
5 - Bolt
❑ Replace
❑ 7 Nm +90°
❑ Coat the thread on the
union nut with clean en‐
gine oil
❑ Tighten union nut to 28
Nm
7 - From the Fuel Filter
8 - Bolt
❑ Replace
❑ 7 Nm +90°
9 - Bolt
❑ Replace
❑ 7 Nm +90°
10 - O-Ring
❑ Replace
❑ Coat with fuel
11 - Low Fuel Pressure Sensor
- G410-
❑ 15 Nm
❑ Union nut tightening specification, ⇒ Item 6 (page 24)

13 - Fuel Return Hose

14 - From Fuel Rail
2.5.2 Fuel Rail with Fuel Return Line
1 - Retaining Plate
2 - Bolt
❑ Replace
❑ 7 Nm +90°
WARNING
Fuel
pressure. Refer to
Area”, page 34 .
Then
ing the connection. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Connectors should not with respect to the correctness of information in this document. Copyright by AUDI AG.
show any signs of dam‐

age
❑ Do not change the
shape of the line
gine oil
❑ Tighten the high pres‐
sure line
⇒ Fig. ““High Pressure
Line Tightening Meth‐
od”“ , page 25
4 - Fuel Pressure Sensor 2 - G624-
❑ Cylinder bank 1 (right) Fuel Pressure Sensor - G247-
❑ Removing and installing. Refer to ⇒ “5.7 Fuel Pressure Sensor G247 ”, page 62
❑ Coat the threads with clean engine oil
❑ 25 Nm
5 - Bolt
❑ Replace
❑ 7 Nm +90°
6 - Fuel Return Line
❑ Tighten union nut to 22 Nm

7 - Bolt
❑ Replace
❑ 7 Nm +90°
8 - Pressure Relief Valve 125 bar
❑ For the high pressure line
❑ 30 Nm
9 - Bolt
❑ Replace Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 7 Nm +90°
10 - Bolt
❑ Replace
❑ 8 Nm +90°
11 - Bolt
❑ Replace
❑ 8 Nm +90°
12 - Fuel Rail
WARNING
Fuel
pressure. Refer to
Area”, page 34 .
Then
ing the connection.

❑ Coat the thread on the union nut with clean engine oil
13 - Support Ring
❑ Make sure it fits correctly
❑ The fuel rail wields force via the support ring to hold the fuel injector tightly in the cylinder head
14 - O-Ring
❑ Replace
❑ Coat with clean engine oil
15 - Spacer Ring
16 - Fuel Injector
❑ Different versions. For the correct allocation, refer to the Parts Catalog.
❑ Removing and installing. Refer to ⇒ “5.6 Fuel Injectors”, page 56

17 - Combustion Chamber Seal

❑ Replacing, refer to ⇒ page 59
18 - Washer
1 - From Fuel Rail

❑ Union nut tightening
specification,
⇒ Item 6 (page 30)
2 - Bolt
❑ Replace
❑ 7 Nm +90°
3 - Bolt
❑ Replace
❑ 7 Nm +90°
❑ Union nut tightening
specification, Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ Item 6 (page 24) permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
5 - Bolt
❑ Replace
❑ 7 Nm +90°
6 - Bolt
❑ Replace
❑ 7 Nm +90°
7 - Bolt
❑ Replace
❑ 7 Nm +90°
gine oil
❑ Tighten union nut to 28
Nm
9 - From the Fuel Filter
10 - Bolt
❑ Replace
❑ 7 Nm +90°
11 - O-Ring
❑ Replace
❑ Coat with fuel
12 - Low Fuel Pressure Sensor - G410-
❑ 15 Nm
13 - Bolt
❑ Replace
❑ 7 Nm +90°
❑ Union nut tightening specification, refer to ⇒ Item 6 (page 24)

15 - Fuel Return Line

16 - From Fuel Rail
❑ Union nut tightening specification, refer to ⇒ Item 6 (page 30)
2.6 Oxygen Sensors Overview

Heated Oxygen Sensor - G39- before catalytic converter and
Oxygen Sensor after Three Way Catalytic Converter - G130- cyl‐
inder bank 1 (right):
1 - Oxygen Sensor after Three Way Catalytic Converter - G130-
2 - Heated Oxygen Sensor - G39-
Removing and installing. Refer to
⇒ “5.11 Oxygen Sensors”, page 72 .
♦ Tightening specifications: 55 Nm
Oxygen Sensor 2 before Catalytic Converter - G108- and Oxygen

Sensor 2 after Catalytic Converter - G131- cylinder bank 2 (left):
1 - Heated Oxygen Sensor 2 - G108-
2 - Oxygen Sensor 2 After Catalytic Converter - G131-
Removing and installing. Refer to
⇒ “5.11 Oxygen Sensors”, page 72 .
♦ Tightening specifications: 55 Nm
Heated Oxygen Sensor connector, Vehicles with manual/R tronic

transmission 086
1- For the Oxygen Sensor 2 after Catalytic Converter - G131-
2- For the Heated Oxygen Sensor 2 - G108-
3- For the Heated Oxygen Sensor - G39-
4- For the Oxygen Sensor after Three Way Catalytic Converter
- G130-

Heated Oxygen Sensor connector, Vehicles with DSG Transmis‐

sion 0BZ
G130-
2.7 Engine Control Module Overview

1 - Bracket
❑ For engine control mod‐
ule
2 - Bolt
❑ 9 Nm
3 - Protective Housing
❑ 2 parts
4 - Shear Bolt
5 - Clamp
❑ For engine control mod‐
ule
6 - Nut
❑ 7 Nm
7 - Engine Control Module
❑ Engine Control Module -
J623- , Removing and
Installing, refer to
Module J623 ”,
page 51
❑ Engine Control Module
2 - J624- , Removing
and Installing, refer to
Module 2 J624 ”,
page 54
2.8 Releasing Pressure in High Pressure

Area
Special tools and workshop equipment required
♦ Vehicle Diagnostic Tester

WARNING
There is a risk of injury because the fuel is under very high

pressure.
♦ The fuel injection system is separated into a high-pressure
section (maximum approximately 140 bar) and a low-
pressure section (4 to 7 bar).
♦ Before opening high pressure parts, for example, remov‐
ing high pressure pump, fuel rail, fuel injectors, fuel pipes
or Fuel Pressure Sensor - G247- , fuel pressure in high
pressure area must be reduced to the recommended pres‐
sure. The procedure for this is as follows.
Procedure
– R8 Coupe: Remove the rear shelf. Refer to ⇒ Body Interior;
Rep. Gr. 70 ; Removal and Installation .
– R8 Spyder: Remove the right rear connector station and move
the connected Ground wire and sockets to the side. Refer to
⇒ Electrical Equipment; Rep. Gr. 97 ; Removal and Installa‐
tion .
– Connect the Vehicle Diagnostic Tester.
– Start engine and run at idle speed.
– Select “engine electronics” in OBD.
– Then select “Measured values” read out.
– Select measured value block 140.
– With the engine running at idle, the fuel pressure will be dis‐
played in display field 3.
♦ Specified value: between 35 and 45 bar

– With the engine running at idle, remove the fuel pump fuse -
S81- in the “9-pin relay and fuse panel” for the fuel pump
control module - J538- .
Note
“9-pin relay and fuse panel” current routing. Refer to Wiring dia‐
grams, Troubleshooting & Component locations.
– Check the fuel pressure on the tester.

• The fuel pressure decreases rapidly because the mechanical
high pressure pump is no longer supplied with fuel from the
transfer fuel pump - G6- .
– Turn the ignition off as soon as the fuel pressure drops to ap‐
proximately 8 bar.
Note
The fuel pressure must not drop below 6 bar, because otherwise
the engine will shut off (risk of catalytic converter damage).
The fuel rail will continue to be filled with fuel, but it will no longer
be under high pressure.
WARNING
Do not let fuel come into contact with skin.

♦ Wear protective eyewear and clothing when opening the
fuel system.
♦ Lay clean cloths around the connection before opening
the high pressure area to collect any fuel that leaks out.
– After reducing fuel pressure, place a clean cloth around the

connection and open the high pressure system at any point
immediately. Escaping fuel must be absorbed.
Note
♦ If the high pressure system is not opened immediately, the

pressure will increase because of post-heating.
♦ The ignition can no longer be switched on, otherwise the pres‐
sure will increase again.
Final procedures
– Install the fuse.
– Check the DTC memory Vehicle Diagnostic Tester, Guided
Functions , Check DTC memory . Generate readiness
code if the DTC memory was erased.
2.9 Protective Body Covers

♦ Audi R8 Rear End Protector - VAS 6411-
♦ Audi R8 Side Panel Protector - VAS 6412- or

♦ Audi R8 Spyder Side Panel Protector - VAS 6428-

Procedure
Note
The Audi R8 Door Protectors - VAS 6413- are not needed when
working in the engine compartment.
– Wash and dry the affected body components.

