2013 AUDI RS6 Service and Repair Manual
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Workshop Manual
Audi A6 2011 ➤
Audi A6 China 2012 ➤
Audi A7 Sportback 2011 ➤
4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve
TFSI - generation II)
Engine ID
CAE
B
CDN
B
CDZ
A
CHJA
CAE
D
Edition 05.2014
Service
Service Department. Technical Information
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Service
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine identification number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety precautions when working on high-voltage vehicles . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 11
2.4 Safety precautions when working on the subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Safety precautions when using testers and measuring instruments during a road test . . . . 12
2.6 Safety precautions when working on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.7 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.3 Removing and installing engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.4 Removing and installing torque reaction support and cross member . . . . . . . . . . . . . . . . 67
2.5 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.1 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.1 Exploded view - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.5 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.1 Exploded view - cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.3 Removing and installing sealing flange (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.4 Renewing needle bearing in drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.1 Exploded view - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.3 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.4 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.5 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.6 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤
4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve TFSI - generation II) - Edition 05.2014
Contents i
4.1 Exploded view - balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.2 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.3 Renewing oil seal for balance shaft (inlet side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.1 Exploded view - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.3 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.4 Separating parts of new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.5 Checking radial clearance of conrod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1 Timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.1 Exploded view - timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.2 Removing and installing timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.3 Renewing oil seal for vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.1 Exploded view - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.2 Exploded view - drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.3 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.4 Removing and installing drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.5 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.1 Exploded view - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.3 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.2 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.3 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 192
4.4 Removing and installing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.1 Exploded view - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 206
1.3 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.4 Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.5 Removing and installing sump (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.6 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
2.1 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3 Crankcase breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3.1 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4 Oil filter/oil pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.1 Exploded view - oil filter/oil pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.2 Removing and installing oil pressure switch F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
4.3 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 220
4.4 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
4.5 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 221
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤
4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve TFSI - generation II) - Edition 05.2014
ii Contents
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
1.3 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
2 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
2.1 Exploded view - coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
2.2 Exploded view - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
2.3 Removing and installing electrical coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2.4 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2.5 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
2.6 Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.7 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 255
2.8 Removing and installing coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3.1 Exploded view - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
4 Radiators/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
4.1 Exploded view - radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
4.2 Exploded view - radiator cowl and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
4.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
4.4 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
4.5 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
4.6 Removing and installing radiator fan control unit J293 / J671 . . . . . . . . . . . . . . . . . . . . . . 281
4.7 Removing and installing auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
1.1 Exploded view - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
1.3 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
2.1 Exploded view - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
2.2 Exploded view - hose connections for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 297
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
2.4 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
1.2 Filling and bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
2.1 Checking dual non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
2.2 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3.1 Exploded view - air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3.2 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
4.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
4.3 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
4.4 Cleaning throttle valve module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
4.5 Checking intake manifold change-over function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
5 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤
4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve TFSI - generation II) - Edition 05.2014
Contents iii
5.1 Exploded view - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
5.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
5.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
5.4 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
6.1 Removing and installing intake air temperature sender G42 . . . . . . . . . . . . . . . . . . . . . . 345
6.2 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
6.3 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
6.4 Removing and installing air mass meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
7.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
8.1 Exploded view - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
8.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
9.1 Wiring and component check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
9.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
1.1 Exploded view - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
1.2 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
1.3 Removing and installing front silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
1.4 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
2 Emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
2.1 Exploded view - emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
2.3 Removing and installing exhaust flap control unit J883 . . . . . . . . . . . . . . . . . . . . . . . . . . 381
3 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
3.1 Exploded view - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
3.2 Removing and installing secondary air pump motor V101 . . . . . . . . . . . . . . . . . . . . . . . . 383
3.3 Removing and installing secondary air inlet valve N112 . . . . . . . . . . . . . . . . . . . . . . . . . . 383
3.4 Removing and installing sender 1 for secondary air pressure G609 . . . . . . . . . . . . . . . . . . 384
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
1.1 Exploded view - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
1.2 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
1.3 Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 386
1.4 Removing and installing knock sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
1.5 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
1.6 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤
4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve TFSI - generation II) - Edition 05.2014
iv Contents
00 – Technical data
1 Identification
(ARL003836; Edition 05.2014)
⇒ “1.1 Engine identification number/engine data”, page 1
1.1 Engine identification number/engine da‐
ta
Engine number
The engine number (“Engine code” and “Serial number”) can be
found at the front of the joint between engine and gearbox.
Additionally there is a sticker on the toothed belt cover showing
the “engine code” and “serial number”.
The engine code is also indicated on the vehicle data stickers.
