Audi Workshop Service and Repair Manuals

Overview of fitting locations   Note t  Some components are located beneath the engine cover panel. For removal refer to → Fig.. t  Components „A“ to „G“ for vehicles with diesel particulate filter are not shown in the diagram.

1 -	Air mass meter -G70-

q	Fitting location → Fig.

2 -	Exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212-

q	Only for engine codes BKE, BPW, BRB, BRC

q	Fitting location → Fig.

3 -	Intake manifold flap motor -V157-

q	Only for engine codes BKE, BPW, BRB, BRC

q	Fitting location → Fig.

4 -	Coolant temperature sender -G62-

q	Fitting location → Fig.

q	Dissipate cooling system pressure before removal if necessary

5 -	Tandem pump

q	Removing, installing and checking → Rep. gr.20

6 -	Multi-pin connector

q	For unit injectors

q	Fitting location → Fig.

7 -	Fuel temperature sender -G81-

q	Fitting location → Fig.

8 -	Charge pressure sender -G31- with intake air temperature sender -G42-

q	Fitting location → Fig.

9 -	Exhaust emissions warning lamp -K83-

q	In instrument cluster

10 -	Accelerator position sender -G79-

q	For engine codes AVB, AVF, AWX, BKE: incorporating kick-down switch -F8- and idling speed switch -F60-

q	For engine codes BPW, BRB, BRC: incorporating accelerator pedal position sender 2 -G185-

q	Fitting location → Fig.

11 -	Brake light switch -F- and brake pedal switch -F47-

q	Fitting location → Fig.

12 -	Clutch pedal switch -F36-

q	Fitting location → Fig.

13 -	4-position relay carrier in electronics box in plenum chamber

q	With fuel pump relay -J17-

q	With terminal 30 voltage supply relay -J317-

q	For engine codes AVB, AVF, AWX: with glow plug relay -J52-

q	For engine codes BKE, BPW, BRB, BRC: with automatic glow period control unit -J179-

q	Engine glow plug strip fuse -S39-

q	Engine electronics fuse -S282-

q	Fitting location → Fig.

14 -	Engine control unit

q	Up to approx. 10.2004: diesel direct injection system control unit -J248-

q	From approx. 11.2004 onwards: engine control unit -J623-

q	Fitting location → Fig.

q	Removing and installing - engine codes AVB, AVF, AWX → Chapter

q	Removing and installing - engine codes BKE, BPW, BRB, BRC → Chapter

15 -	Electrical connectors on left side of bulkhead

q	For engine codes AVB, AVF, AWX, BKE:

q	For engine speed sender -G28-

q	For Hall sender -G40-

q	Fitting location → Fig.

q	For engine codes BPW, BRB, BRC:

q	For exhaust gas temperature sender 1 -G235-

q	For engine speed sender -G28-

q	For Hall sender -G40-

q	For Lambda probe -G39-

q	Fitting location → Fig.

16 -	Engine speed sender -G28-

q	On cylinder block (rear left)

17 -	Glow plugs

q	Glow plug 1 -Q10-

q	Glow plug 2 -Q11-

q	Glow plug 3 -Q12-

q	Glow plug 4 -Q13-

q	Different types of glow plugs → Chapter

q	Removing and installing metal glow plugs → Chapter

q	Removing and installing ceramic glow plugs → Chapter

Caution Due to the special properties of the material used, ceramic glow plugs are easily damaged and require extra care when handling and removing/installing.

18 -	Hall sender -G40-

q	For camshaft position

q	Fitting location → Fig.

19 -	Charge pressure control solenoid valve -N75-

q	Fitting location → Fig.

20 -	Exhaust gas recirculation valve -N18- and variable intake manifold flap change-over valve -N239-

q	Only for vehicles with engine codes AVB, AVF and AWX

q	Fitting location → Fig.

21 -	Unit injectors

q	Unit injector solenoid valve, No. 1 cyl. -N240-

q	Unit injector solenoid valve, No. 2 cyl. -N241-

q	Unit injector solenoid valve, No. 3 cyl. -N242-

q	Unit injector solenoid valve, No. 4 cyl. -N243-

q	Removing and installing unit injectors → Chapter

A -	Lambda probe -G39- with Lambda probe heater -Z19-

q	Fitting location → Fig.

q	Removing and installing → Chapter

B -	Temperature sender before particulate filter -G506-

q	Fitting location → Fig.

q	Removing and installing → Rep. gr.26

C -	Temperature sender after particulate filter -G527-

q	Fitting location → Fig.

q	Removing and installing → Rep. gr.26

D -	Electrical connector for temperature sender after particulate filter -G527-

q	Fitting location → Fig.