R8 Coupe and R8 GT:
– Attach the Audi R8 side panel protector - VAS 6412- to the left
and right rear side panels.
– Position the Audi R8 rear protector - VAS 6411- on the side
panel protector.
R8 Spyder:
– Attach the Audi R8 Spyder Side Panel Protector - VAS 6428-
to the left and right rear side panels.
– Position the Audi R8 rear protector - VAS 6411- on the side
panel protector.

3 Specifications
⇒ “3.1 Technical Data”, page 38
⇒ “3.2 Fastener Tightening Specifications”, page 38
3.1 Technical Data

Engine Data 4.2L FSI Engine
Idle speed cannot be adjusted, it is 640 to 840 RPM
regulated by idle stabilization
Engine speed limitation via fuel in‐ 6500 RPM
jector shut-off
Fuel pressure Fuel supply-pressure up to 3 to 6 bar pressure
high-pressure pump, (is
produced by an electric fuel
pump in the fuel tank)
Fuel high pressure (pro‐ Between 20 and 40 bar pressure at idle
duced by a mechanical sin‐ to approximately 125 bar pressure at cer‐
gle-piston pump) at approx‐ tain operating points
imately 85 degree coolant
temperature
3.2 Fastener Tightening Specifications

Component Bolt Size Nm
Adapter to Air Guide - 4
Air Duct - 8
Air Guide - 8
Air Filter Housing Upper/Lower Sections - 8
Camshaft Position Sensor - 10
Clamp to Intake Manifold
- 9
Engine Speed
with respect to Sensor
the correctness of information in this document. Copyright by AUDI AG. - 9
Fuel Filler Tubes - 9
Fuel Pressure Sensor - 22
Fuel Rail2 - 9
Fuel Supply Line - 25
Heat Shield - 3
High Pressure Line Connection, Union Nut1 - 40
High Pressure Pumps - 10
Hose Clamps - 5.5
Intake Manifold Flap Vacuum Actuator - 9
Intake Manifold Runner Position Sensor - 2.5
Knock Sensor - 20
Locking Flange Cover - 9
Low Fuel Pressure Sensor - 15
Mass Airflow Sensor - 1.5
Oxygen Sensor - 55
Pressure Relief Valve for High Pressure Line - 25
Retaining Clip - 9
Strainer - 1.2
Throttle Valve Control Module - 9


• 1 Coat the threads on the union nut with fuel.
• 2 Fasten in diagonal sequence in steps
Intake Manifold Tightening Specification

♦ First tightening: 8 Nm
♦ Then tighten the bolts -8 and 9- only to 11 Nm
♦ Second tightening for all other bolts: 9 Nm and the 90 degrees
High Pressure Line Tightening Method

– First tighten the high pressure line union nuts by hand.
– Make sure the high pressure line does not have tension.
– Use a torque wrench 5-50 Nm - V.A.G 1331- with 17 mm
socket - V.A.G 1331/6- to tighten the high pressure line union
nuts.
• 25 Nm
3. Specifications 39
4 Diagnosis and Testing

⇒ “4.1 Vacuum System, Checking”, page 40
⇒ “4.2 Wiring and Components, Checking with Test Box VAG
1598/42”, page 40
⇒ “4.3 Leak Test on Vehicle”, page 42
4.1 Vacuum System, Checking

♦ Hand Vacuum Pump - VAS 6213-
Procedure
– Check all vacuum lines in the vacuum system for:
♦ Cracks
♦ Damage caused by
Protected by animals
copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Crimps with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Leaks
– Check the vacuum line leading to and from the solenoid valve.
– If there is a fault stored in the Diagnostic Trouble Code (DTC)
memory, check the vacuum lines for the named component,
but also all the vacuum lines to the other components.
– If the -VAS 6213- does not produce any vacuum or if the vac‐
uum drops again right away, then check the hand vacuum
pump and the connection hoses for leaks.
4.2 Wiring and Components, Checking with

Test Box VAG 1598/42
♦ Adapter Lead - V.A.G 1598/39-1-
♦ Adapter Lead, 94-Pin - V.A.G 1598/39-2-
♦ Test Box 105-Pin - V.A.G 1598/42-

Note
♦ The test box has 105 terminals. The connection cable can be
separated from the test box. This means that as new Engine
Control Module (ECM) connectors are introduced in the future,
only a new cable must be designed and no longer the entire
test box.
♦ The smaller of the two connectors on the ECM is assigned with
terminals 1 to 60. The larger of the two connectors is assigned
with terminals 1 to 94.
♦ For testing at the 60-pin harness connection, the -V.A.G
1598/39-1- is connected to the test box with connector -A-.
Components of the 60-pin harness connection, refer to ⇒ Wir‐
ing diagrams, Troubleshooting & Component locations.
♦ For testing at the 94-pin harness connection, the -V.A.G
1598/39-2- is connected to the test box with connectors -A-
and -B-. Components of the 94-pin harness connection, refer
to ⇒ Wiring diagrams, Troubleshooting & Component loca‐
tions.
♦ The -V.A.G 1598/42- is designed so that it can be connected
simultaneously to the ECM harness and the ECM itself.
♦ This is advantageous because electronic engine control re‐
mains fully functional (for example measurement of signals
with engine running) when the test box is attached.
♦ The procedures will indicate whether the ECM is to remain
connected to the test box or not.
WARNING
To avoid damaging electronic components, switch to the cor‐

responding measuring range and observe all test conditions
before connecting the test leads.
The respective ECM must be removed to disconnect the connec‐

tors from
permitted it. authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
unless
♦ Engine Control Module (ECM) - J623- , removing and instal‐
ling, refer to
⇒ “5.4 Engine Control Module J623 ”, page 51 .
♦ Engine Control Module (ECM) 2 - J624- , removing and in‐
stalling, refer to
⇒ “5.5 Engine Control Module 2 J624 ”, page 54 .
4. Diagnosis and Testing 41

– Connect -V.A.G 1598/42- to wiring harness with -V.A.G

1598/39-1- or -V.A.G 1598/39-2- . Clamp the test box Ground
(GND) clip to battery negative terminal. The procedure will in‐
dicate whether the ECM is to be connected to the test box or
not.
– Perform the test as described in the corresponding repair pro‐
cedure.
Installing the ECM
Install in reverse order of removal.
– Thereafter, the ECM must be equipped with the protective
housing.
– Clean threaded holes for shear bolts of locking compound
residue. Cleaning can be performed with a thread cutter (tap).
– Always use new shear bolts.
Perform the following work after the EC) is reconnected:
– Check the Diagnostic Trouble Code (DTC) memory.
4.3 Leak Test on Vehicle

With vehicle stationary:
– Let engine run at idle with the vehicle stationary until the oil
temperature reaches 80° C (176° F).
– Turn off the ignition.
– Check all line connections and the entire fuel system for leaks.
Note
Replace the part if there are leaks in spite of correct tightening

specifications.

– Assemble the vehicle completely following the instructions in

the corresponding repair manual.
Road test:
– Complete a road test that is longer than 30 km (19 mph) with
at least one full acceleration.
– Remove all engine compartment
with respecttrim, noise insulation
to the correctness of informationand
in this document. Copyright by AUDI AG.
wheel housing liners and check all line connections and the
entire fuel system again for leaks.
– Assemble all vehicle components for the last time.

5 Removal and Installation

⇒ “5.1 Air Filters and Mass Airflow Sensor G70 / Mass Airflow
Sensor 2 G246 ”, page 43
⇒ “5.2 Air Filter Housing”, page 47
Coupe ⇒ “5.3 Engine Compartment Trim”, page 51
⇒ “5.4 Engine Control Module J623 ”, page 51
⇒ “5.5 Engine Control Module 2 J624 ”, page 54
⇒ “5.6 Fuel Injectors”, page 56
⇒ “5.7 Fuel Pressure Sensor G247 ”, page 62
⇒ “5.8 High Pressure Pumps”, page 63
⇒ “5.9 Intake Flap Vacuum Actuator”, page 68
⇒ “5.10 Intake Manifold”, page 68
⇒ “5.12 Throttle Valve Control Module J338/J544 ”, page 74
5.1 Air Filters and Mass Airflow Sensor -

G70- / Mass Airflow Sensor 2 - G246-
page 43
5.1.1 Vehicles with Manual/R tronic Transmis‐

sion 086
Removing
– Install protective body covers. Refer to
⇒ “2.9 Protective Body Covers”, page 36 .
R8 Coupe:
– Remove the engine cover. Refer to ⇒ Engine Mechanical;
– Remove the engine compartment trim. Refer
permitted unless authorised toAG.
by AUDI ⇒ AUDI
Body Ex‐ not guarantee or accept any liability
AG does
terior; Rep. Gr. 53 ; Removal and
with respect Installation
to the correctness of .information in this document. Copyright by AUDI AG.
All vehicles:
– Remove all the bolts -arrows- from the air filter housing upper
section.
– Disconnect the connectors from the Mass Airflow Sensor 2 -
G246- -2- and Mass Airflow Sensor - G70- -4-.
– Loosen both hose clamps -1- and -3-.
– Remove the air filter upper section.
– Remove the air filter elements with both mass airflow sensors.
5. Removal and Installation 43