Engine data
Code letters CAEB CAED CDNB
Capacity ltr. 1.984 1.984 1.984
Power output kW at rpm 155/4300 … 6000 162/4300 … 6000 132/4000 … 6000
Torque Nm at rpm 350/1500 … 4200 350/3000 … 5000 320/1500 … 3900
Bore ∅ mm 82.5 82.5 82.5
Stroke mm 92.8 92.8 92.8
Compression ratio 9.6 9.6 9.6
RON
95
1)
98
2)
95
1)
Injection system/ignition system FSI FSI FSI
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Knock control yes yes yes
Turbocharging/supercharging yes yes yes
Exhaust gas recirculation no no no
Hybrid drive no no no
Intake manifold change-over no no no
Variable valve timing yes yes yes
Secondary air system no no no
•
1)
Unleaded petrol RON 91 can also be used, but results in reduced power
•
2)
Unleaded premium RON 95 can also be used, but results in reduced power
Code letters CDZA CHJA
Capacity ltr. 1.984 1.984
Power output kW at rpm 132/4200 … 6000 155/4200 … 6000
Torque Nm at rpm 320/1500 … 4000 350/1500 … 4200
Bore ∅ mm 82.5 82.5
Stroke mm 92.8 92.8
Compression ratio 9.6 9.6
RON
98
2)
95
1)
Injection system/ignition system FSI FSI
Firing order 1-3-4-2 1-3-4-2
Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤
4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve TFSI - generation II) - Edition 05.2014
1. Identification 1
Code letters CDZA CHJA
Knock control yes yes
Turbocharging/supercharging yes yes
Exhaust gas recirculation no no
Hybrid drive no yes
Intake manifold change-over no no
Variable valve timing yes yes
Secondary air system no no
•
1)
Unleaded petrol RON 91 can also be used, but results in reduced power
•
2)
Unleaded premium RON 95 can also be used, but results in reduced power
Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤
4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve TFSI - generation II) - Edition 05.2014
2 Rep. gr.00 - Technical data
2 Safety precautions
⇒ “2.1 Safety precautions when working on high-voltage vehi‐
cles”, page 3
⇒ “2.2 Safety precautions when working on the fuel supply sys‐
tem”, page 10
⇒ “2.3 Safety precautions when working on vehicles with start/
stop system”, page 11
⇒ “2.4 Safety precautions when working on the subframe”,
page 11
⇒ “2.5 Safety precautions when using testers and measuring in‐
struments during a road test”, page 12
⇒ “2.6 Safety precautions when working on the ignition system”,
page 12
⇒ “2.7 Safety precautions when working on the cooling system”,
page 13
2.1 Safety precautions when working on
high-voltage vehicles
⇒ “2.1.1 Working on high-voltage vehicles”, page 3
⇒ “2.1.2 Performing visual check of high-voltage components and
wires for damage”, page 8
2.1.1 Working on high-voltage vehicles
WARNING
Safety hazard: the engine can start unexpectedly.
Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.
WARNING
Working on vehicles with high-voltage wiring:
• Do not support yourself or tools on high-voltage wiring or
associated components --> this can damage the insula‐
tion.
• High-voltage wiring must not be excessively bent or
kinked --> this can damage the insulation.
• The round high-voltage connectors are colour-coded with
an external coloured ring and are provided with mechan‐
ical coding or guide lugs. It is important to observe this
coding when joining up the round high-voltage connec‐
tors, otherwise the connectors can be damaged.
Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤
4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve TFSI - generation II) - Edition 05.2014
2. Safety precautions 3
DANGER!
Risk of fatal injury if high-voltage components are damaged.
Observe the following when working in the vicinity of high-volt‐
age components or wiring:
♦ It is not permitted to use cutting or forming tools, other
sharp-edged tools or heat sources such as welding, braz‐
ing, soldering, hot air or thermal bonding equipment.
♦ Before starting work, visually inspect the high-voltage
components in the areas involved.
♦ Before working in the engine compartment, visually in‐
spect the power and control electronics for electric drive -
JX1- , electric drive motor - V141- , air conditioner
compressor - V470- and high-voltage wiring.
♦ Before working on the vehicle underbody, visually inspect
the high-voltage wiring and covers.
♦ Before working on the rear section of the vehicle, visually
inspect the high-voltage wiring and the electro-box with
the maintenance connector for high-voltage system - TW
- .
♦ Visually inspect all potential equalisation lines.
Check the following when making the visual inspection:
♦ There must be no external damage on any component.
♦ The insulation of the high-voltage wiring and potential
equalisation lines must not be damaged.
♦ There must be no unusual deformation of the high-voltage
wiring.
♦ All high-voltage components must be identified by a red
warning sticker.
De-energising high-voltage system
DANGER!
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) con‐
firms that the system is de-energised and uses the locking
cap - T40262- to ensure that the system cannot be re-
energised. The ignition key and the maintenance connec‐
tor for high-voltage system - TW - are then stored in a safe
place by the qualified person.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.
Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤
4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve TFSI - generation II) - Edition 05.2014
4 Rep. gr.00 - Technical data
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