E -	Exhaust gas temperature sender 1 -G235-

q	Fitting location → Fig.

q	Removing and installing → Rep. gr.26

F -	Electrical connectors on left side of bulkhead

q	For exhaust gas temperature sender 1 -G235-

q	For engine speed sender -G28-

q	For Hall sender -G40-

q	For Lambda probe -G39-

q	Fitting location → Fig.

G -	Electrical connectors on right side of bulkhead and exhaust gas pressure sensor 1 -G450-

q	For exhaust gas pressure sensor 1 -G450-

q	For temperature sender before particulate filter -G506-

q	Fitting location → Fig.

q	Removing and installing exhaust gas pressure sensor 1 -G450- → Chapter

Removing engine cover panel –  Pull dipstick -1- out of guide tube. –  Unclip cover caps. –  Unscrew nuts -arrows- and detach engine cover panel. –  Remove insulation beneath cover. –  Re-insert dipstick in guide tube.

Fitting location of accelerator position sender -G79- with kick-down switch -F8- and idling switch -F60- or accelerator position sender 2 -G185- t  In accelerator pedal module -arrow-   Note Diagram shows set-up on left-hand drive vehicles.

Fitting location of brake light switch -F- and brake pedal switch -F47-, clutch pedal switch -F36- 1 -  Brake light switch -F-, brake pedal switch -F47- 2 -  Clutch pedal switch -F36-   Note Switches must not be installed more than once, otherwise they may not fit securely.

Fitting location of engine control unit t  In electronics box (plenum chamber) t  Up to approx. 10.2004: diesel direct injection system control unit -J248- t  From approx. 11.2004 onwards: engine control unit -J623-

Fitting location of 4-position relay carrier 1.2 -  Fuel pump relay -J17- 2 -  Glow plug relay -J52- or terminal 30 voltage supply relay -J317- 3 -  Glow plug relay -J52- or automatic glow period control unit -J179- or terminal 30 voltage supply relay -J317- A -  Engine electronics fuse -S282- B -  Engine glow plug strip fuse -S39- t  In electronics box (plenum chamber)

Fitting location of exhaust gas recirculation valve -N18- and variable intake manifold flap change-over valve -N239- Only for engine codes AVB, AVF and AWX. 1 -  Exhaust gas recirculation valve -N18- 2 -  Variable intake manifold flap change-over valve -N239- t  In engine compartment (front right).

Fitting location of exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212- and intake manifold flap motor -V157- Only for engine codes BKE, BPW, BRB, BRC 1 -  Exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212- 2 -  Intake manifold flap motor -V157- t  On engine (right-side).

Fitting location of charge pressure control solenoid valve -N75- t  On engine (front right).

Fitting location of charge pressure sender -G31- with intake air temperature sender -G42- t  In air pipe

Fitting location of air mass meter -G70- t  On air cleaner housing

Fitting location of coolant temperature sender -G62- 3 -  Coolant temperature sender -G62- t  On rear of cylinder head.

Fitting location of fuel temperature sender -G81- t  In engine compartment (rear left)

Fitting location of electrical connectors on left side of bulkhead Only for engine codes AVB, AVF, AWX, BKE. 1 -  Earth point 2 -  Engine speed sender -G28- 3 -  Hall sender -G40-   Note Electrical connectors on left side of bulkhead (engine codes BPW, BRB, BRC) → Fig..

Fitting location of Hall sender -G40- t  At camshaft sprocket on engine (front).

Fitting location of multi-pin connector for unit injectors t  To disconnect, pull release pin -arrow 1- and slacken knurled nut -arrow 2-.

Fitting location of Lambda probe -G39- with Lambda probe heater -Z19- and temperature sender before particulate filter -G506- t  In particulate filter 1 -  Lambda probe -G39- with Lambda probe heater -Z19- 2 -  Temperature sender before particulate filter -G506-

Fitting location of temperature sender after particulate filter -G527- t  In exhaust pipe behind particulate filter -arrow-

Fitting location of electrical connector for temperature sender after particulate filter -G527- t  On gearbox (front left) -arrow-

Fitting location of exhaust gas temperature sender 1 -G235- t  In turbocharger -arrow-

Electrical connectors on left side of bulkhead Only for engine codes BPW, BRB, BRC 1 -  For exhaust gas temperature sender 1 -G235- 2 -  For engine speed sender -G28- (grey) 3 -  For Hall sender -G40- (black) 4 -  For Lambda probe -G39-

Electrical connectors on right side of bulkhead and exhaust gas pressure sensor 1 -G450- 1 -  Exhaust gas pressure sensor 1 -G450- 2 -  For temperature sender before particulate filter -G506-