– Remove the screws -arrows- and pull the mass airflow sensor
-G70- / -G246- -2- off the air filter -1-.
Installing
Install in reverse order of removal. Note the following:
To ensure both mass airflow sensors work correctly, follow the
information and procedure below.
Note
♦ If the air filter elements are very dirty or soaked, dirt particles
or moisture may have contaminated the mass airflow sensor
and may be causing incorrect mass airflow values. This results
in a reduction of power, since a lower injection quantity is cal‐
culated.
♦ Always use an Original air filter
♦ Air filter housing must always be clean.
alog.
♦ Note the following when cleaning the air filter housing with
pressurized air: To prevent malfunctions, cover the critical air
flow components, such as the mass air flow sensor, air guide
pipes, etc., with a clean cloth.
♦ Observe disposal regulations!
– Clean out the water drain, which is the small hole in the air
filter housing lower section, using compressed air.
– Clean air filter housing (upper and lower sections) of salt res‐
idue, dirt or leaves (use vacuum cleaner if necessary).
– Check the mass airflow sensor and air duct hose (intake air
side) for salt residue, dirt, and leaves.
– Check the air ducts to the air filter housing for dirt and leaves.
– Install the mass airflow sensors on the air filter elements.
– Ensure the O-ring is installed correctly -1- and replace it if it is

damaged.

– Carefully guide both air filter elements into the grooves -1- and
-2-.
– Set the upper part of air filter housing onto lower part of air
filter housing, without using much force.
– Make sure the air guide hoses are attached securely to both
mass airflow sensors.
– Install the air guides with the screw-type clamps, refer to
⇒ Fig. ““Install air guides with screw-type clamps”“ , page 9 .
– Connect the connectors to the mass airflow sensors.
Note
Removing and installing the left air filter is described.

Removing with respect to the correctness of information in this document. Copyright by AUDI AG.

R8 Coupe:
All:
– Remove the bolts -arrows- and the air filter upper section.
– Disconnect the connectors -2- from Mass Airflow Sensor 2 -

G246- .
– Loosen the screw clamp -1- and remove the bolt -3-.
– Remove the air filter element with the Mass Airflow Sensor 2
- G246- .

– Remove the screws -arrows- and pull the mass airflow sensor
-G70- / -G246- -2- off the air filter -1-.
Installing
To ensure both mass airflow sensors work correctly, follow the
information and procedure below.
Note
♦ If the air filter elements are very dirty or soaked, dirt particles
or moisture may have contaminated the mass airflow sensor
and may be causing incorrect mass airflow values. This results
in a reduction of power, since a lower injection quantity is cal‐
culated.
♦ Always use an Original air filter
alog.
♦ Observe disposal regulations!
– Clean out the water drain, which is the small hole in the air
filter housing lower section, using compressed air.
– Clean air filter housing (upper and lower sections) of salt res‐
idue, dirt or leaves (use vacuum cleaner if necessary).
– Check the mass airflow sensor and air duct hose (intake
permittedair
side) for salt residue, dirt, and leaves. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Check the air ducts to the air filter housing for dirt and leaves.
– Install the mass airflow sensors on the air filter elements.
– Ensure the O-ring is installed correctly -1- and replace it if it is

damaged.

– The air filter element must be guided carefully into the grooves
-arrows-.
– Set the upper part of air filter housing onto lower part of air
filter housing, without using much force.
– Make sure the air guide hoses are secure.
– Connect the electrical connector.
– Install the engine cover. Refer to ⇒ Engine Mechanical; Rep.
5.2 Air Filter Housing

⇒ “5.2.1 Audi R8 Coupe with Manual/R tronic Transmission 086”,
page 47
⇒ “5.2.2 Audi R8 Spyder
permitted with by
unless authorised Manual/R
AUDI AG. AUDItronic Transmission
AG does not guarantee or 086”,
accept any liability
page 48 with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ “5.2.3 R8 Coupe/Spyder with DSG Transmission 0BZ”,

page 49
5.2.1 Audi R8 Coupe with Manual/R tronic

Transmission 086
Removing
– Remove the engine compartment trim. Refer to ⇒ Body Ex‐
terior; Rep. Gr. 53 ; Removal and Installation .

– Disconnect the connectors from the Mass Airflow Sensor 2 -

G246- -3- and Mass Airflow Sensor - G70- -5-.
– Loosen the hose clamps -2- and -4-.
– Remove all screws -arrows- from the air filter housing.
– Remove the boots -1- and -6- from the air filter housing.
– Remove air filter housing with the mass airflow sensors.
Installing
• Tightening specification. Refer to
page 5 .
Note
alog.
– Check the air duct to the air filter housing for dirt and leaves.
– Install the engine compartment trim. Refer to ⇒ Body Exterior;
5.2.2 Audi R8 Spyder with Manual/R tronic

Transmission 086
Removing
– Remove the air filter elements. Refer to
page 43 .

– Remove the bolts -arrows- and press the left secondary air
injection pipe -1- to the side.
– Repeat the procedure on the other side of the vehicle.
– Remove the air filter housing bolts -arrows-.

– Remove the boots -1- and -2- from the air filter housing.
– Remove air filter housing with the mass airflow sensors.
Installing
• Tightening specification. Refer to
⇒ “2.1 Air Filter Overview”, page 5 .
Note

alog.
– Install the secondary air injection pipes. Refer
Protected to ⇒ Engine
Mechanical; Rep. Gr. 26 ; Removal and Installation
permitted . by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
– Install the air filter elements. Refer to
page 43 .
5.2.3 R8 Coupe/Spyder with DSG Transmis‐

sion 0BZ
Note
Removing and installing the left air filter is described.
Removing
R8 Coupe:

– Remove the affected engine compartment trim. Refer to ⇒

Body Exterior; Rep. Gr. 53 ; Removal and Installation .
R8 Spyder:
– Remove the bolts -arrows- and press the left secondary air
injection pipe -1- to the side.
All:
– Loosen the clamp -3- and remove the air guide hose.
– Free up the crankcase ventilation hose -2- on the air guide
housing.
– Remove the air filter housing bolts -arrows-.
– Remove the boot -1- from the air filter housing.
– Disconnect the connector -4- from mass airflow sensor 2 -
G246- .
– Remove the air filter housing.
Installing
• Tightening specification
Note

♦ Secure all hose connections with hose
Protected by copyright. clamps
Copying oforthe
for private samepurposes, in part or in whole, is not
commercial
type as those equipped by the
permitted factory.
unless authorisedRefer
by AUDI to
AG.the
AUDIParts
AG does Cat‐
not guarantee or accept any liability
alog. with respect to the correctness of information in this document. Copyright by AUDI AG.

5.3 Engine Compartment Trim

Removing
– Carefully remove the engine cover -2-. Do not jerk or pull to
one side.
Remove the power steering reservoir cap on the left engine com‐
partment trim.
Note
A second technician must hold the lid securely when the bottom
of the rear lid gas strut -3- is disengaged.
– Lift the retaining spring -2- with a small screwdriver -1-

-arrow- and remove the bottom of the gas-filled strut from the
ball stud.
– Remove the left -1- and right -3- engine compartment trim by
loosening the quick-release fasteners.
Installing
– Carefully press the engine cover -2- back into the retainer.
– Install the engine compartment trim -1 and 3-.
– Secure the gas-filled struts with the fastener.
5.4 Engine Control Module - J623-

♦ Hot Air Blower - VAS 1978/14A- with nozzle attachment from
the Wiring Harness Repair Kit - VAS 1978 B- .
♦ Small commercially available locking pliers

Note
♦ The Engine Control Module (ECM) -1- is bolted to a protective

housing -5-. To make removing the shear bolts -4- for the re‐
taining tabs -2- more difficult, the threads are coated with
locking compound.
♦ To disconnect the connectors from the ECM (for example to
connect the test box or to replace the ECM), the protective
housing must be removed.
Removing
– If the ECM was replaced, select “replaced engine control mod‐
ule” in “Guided Functions” using the vehicle diagnosis tester.
– Turn the ignition and remove the ignition key. with respect to the correctness of information in this document. Copyright by AUDI AG.

R8 Coupe
– Remove the right engine compartment trim. Refer to ⇒ Body
Exterior; Rep. Gr. 53 ; Removal and Installation .
– Open the four nuts on the ECM retaining clips and tilt the clips
to the side.
– Remove the ECM -3-.
R8 Spyder
– Remove the cover -1-.

– Loosen the bolts -arrows- and remove them with the clips.
– Remove the Engine Control Module - J623- .
All Vehicles
The ECM is secured with a retainer and shear bolts with a pro‐
tective housing to make it more difficult to access the connectors.

The threads of the shear bolts -4- (that are not installed in the
ECM) are coated with a locking compound. For this reason, the
threads must be heated with the heat gun to remove both bolts.
The threads of both shear bolts -3- (that are installed in ECM) are
not coated with a locking compound. The threads in the ECM
housing must not be heated and do not require to be heated (un‐
intentional heating of the ECM).
Set the adjustment on the heat gun as shown in the illustration,

with the temperature potentiometer -2- set to maximum heat and
the two-stage airflow switch -3- set to level 3.
WARNING
By heating the threads, the retaining tabs, shear bolts and parts
of the metal housing become very hot. Do not burn yourself on
this! Make sure that only the threads are heated as much as
possible, and not any of the surrounding parts. Possibly cover
these parts.
Warm threads on connector side of shear bolts as shown in the

illustration.
Switch on the heat gun and heat the bolt for approximately 20 to
30 seconds.
– Remove shear bolts with suitable locking pliers (see direction

of -arrow-).
– The shear bolts installed in the ECM do not need to be heated
for removal. They can be removed without heat.
– Disconnect metal retainers from the connectors.
– Remove both retainer bolts from the ECM.

– Disengage the connectors from the ECM and disconnect the

connector.
– Remove the used ECM and connect the new ECM.
Installing the ECM
Installation is carried out in the reverse order while noting the fol‐
lowing:
– After that, the ECM must be equipped with the metal retainer.
– Clean threaded holes for the shear bolts of locking compound
Perform the Following Step after Installing a New ECM
– Activate the ECM in “Guided Functions” under “replace engine
control module”. Use a vehicle diagnosis tester for this.
5.5 Engine Control Module 2 - J624-

♦ Hot Air Blower - VAS 1978/14A- with nozzle attachment from
the Wiring Harness Repair Kit - VAS 1978 B- .
♦ Small commercially available locking pliers
Note
♦ The ECM -1- is bolted to a protective housing -5-. To make

removing the shear bolts -4- for the retaining tabs -2- more
difficult, the threads are coated with locking compound.
♦ To disconnect the connectors from the Engine Control Module
(ECM) (for example to connect the test box or to replace the
ECM), the protective housing must be removed.
Removing
– If the ECM was replaced, select “replaced engine control mod‐
ule” in “Guided Functions” using the vehicle diagnosis tester.
– Turn the ignition and remove the ignition key.
R8 Coupe
– Remove the left engine compartment trim. Refer to ⇒ Body
Exterior; Rep. Gr. 53 ; Removal and Installation .
– Open the four nuts on the engine control module 2 - J624-

retaining clips and tilt the clips to the side.
– Remove Engine Control Module 2 - J624- -3-.
R8 Spyder:

– Remove the cover -1-.

– Loosen the bolts -arrows- and remove them with the clips.
– Remove the Engine Control Module 2 - J624- .
All Vehicles
The ECM is secured with a retainer and shear bolts with a pro‐
tective housing to make it more difficult to access the connectors.
The threads of the shear bolts -4- (that are not installed in ECM)
are coated with a locking compound. For this reason, the threads
must be heated with the heat gun to remove both bolts.
The threads of both shear bolts -3- (that are installed in ECM) are
not coated with a locking compound. The threads in the ECM
housing must not be heated and do not require to be heated (un‐
intentional heating of the ECM).
Set the adjustment on the heat gun as shown in the illustration,

with the temperature potentiometer -2- set to maximum heat and
the two-stage airflow switch -3- set to level 3.
WARNING
By heating the threads, the retaining tabs, shear bolts and parts
of the metal housing become very hot. Do not burn yourself on
this! Make sure that only the threads are heated as much as
possible, and not any of the surrounding parts. Possibly cover
these parts.
Warm threads on connector side of shear bolts as shown in illus‐

tration.
Switch on heat gun and heat the bolt for approximately 20 to 30

seconds.

– Remove shear bolts with suitable locking pliers (see direction

of -arrow-).
– The shear bolts installed in the ECM do not need to be heated
for removal. They can be removed without heat.
– Disconnect metal retainers from the connectors.
– Remove both retainer bolts from the ECM.
– Disengage the connectors from the ECM and disconnect the

connector.
– Remove the old ECM and connect the new ECM.
Installing
Installation is carried out in the reverse order while noting the fol‐
lowing:
– After that, the ECM must be equipped with the metal retainer.
– Clean threaded holes for shear bolts of locking compound
Perform the Following Step after Installing a New ECM
– Activate the ECM in “Guided Functions” under “replace engine
control module”. Use a vehicle diagnosis tester for this.
5.6 Fuel Injectors

♦ Torque Wrench - V.A.G 1331-
♦ 17 mm Socket - V.A.G 1331/6-
♦ Socket Insert AF14 - V.A.G 1331/8- for the fuel supply line.
♦ Tool Set - T10133-
♦ Round file approximately 6 mm

Convert the puller -T10133/2- to the puller -T10133/2 A- .

– File the semicircle as shown in the illustration. The semi-circle
allows the tool to slide farther onto the fuel injector, thus pro‐
viding the tool with a larger contact surface.
– Mark the modified tool with an "A" at the end of the tool num‐
ber.
Removing
WARNING
♦ Fuel system is under high pressure! Before opening high

pressure components of the fuel injection system, pres‐
sure must be relieved to residual pressure. Refer to
page 34 .
♦ Then wrap a clean cloth around the connection and relieve
residual pressure by carefully loosening the connection.
– Remove the intake manifold. Refer to

⇒ “5.10 Intake Manifold”, page 68 .
Note
♦ Seal intake channels in cylinder heads with clean cloths.

♦ The illustration shows the left cylinder bank.
fuel rail with fuel supply line

– Remove the bolts -1 and 3- and the clamp -2-.
– Remove the union nuts -arrows- and then carefully push the
fuel return line to the side.
Note
Do not change the shape of the fuel return line.
fuel rail with fuel return hose:

– Remove the return hose -6- from the fuel rail connection.
All:
– Disconnect the connectors from the fuel injectors.
– Remove the high pressure line from the fuel rail connector and
the high pressure pump -arrows-.
– Remove bolts -1, 2, 3, 4, 5 and 7-.permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
Do not bend the high pressure line to a different angle.
– Remove fuel rail with fuel injectors.

If the fuel injectors cannot be pulled out of the cylinder head by

hand, proceed as follows:
Version 1 fuel injection valves:
– Bend the tabs -1- on the radial balance to the side -arrow-
using a screwdriver.
All:
– Remove the support ring -2- from the fuel injector.
– Disconnect the connector.
– Mount the puller -T10133/2A- into the groove on the fuel in‐
jector.
– Mount the puller -T10133/16A- and turn to the bolt -1- to re‐
move the fuel injector.
Note
♦ When setting the puller in place, the radial adjustment can be

destroyed, because the retaining tabs break.
♦ The combustion chamber sealProtected
must always be replaced be‐
fore installing the high-pressure fuel injector.

Fuel Injector Version 1, Disassembling

– Remove the o-ring -5- and spacer ring -4- from the fuel injector
-3-.
– Replace the old combustion chamber seal -2- ⇒ page 59 .
Fuel Injector Version 2, Disassembling

– Remove the o-ring -3- and spacer ring -2- from the fuel injector
-1-.
– Remove the seal -5-.
– Replace the old combustion chamber seal -6- ⇒ page 59 .

Combustion Chamber Seal (Teflon Seal), Replacing

– Carefully remove the old Teflon seal -arrow- with the appro‐
priate tool (e.g. with cut the seal open with a razor and spread
seal open with a small screwdriver and pull it forward and off.)
When doing this, make sure not to damage the groove and
circumferential rib in the groove base.
Note
If the groove is damage, the fuel injector must be replaced.
– When installing a fuel injector, use a clean cloth to clean com‐

bustion residue from the groove for combustion chamber seal
and the shaft of the fuel injector.
– Place the Assembly Cone - T10133/5- with the new combus‐

tion chamber seal -1- onto the fuel injector -2-.
– Push the combustion chamber seal onto the Assembly Cone

- T10133/6- as far as possible using the Guide Sleeve -
T10133/5-
– Turn the Assembly Sleeve

Protected - T10133/6-
by copyright. Copying foraround and push
private or commercial the in part or in whole, is not
purposes,
combustion chamber seal
permitted into
unless the groove.

Note
When pushing the combustion chamber seal onto the fuel injec‐
tor, the seal spreads open. Therefore after pushing it on, it must
be tightened again in two steps, as follows.
– Press the Sizing Sleeve - T10133/7- with a slight turning mo‐

tion (approximately 180°) onto the fuel injector until it stops.
– Pull the sizing sleeve -T10133/7- off again, turning it in the
opposite direction.
– Press the sizing sleeve -T10133/8- with a slight turning motion

(approximately 180°) onto the fuel injector until it stops.
– Pull the Sizing Sleeve - T10133/8- off again using a turning
motion in the opposite direction.
Note
♦ Replace the o-ring.

♦ Replace spacer ring if damaged.

– Install the components from the repair set on the fuel injector
-3-:
1 - Radial Adjustment
4 - Spacer Ring
5 - O-Ring
6 - Support Ring
– Clip the radial adjuster -1- onto the support ring -2-.


– Install the components from the repair set on the fuel injector
-1-:
2 - Spacer Ring
3 - O-Ring
4 - Support Ring
5 - Washer
All:
– Coat the new o-ring with oil before installing it. This makes it
easier to install the fuel injector in the fuel rail.
Note
♦ Do not oil or grease the combustion chamber sealing ring on

the fuel injector.
♦ When installing the injector valve, make sure there is no clean‐
ing product or oil in the holes in the cylinder head.
Fuel Injectors, Installing

– Clean the hole in the cylinder head with the nylon cylinder
brush - T10133/4- .
– Moisten the new O-ring with clean engine oil before installing.
– Insert the fuel injector all the way into the hole in the cylinder
head using the assembly mandrel -T10133/9- .
• The electrical connection of the fuel injector must engage in
the intended recess of the cylinder head.
Note
The fuel injector must not be difficult to install. If necessary, wait

as the combustion chamber seal continues to pull itself together.
– Make sure the fuel injector is positioned correctly in the cylin‐

der head:
• The electrical connection of the fuel injector must engage in
the intended recess of the cylinder head.

– Press fuel rail evenly onto fuel injectors.

– Tighten bolts -1, 2, 3, 4, 5 and 7- in stages in a diagonal se‐
quence.
Note
♦ The high pressure line connectors -arrows- must not be dam‐

aged.
♦ Do not bend the high pressure line to a different angle.
– Next tighten the ring nuts by hand.

– Make sure the lines do not have tension.
– To tighten the ring nuts use Torque Wrench 5-50Nm - V.A.G
1331- with the corresponding socket.
– Only install the retaining tabs after tightening the high pressure
line.
– Install the intake manifold. Refer to
– Perform a leak test. Refer to
⇒ “4.3 Leak Test on Vehicle”, page 42 .
5.7 Fuel Pressure Sensor - G247-
Note
Removing and installing the Fuel Pressure Sensor - G247- on

cylinder bank 1 (right) is shown in the illustration.
Removing with respect to the correctness of information in this document. Copyright by AUDI AG.
The fuel pressure sensor measures the actual fuel pressure in the
high pressure system and delivers a voltage signal to the Engine
Control Module - J623- .
WARNING
♦ Follow the guidelines for a clean working environment

when working on the fuel system
⇒ “1.1.3 Test and Measuring Instruments during Test
Drive”, page 3 .
♦ Always follow these rules before and during work.

– Clean the threads around the fuel pressure sensor with a com‐
mercially available cold cleaner before removing.
Note
Clean carefully, cleaner must not enter the connector.
– Dry the fuel pressure sensor.

– Disconnect the Fuel Pressure Sensor - G247- connector -1-.

– Remove the Fuel Pressure Sensor - G247- -2-.
– Suction any dirt out of the hole, the threads and the sealing
surface. Do not use mechanical tools.
Note
Seal the hole immediately with a suitable plug to prevent dirt from
entering.
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Install in reverse order of removal. Note thewith
following:
respect to the correctness of information in this document. Copyright by AUDI AG.
• For the correct tightening specification for the Fuel Pressure

Sensor - G247- , refer to
⇒ “2.2 Fuel Injection System Component Location”, page 9 .
– Install the intake manifold. Refer to
5.8 High Pressure Pumps

⇒ “5.8.1 High Pressure Pump with Fuel Supply Hose”,
page 63
⇒ “5.8.2 High Pressure Pump with Fuel Supply Line”, page 65
5.8.1 High Pressure Pump with Fuel Supply

Hose
♦ 17 mm Socket - V.A.G 1331/6-
♦ Assembly Tool - T10118-
Removing
WARNING

page 34 .
– R8 Coupe: Remove the affected engine compartment trim.

Refer to ⇒ Body Exterior; Rep. Gr. 53 ; Removal and Instal‐
lation .

– R8 Spyder: Remove engine compartment trim -1-. Refer to ⇒

Remove the high pressure pump from cylinder bank 1.

– Disconnect the connector -1- from the fuel pressure sensor -
N290- .
– Loosen the high pressure line union nut.
– Remove the fuel supply line from the high pressure pump.
– Remove the high pressure pump bolts.
Note
Do not change the angles of the high pressure lines.

– Carefully remove high pressure pump.

– Remove roller tappet from cylinder head.

– Disconnect the connector -1- from the fuel metering valve 2 -
N402- .

– Remove the bolts -1- and press the fuel line to the side to open
the union nut on the high pressure pump.
– Loosen the high pressure line union nut.
– Remove the fuel supply line from the high pressure pump.
– Remove the high pressure pump bolts.
Note

Installing
Note
Always replace O-ring.
– Insert roller tappet in cylinder head.

– Only raise the fuel lines slightly to insert the high pressure
pump.
– Insert high pressure pump in cylinder head and tighten.
♦ Tightening specifications, see High pressure pump, assembly
overview ⇒ “2.3 High Pressure Pump Overview”, page 22 .
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Coat the thread on the union nut with clean engine oil.
♦ High pressure line connections must not show any signs of

damage.
♦ Do not change the angles of the high pressure lines.
– Tighten the high pressure line union nut by hand.

– Ensure the fuel lines are seated without tension.
– To tighten the 17 mm high pressure union nut, use the torque
wrench - V.A.G 1331- with 17 mm socket - V.A.G 1331/6- .
♦ High pressure line tightening specification, see High Pressure
Pump, Assembly Overview
⇒ “2.3 High Pressure Pump Overview”, page 22 .
5.8.2 High Pressure Pump with Fuel Supply

Line
♦ 17 mm Socket - V.A.G 1331/6-
♦ Socket Insert AF14 - V.A.G 1331/8- for the fuel supply line.


Removing
WARNING

page 34 .
– R8 Coupe: Remove the affected engine compartment trim.

Refer to ⇒ Body Exterior; Rep. Gr. 53 ; Removal and Instal‐
lation .
– R8 Spyder: Remove engine compartment trim -1-. Refer to ⇒

– Disconnect the connector -3- from the Fuel Metering Valve -
N290- .
– Loosen the high pressure line ring nut -1- and the fuel supply
line -2-.
– Remove the high pressure pump bolts -arrows-.
Note



– Disconnect the connector -1- on the fuel metering valve 2 -
N402- .
– Loosen the high pressure line ring nut -2- and the fuel supply
line -3-.
– Remove the high pressure pump bolts -arrows-.
Note

Installing
Note
Always replace O-ring.
– Insert roller tappet in cylinderProtected

head.by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Only raise the fuel lines slightlywithtorespect
insert thecorrectness
to the high pressure
pump.
– Insert high pressure pump in cylinder head and tighten.
♦ Tightening specifications, see High pressure pump, assembly
overview ⇒ “2.3 High Pressure Pump Overview”, page 22 .
Note
♦ Coat the thread on the union nut with clean engine oil.
♦ High pressure line connections must not show any signs of
damage.
♦ Do not change the angles of the high pressure lines.
– Tighten the high pressure line union nut by hand.

– Ensure the fuel lines are seated without tension.
– To tighten the ring nuts use the Torque Wrench 5-50Nm -
V.A.G 1331- with the corresponding socket.
♦ For tightening specifications of the high pressure and fuel sup‐
ply lines see high pressure pump assembly overview. Refer to
⇒ “2.3 High Pressure Pump Overview”, page 22 .

5.9 Intake Flap Vacuum Actuator

Removing
– Disconnect vacuum hose -1-.
– Press the mounting pins -arrow- back out of the actuator rod.
– Remove bolts -2- and -3- and the vacuum actuator.
Installing
– Press the mounting pins -2- into the actuator rod -1- from be‐
hind.
– Ensure the rounded area -arrow- on the head of the mounting
pin engages in the opening on the actuator rod.
5.10 Intake Manifold

Removing
R8 Coupe:

Note
A vehicle with a manual/R tronic transmission 086 is shown in the

following illustration.
– Remove the vacuum lines -3- and -5-.

Rest of world vehicles:
– Remove the crankcase ventilation hose -4- from the air guide
hose by pressing the release tabs.
– Remove the left and right air guide hose by loosening hose
clamps -1, 2, 6 and 7-.
USA vehicles:
– Remove the left air guide hose by loosening hose clamps -1-
and -2-.
– Move the right air guide hose with the crankcase ventilation
hose -4- attached to the side by loosening hose clamps -6-
and -7-.
Caution permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
USA vehicles only.

♦ Do not open hose connection -4-!
R8 Spyder:
– Remove the air filter housing. Refer to
⇒ “5.2 Air Filter Housing”, page 47 .
– Remove the throttle valve control unit -J338- / -J544- . Refer
to
⇒ “5.12 Throttle Valve Control Module J338/J544 ”,
page 74 .
– Remove engine compartment trim -1-. Refer to ⇒ Body Exte‐
rior; Rep. Gr. 53 ; Removal and Installation .
All:
– Remove the crankcase ventilation hoses -arrows-.
– Remove vacuum hoses -1- and -2- to the EVAP canister.
– Remove the bolt from the high pressure fuel line retaining
clamp on the rear of the intake manifold.

Vehicles with fuel hoses:

– Remove the bolt -arrow- on the retaining clamp.
– Disconnect the connector -1- from the Throttle Valve Control
Module - J338- .
Vehicles with fuel lines:

– Remove the bolts -arrows- from the retaining clamps.
Module - J338- .
All:
Module 2 - J544- and connector -2- from the Intake Manifold
Runner Position Sensor 2 - G512- .
– Remove the bolts -1- on the fuel line.

– Remove the bolt -arrow- on the wiring harness bracket and
move the wiring harness to the side.

Vehicles with one vacuum reservoir:

– Disconnect the connector -1- from the Intake Manifold Runner
Position Sensor - G336- and connector -2- from the Intake
Manifold Runner Control Valve - N316- .
– Disconnect the vacuum hose -3- to the vacuum reservoir and
vacuum hose -4- to the secondary air injection solenoid valve
- N112- .
Vehicles with two vacuum withreservoirs:
– Disconnect the connector -1- from the Intake Manifold Runner

Position Sensor - G336- and connector -3- from the Intake
Manifold Runner Control Valve - N316- .
– Disconnect the vacuum lines -2- to the vacuum reservoir and
vacuum hose -4- to the Secondary Air Injection Solenoid Valve
- N112- .
All:
– Remove the bolt -arrow- and move the bracket with the wiring
harness to the side.

– Remove the bolts in a -10 to 1- sequence and remove the in‐

take manifold.
Note
Seal intake channels in cylinder heads with clean cloths.
Installing
• Tightening specifications, see intake manifold assembly over‐
view ⇒ “2.4 Intake Manifold Overview”, page 25 and
⇒ Fig. ““Intake manifold tightening specification”“ , page 27 .
Note
♦ If a fuel injector was removed form the cylinder head, then the
Teflon seal must be replaced. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Replace the seals


alog.
♦ When installing, bring all cable ties back to same positions.
– Install the Throttle Valve Control Module. Refer to

⇒ “5.12 Throttle Valve Control Module J338/J544 ”,
page 74 .
– Install the air filter housing. Refer to
– Install the engine compartment trim.
– Delete any DTC memory entries that occurred during testing
5.11 Oxygen Sensors

♦ Oxygen Sensor Wrench Set - 3337-
Removing
– Remove the air filter housing. Refer to
R8 Spyder:
– Remove the service flap. Refer to ⇒ Body Exterior; Rep. Gr.
55 ; Removal and Installation .

Vehicles with manual/R tronic transmission 086

– Remove the electrical connectors from the bracket and dis‐
connect:
1- For the Oxygen Sensor 2 after Catalytic Converter - G131-
2- For the Heated Oxygen Sensor 2 - G108-
3- For the Heated Oxygen Sensor - G39-
4- For the Oxygen Sensor after Three Way Catalytic Converter
- G130-
– Free up electrical wires to oxygen sensors.
Vehicles with DSG transmission 0BZ:

– Remove the electrical connectors from the bracket and dis‐
connect:
G130-
Heated Oxygen Sensor - G39- before catalytic converter and

Oxygen Sensor after Three Way Catalytic Converter - G130- cyl‐
inder bank 1 (right):
– Remove the Heated Oxygen Sensor - G39- -2- using Ring
Spanner Set - 3337- .
– Remove the Oxygen Sensor After Three Way Catalytic Con‐
verter - G130- -1- using a tool from the Ring Spanner Set -
3337- .

Oxygen Sensor 2 before Catalytic Converter - G108- and Oxygen

Sensor 2 after Catalytic Converter - G131- cylinder bank 2 (left):
– Remove the engine compartment crossmember. Engine Me‐
chanical. Refer to ⇒ Engine Mechanical; Rep. Gr. 10 ;
Removal and Installation .
Note
The installation location is shown with the engine removed.

– Remove the Heated Oxygen Sensor 2 - G108- -1- using a tool
from the Ring Spanner Set - 3337- .
– Remove the Oxygen Sensor 2 After Catalytic Converter -
G131- -2- using a tool from the Ring Spanner Set - 3337- .
Installing
• Tightening specifications, see oxygen sensor assembly over‐
view, refer to ⇒ “2.6 Oxygen Sensors Overview”, page 33
Note
♦ New oxygen sensors are coated with assembly paste; the

paste must not get into slots of oxygen sensor body.
♦ For a used oxygen sensor, only coat threads with hot bolt
paste. This paste must not come into contact with oxygen
sensor slots. Hot bolt paste. Refer to Parts Catalog.
♦ Always install the oxygen sensor wire in the same location so
it does not come into contact with the exhaust pipe.
– Install the engine compartment crossmember. Engine Me‐

chanical. Refer to ⇒ Engine Mechanical; Rep. Gr. 10 ;
– Install the air filter housing. Refer to ⇒ page 47 .
– Install the service flap. Refer to ⇒ Body Exterior; Rep. Gr. 55 ;
Check DTC memory , and then Generate
Protected readiness
by copyright. code
Copying for private .
or commercial purposes, in part or in whole, is not
5.12 Throttle Valve Control Module - J338/
J544-
Removing

Right throttle valve control module - J338- :

– Loosen the hose clamps -arrows- and remove the air guide
hose.
– Move the air guide hose, with the crankcase housing ventila‐
tion hose -1- still connected, to the side.
Left throttle valve control module 2 - J544- :

– Loosen the hose clamps -arrows- and remove the air guide
hose.
– Move the brake booster air guide hose with the vacuum hose
still attached -1- to the side.
Continued for both sides:

– Disconnect the connector -1-.
– Remove the bolts -arrows- and the throttle valve control mod‐
ule.
Installing
• Tightening specifications. Refer to
⇒ “2.4 Intake Manifold Overview”, page 25 .
Note
♦ Replace the seals

♦ The hose connections as well as the air guide pipes and hoses
must be free of oil and grease before installing.
alog.
♦ In order to be able to mount the air guide hoses on their con‐
nectors, spray the screws on the previously used clamps with
a rust remover.

– After replacing, perform an “Adaptation” in “Guided Func‐
tions”. Refer to Vehicle Diagnostic Tester.

6 Special Tools
♦ Ring Spanner 7-Piece Set - 3337-
♦ Pry Lever - Rmv Outside Mirror - 80 - 200-
♦ Tool Set - T10133-
♦ Adapter - V.A.G 1318/11-

♦ Adapter - V.A.G 1318/12-

♦ Torque Wrench 5-50 Nm - V.A.G 1331-
♦ Tool Insert, AF 17 - V.A.G 1331/6-
♦ Remote Control - V.A.G 1348/3A- with Remote Control - V.A.G

1348/3-3-
♦ Adapter Lead - V.A.G 1598/39-1-
♦ Adapter Lead,
with respect to the94-Pin - V.A.G
correctness 1598/39-2-
♦ Test Box 105-Pin - V.A.G 1598/42-

♦ Hot Air Blower - VAS 1978/14A- -1- with nozzle attachment
-2- from the Wiring Harness Repair Kit - VAS 1978 B- .
♦ Small commercially available locking pliers -3-
6. Special Tools 77
♦ Hand Vacuum Pump - VAS 6213-
♦ Rear End Protector - VAS 6411-
♦ Side Panel Protector - VAS 6412-

♦ Door Protectors - VAS 6413-
♦ Side Panel Protector for Audi R8 Spyder - VAS 6428-
♦ Not illustrated:
♦ Connector Test Set - V.A.G 1594C-

28 – Ignition/Glow Plug System

1 General Information
⇒ “1.1 Safety Precautions”, page 79
⇒ “1.2 Ignition System”, page 79
1.1 Safety Precautions

If special testing equipment is required during road test, note the
following:
WARNING
Improperly secured testing and measuring equipment and dis‐

traction during a road test increase the risk of an accident.
The passenger airbag could pose a risk if it deploys in a colli‐
sion.
• Operating testing equipment while driving causes it to shift
position.
• There is an increased risk of injury due to unsecured test‐
ing equipment.
♦ Position passenger's seat as far back as possible.
♦ Do NOT use the following vehicle diagnosis testers: VAS
5051 , VAS 5051A and VAS 5051B .
♦ Testing and measuring instruments -1- must lay flat on the
passenger's thighs and be operated by him or her, as
shown in the illustration.
To reduce the risk of personal injury and/or damage to the fuel

injection and ignition system, always observe the following:
♦ Do not touch or remove ignition wires when the engine is run‐
ning or turning at starter speed.
♦ Always switch ignition off before disconnecting or reconnect‐
ing wires for the ignition system, including high voltage wiring
and test leads.
♦permitted
If theunless
engine is to be cranked at starting RPM without starting
(for example for compression testing), disconnect connectors
from ignition coils and from fuel injectors. After performing
work, check and erase Diagnostic Trouble Code (DTC) mem‐
ory.
♦ If the DTC memory was erased, then it is necessary to gen‐
erate a readiness code in the Engine Control Module (ECM)
in “Guided Functions” vehicle diagnosis tester.
♦ Cleaning the engine should only be performed with ignition
switched off.
♦ The battery must only be disconnected and connected with the
ignition switched off, since the ECM can otherwise be dam‐
aged.
1.2 Ignition System

♦ The Engine Control Module (ECM) is equipped with On Board
Diagnostics (OBD).
♦ For the electric components to work properly, a voltage of at

least 11.5 Volts is required.
♦ It is possible that the control module will recognize a malfunc‐
tion and store a Diagnostic Control Module (DTC) during some
tests. After completing all checks and repairs, check the DTC
memory and erase the memory, if necessary.
♦ If the engine only starts briefly and then turns off again after
troubleshooting, repair or checking of the components, it may
be that the immobilizer is blocking the ECM. The DTC memory
must then be checked and if necessary, control module must
be adapted.
80 Rep. Gr.28 - Ignition/Glow Plug System

2 Description and Operation

⇒ “2.1 Ignition Overview”, page 81
2.1 Ignition Overview
1 - Ignition Coil Connector

❑ 4-pin
2 - Bolt
❑ 10 Nm
3 - 3-Pin Connector
4 - Camshaft Position (CMP)
Sensor
❑ Camshaft Position
(CMP) sensor - G40-
cylinder bank 1
(CMP) sensor 3 - G300-
cylinder bank 1
cylinder bank 2
cylinder bank 2
5 - O-ring
oil
6 - Bolt permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 20 Nm
❑ Tightening specifica‐
tions affect the function
of the knock sensor
7 - Knock Sensors (KS)
❑ contact surfaces be‐
tween knock sensor and
cylinder block must be
free of corrosion, dirt
and grease
❑ Knock Sensor (KS) 1 - G61- cylinder bank 1
8 - Spark Plug
❑ 30 Nm
❑ Removing and installing with the spark plug removal tool - 3122 B- , refer to Maintenance Procedures
Rep. Gr. 03
9 - Ignition Coil


❑ Removing and installing, refer to ⇒ “4.3 Ignition Coils”, page 87
❑ To remove, use the ignition coil puller - T40039-

3 Specifications
⇒ “3.1 Fastener Tightening Specifications”, page 83
⇒ “3.2 Test Data”, page 83
3.1 Fastener Tightening Specifications

Camshaft PositionProtected
Sensor by copyright. Copying for private or commercial purposes, in part or in whole, is not- 10
Ignition Coil Electrical
withWiring
respect toto
theCylinder Head
correctness of Cover
information in this document. Copyright by AUDI AG. - 5
Knock Sensors - 20
Spark Plug - 30
3.2 Test Data

Engine Data 4.2L / 4V FSI Engine
Idle speed (not adjustable)
Ignition timing Not adjustable, regulated by the control module
Ignition/Glow Plug System Single coil ignition system with 8 ignition coils (out‐
put stages integrated) that are connected directly to
spark plugs via the ignition cables.
Spark plugs Names ⇒ Data sheets for exhaust emission test
Tightening Specifications Maintenance Procedures Rep. Gr. 03
Ignition sequence 1-5-4-8-6-3-7-2
3. Specifications 83
4 Removal and Installation

⇒ “4.1 Camshaft Position Sensor”, page 84
⇒ “4.2 Engine Speed Sensor G28 ”, page 86
⇒ “4.3 Ignition Coils”, page 87
⇒ “4.4 Knock Sensors”, page 89
4.1 Camshaft Position Sensor

Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
During installation, install all heat insulation sleeves at the same

locations.
R8 Coupe
R8 Spyder
– Remove engine compartment trim -1-. Refer to ⇒ Body Exte‐
rior; Rep. Gr. 53 ; Removal and Installation .
Removing on Cylinder Bank 1 (Right):

Camshaft Position Sensor 3 - G300- :
– Remove the bolts -5-.
– Slide the coolant reservoir forward slightly -arrow- and remove
it from the bracket.
– Tie the coolant reservoir with connected coolant hoses
-1, 3 and 4- and connected electrical connector -2- to the rear
lid hinge.
– Remove the bolt -arrows- and the coolant reservoir bracket.

R8 Spyder
– Remove the bolts -4 and 6-, the nut -1- and the heat shield
-2-.
– Remove the bolts -3- and -5- on the wiring harness bracket.
All Vehicles
– Remove the bolts -arrows- and remove the heat shield -1-.
Camshaft Position (CMP) Sensor - G40- / Camshaft Position

(CMP) Sensor 3 - G300-
– Disconnect the connector on the respective camshaft position
sensor.
– Remove the bolt and remove the respective camshaft position
sensor.
4 - Camshaft Position Sensor - G40-
9 - Camshaft Position Sensor 3 - G300-
Removing on cylinder bank 2 (left):

Camshaft Position Sensor 4 - G301- :
– Remove the bolts -arrows- and remove the heat shield -1-.

Camshaft Position Sensor 2 - G163- / Camshaft Position Sensor

4 - G301- :
– Disconnect the connector on the respective camshaft position
sensor.
– Remove the bolt and remove the respective camshaft position
sensor.
Installing
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Replace the O-ring if damaged
– Coat the o-ring with clean engine oil and carefully press the
camshaft position sensor in by hand.
– Tighten the camshaft position sensor and connect the electri‐
cal connector.
– Install the heat shield.
♦ Tightening specification: Ignition System Assembly Overview,
refer to ⇒ “2.1 Ignition Overview”, page 81
4.2 Engine Speed Sensor - G28-

page 86
4.2.1 Vehicles with Manual/R tronic Transmis‐

sion 086
Removing
– Remove the power steering pump. Refer to Suspension, FWD
and AWD - Steering ⇒ Suspension, Wheels, Steering; Rep.


– Remove the bolt -1- and the engine speed sensor - G28- .
Installing
– Install power steering pump. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 48 ; Removal and Installation .
♦ Tightening specification: installed location overview, refer to
Note
Depending on the version, the Engine Speed Sensor - G28- is on

the left or the right of the transmission.
Removing
– Remove the underbody cover. Refer to ⇒ Body Exterior; Rep.
– Remove the bolt -2-.
– Remove the Engine Speed Sensor - G28- -3-.
Installing
♦ Tightening specification: installed location overview, refer to
– Install the underbody cover. Refer to ⇒ Body Exterior; Rep.
4.3 Ignition Coils

♦ Ignition Coil Puller - T40039-
Removing
R8 Coupe

R8 Spyder
– Remove the left engine compartment trim panel -1-. Refer to
⇒ Body Exterior; Rep. Gr. 53 ; Removal and Installation .

– Remove the bolts -5-.
– Slide the coolant reservoir forward slightly -arrow- and remove
it from the bracket.
– Move the coolant reservoir with the coolant hoses still con‐
nected -1, 3 and 4- and the connector still connected -2- and
tie it up.
– Remove the bolts -1- and -2-.

Removing on Cylinder Bank 2 (Left):
– Remove the bolts permitted
-1withand 2-.
– Remove the bolts -1- and -2-.

Continued for both sides:

– Pull the ignition coils out of the spark plug shaft using a Puller
- T40039- .
– Release electrical connectors and remove connectors simul‐
taneously from ignition coils.
Installing the Ignition Coils
– Insert all ignition coils loosely into spark plug shaft.
– Align the ignition coils to the connectors and then connect all
of the connectors simultaneously onto the ignition coils.
– Press the ignition coils uniformly onto the spark plugs by hand
(do not use any impact tools).
Tightening Specifications
Component Nm
Ignition coil electrical wiring to cylinder head 5
cover
4.4 Knock Sensors

Removing
– Remove intake manifold. Refer to
⇒ “5.10 Intake Manifold”, page 68
WARNING
♦ Fuel system is under high pressure! Before opening the

high pressure components

with respectof thecorrectness
fuel injection system,
to the of information in this document. Copyright by AUDI AG.
pressure must be relieved to residual pressure. Refer to
page 34 .
♦ Then wrap a clean rag around the connection and relieve
Electrical Connectors
7 - Knock Sensors (KS) 4 - G199-


– Remove the bolt -1- and the ring nuts -arrows-.
– Free up the high pressure lines and carefully push aside.
Note
Do not bend the high pressure line to a different angle.
– Remove the bolts -arrows- and
with the bracket
respect -1-. of information in this document. Copyright by AUDI AG.
to the correctness
– Remove the corresponding knock sensor and free up the

wires.
10 - KS 1
6 - KS 2

Removing on Cylinder Bank 2 (Left):

– Remove the corresponding knock sensor and free up the
wires.
10 - KS 3
7 - KS 4
Installing
♦ Tightening specification: Ignition System Assembly Overview,
refer to ⇒ “2.1 Ignition Overview”, page 81 .
Note
Tightening specifications affects function of KS.
– Reinstall intake manifold. Refer to


5 Special Tools
♦ Ignition Coil Puller - T40039-
Edition 08.08.2013

Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in
this manual, we suggest you leave such repairs to an authorized Audi retailer or other qualified
shop. We especially urge you to consult an authorized Audi retailer before beginning repairs on
any vehicle that may still be covered wholly or in part by any of the extensive warranties issued by
Audi.
•= Disconnect the battery negative terminal (ground strap)whenever you work on the fuel system or
the electrical system. Do not smoke or work near heaters or other fire hazards. Keep an approved
fire extinguisher handy.
•= Audi is constantly improving its vehicles and sometimes these changes, both in parts and
specifications, are made applicable to earlier models. Therefore, part numbers listed in this
manual are for reference only. Always check with your authorized Audi retailer parts department
for the latest information.
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be
necessary to reestablish Transmission Control Module (TCM) basic settings using the VAG 1551
Scan Tool (ST).
•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose.
Do not support a vehicle on cinder blocks, hollow tiles or other props that may crumble under
continuous load. Never work under a vehicle that is supported solely by a jack. Never work under
the vehicle while the engine is running.
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before
disconnecting the battery
permitted or removing
unless authorised the radio.
by AUDI If the
AG. AUDI AG wrong code isorentered
does not guarantee accept any when
liability the power is
restored, the radio maywith lock
respectup and
to the become
correctness inoperable,
of information even if Copyright
in this document. the correct
by AUDIcode
AG. is used in a later
attempt.
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block
the wheels to keep the vehicle from rolling. Disconnect the battery negative terminal (ground
strap) to prevent others from starting the vehicle while you are under it.
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to
yourself and others if you are tired, upset or have taken medicine or any other substances that
may impair you or keep you from being fully alert.
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work
with acid. Wear goggles, gloves and other protective clothing whenever the job requires working
with harmful substances.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when
you work near machine tools or running engines. If your hair, clothing, or jewelry were to get
caught in the machinery, severe injury could result.
=Page 1 of 3
© 2002 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual
property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be
reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be
modified or reposted to other sites, without the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are
designed to be used only once and are unreliable and may fail if used a second time. This
includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow the
recommendations in this manual - replace these fasteners with new parts where indicated, and
any other time it is deemed necessary by inspection.
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or
under the vehicle. Make sure the bulb is enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create
dust by grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and
asbestos dust. Breathing asbestos can cause serious diseases such as asbestosis or cancer, and
may result in death.
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running
machinery, or be crushed by heavy parts.
•= Before starting a job, make certain thatpermitted
you haveunless all the necessary
authorised tools
by AUDI AG. AUDI AGand parts
does not on hand.
guarantee Read
or accept any liability
all the instructions thoroughly, do not attempt shortcuts. Use tools that are appropriate to the work
and use only replacement parts meeting Audi specifications. Makeshift tools, parts and
procedures will not make good repairs.
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage
containers that might mislead someone into drinking from them. Store flammable fluids away from
fire hazards. Wipe up spills at once, but do not store the oily rags, which can ignite and burn
spontaneously.
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these
tools to tighten fasteners, especially on light alloy parts. Always use a torque wrench to tighten
fasteners to the tightening torque listed.
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping
hydrogen gas is ignited, it will ignite gas trapped in the cells and cause the battery to explode.
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper
way to dispose of the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or
lake. Consult local ordinances that govern the disposal of wastes.
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C
system should be serviced only by trained automotive service technicians using approved
refrigerant recovery/recycling equipment, trained in related safety precautions, and familiar with
regulations governing the discharging and disposal of automotive chemical refrigerants.
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect
the battery negative terminal (ground strap) and the ABS control module connector.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive
heat will increase system pressure and may cause the system to burst.
=Page 2 of 3
Version 1.0
Cautions & Warnings
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the
Transmission Control Module (TCM), the ABS control module, and the trip computer. In cases
where one or more of these components is not separately fused, disconnect the control module
connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system
(SRS), that automatically deploys an airbag in the event of a frontal impact. The airbag is operated
by an explosive device. Handled improperly or without adequate safeguards, it can be accidentally
activated and cause serious personal injury. To guard against personal injury or airbag system
failure, only trained Audi Service technicians should test, disassemble or service the airbag
system.
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed
16.5 volts at the battery with the boosting cables attached. Wait at least one minute before
boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be
tested by trained Audi Service technicians using the VAG 1551 Scan Tool (ST) or an approved
equivalent. The airbag unit must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that
may have been inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of
ignition away from the tire repair area. Inflate and deflate the tire at least four times before
breaking the bead from the rim. Completely remove the tire from the rim before attempting any
repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or
lap while the vehicle is in motion. Objects between you and the airbag can increase the risk of
injury inwith
anrespect
accident.
to the correctness of information in this document. Copyright by AUDI AG.
I have read and I understand these Cautions and Warnings.
=Page 3 of 3
Version 1.0

D3E800A4762-Fuel Injection and Ignition

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Copyright © 2014 Audi AG, Ingolstadt D3E800A4762

24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

24 – Multiport Fuel Injection

1.1 Safety Precautions

1.1.1 Fuel System

There is a risk of injury because the fuel is under very high

Risk of destroying electronic components when disconnecting

– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.

1.1.2 Ignition System

♦ Individuals with a pacemaker must not stay in the danger area

♦ Cleaning the engine should only be performed with ignition

– R8 Spyder: Remove the right rear connector station and move

♦ By removing fuse fuel pump fuse - S81- , the voltage supply

2 Rep. Gr.24 - Multiport Fuel Injection

1.1.3 Test and Measuring Instruments during

Improperly secured testing and measuring equipment and dis‐

♦ Position passenger's seat as far back as possible.

1.2 Clean Working Conditions

1.3 On Board Diagnostics

4 Rep. Gr.24 - Multiport Fuel Injection

2 Description and Operation

2.1 Air Filter Overview

2.1.1 Vehicles with Manual/R tronic Transmission 086

1 - Air Guide Hose

2. Description and Operation 5

6 Rep. Gr.24 - Multiport Fuel Injection

31 - Water Drain Valve

2.1.2 Vehicles with DSG Transmission 0BZ

1 - Air Guide Hose

⇒ “5.1 Air Filters and

2. Description and Operation 7

8 Rep. Gr.24 - Multiport Fuel Injection

Install air guides with screw-type clamps

Tightening specification for:

2.2 Fuel Injection System Component Location

On the Left Side of the Engine Compartment

1 - Engine Control Module

2. Description and Operation 9

❑ Knock Sensor (KS) 2 - G66- connector

10 Rep. Gr.24 - Multiport Fuel Injection

13 - Intake Manifold Runner Position Sensor 2 - G512-

On the Right Side of the Engine Compartment

2. Description and Operation 11

1 - Fuel Pressure Sensor -

12 Rep. Gr.24 - Multiport Fuel Injection

cations, Engine from

2. Description and Operation 13

16 - Knock Sensor 2 - G66-

A - Fuel Injectors, Cylinder Bank 1

14 Rep. Gr.24 - Multiport Fuel Injection

⇒ Fig. ““Component Location, Oxygen Sensors, Cylinder Bank 2”“ , page 22

2. Description and Operation 15

Engine Control Module (ECM) - J623- Component Location - R8

Engine Control Module (ECM) 2 - J624- Component Location -

Engine Control Module (ECM) - J623- Component Location - R8

Engine Control Module (ECM) 2 - J624- Component Location -

16 Rep. Gr.24 - Multiport Fuel Injection

Engine Speed Sensor - G28- , Vehicles with manual/R tronic

Engine Speed Sensor - G28- , vehicles with DSG transmission

Intake Manifold Runner Position Sensor 2 - G512- -2-