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1、Service.Workshop Manual Audi A4 2001 Engine codeAVJBooklet Motronic Fuel Injection andIgnition Syst. (4-cyl. Turbo)Edition04.01Service. Technical InformationService.List of Workshop Manual Repair groupsAudi A4 2001 Engine codeAVJBookletMotronic Fuel Injection and Ignition System (4-cylinder Turbo) I

2、ssue date 04.01When filing a Technical Bulletin, enter the Bulletin no. in the appropriate box for the Repair group in the list below. When using the Workshop Manual, you can see at a glance whether Bulletins have been publis- hed with information affecting the Repair group you wish to refer to.Repa

3、ir groupTechnical Bulletins01 Self-diagnosis24 Mixture preparation, Injection28 Ignition systemTechnical information must always be available to all workshop personnel, as compliance with the instructions given is essential to ensure the roadworthiness and safety of the vehicles in question. In addi

4、tion, all normal safety precautions applicable when working on motor vehicles should be observed.This document is protected by copyright. It may not be reproduced or used in any form without the consent of the copyright holder.Copyright 2001 Audi AG, IngolstadtPrinted in Germany A00.5913.59.20Worksh

5、op Manual Audi A4 2001 Engine codeAVJMotronic Fuel Injection and Ignition System (4-cylinder Turbo) Issue date 04.01A00.5901.33.20Contents01Self-diagnosisPageSelf-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6、 . . . . . . . . . . .- Technical data of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-101-1- Safety precautions01-1- Connect vehicle diagnostic, testing and information system VAS 5051 and select functions

7、01-2Interrogating and erasing fault memory01-7- Interrogating fault memory01-7- Erasing fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- End of output . . . . . . . . . . . . . . . . . . . . . . .

8、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-901-1101-12- Fault co

9、des 16485 - 17636- Fault codes 17645 - 18339Final control diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10、 . . . . . . . . . .- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-1301-2501-42- Vehicles with control unit no. 8E0 906 .- Vehicles with control unit no. 8E0 909 . . . . . . . . . . . . . . . . . . . . . . . . . . .

11、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-4301-53Basic setting01-65- Vehicles with control unit no. 8E0 906 .- Vehicles with control unit no. 8E0 909 . . . . . . . . . . . . . . . . . . .

12、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-6701-71Encoding control unit- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13、 . . . . . . . . . . . . . . .01-74- Coding table01-76Reading measured value block - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-78Readiness code - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-80- Reading out readiness code01-82- Generate readiness code - Vehicles with control unit no. 8E0 90601-87- Generating readiness code - Vehicles with control unit no. 8E0 90901-11324Mixture preparation, InjectionPageServicing Motronic i

15、njection system - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1- Safety precautions24-1- Rules for cleanliness24-3- Technical data24-4- Fitting locations overview24-5- Wiring and component check with test box V.A.G 1598/31 . . . . . . . . . .

16、 . . . . . . . . . . . . . . . . . . . . . . . . . . .- Procedure following interruption of voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Renewing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17、 . . . . . . . . . . . . . . . . . . . . . . . .24-1724-1924-20- Exhaust warning lamp -K83 in dash panel insert24-24- Check exhaust warning lamp -K83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking idling speed . . . . . .

18、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-2624-27- Checking system pressure and holding pressure24-34- Checking injectors24-43- Dismantling and assembling fuel manifold with injectors24-48- Removing and installing

19、 injectors24-50- Testing injection quantity, leak tightness and spray pattern of injectors24-53- Checking fuel pump relay -J17 and relay actuation24-57- Checking air mass meter -G7024-65- Checking intake air system for leaks (unmetered air)24-74Bleeding fuel system - . . . . . . . . . . . . . . . .

20、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-77- Bleeding injection system24-77Checking lambda control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Check lambda

21、probe and lambda control upstream of catalytic converter -24-78vehicles with control unit no. 8E0 90624-78- Checking lambda probe and lambda control upstream of catalytic converter -vehicles with control unit no. 8E0 90924-92- Checking lambda ageing and lambda control upstream of catalytic converter

22、 -vehicles with control unit no. 8E0 90624-107- Checking lambda ageing, lambda probe upstream of catalytic converter -vehicles with control unit no. 8E0 90924-112- Checking lambda probe heating -Z19 for lambda probe upstream of catalytic converter . . . . . . . . . . . .- Checking lambda probe and l

23、ambda control upstream of catalytic converter -24-117vehicles with control unit no. 8E0 90624-123- Checking lambda probe and lambda control upstream of catalytic converter -vehicles with control unit no. 8E0 90924-136- Checking lambda probe ageing, lambda probe downstream of catalytic converter -veh

24、icles with control unit no. 8E0 90624-149- Checking lambda probe ageing, lambda probe downstream of catalytic converter -vehicles with control unit no. 8E0 90924-154- Checking lambda probe heating -Z29 for lambda probe downstream of catalytic converter24-159- Removing and installing lambda probe24-1

25、65Checking fuel tank breather24-167- Checking activated charcoal filter system solenoid valve 1 -N8024-167Checking electronic engine power control (electronic throttle)24-173- Function of the electronic throttle system24-173- Fault lamp for electronic throttle in dash panel insert . . . . . . . . .

26、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking electronic throttle control fault lamp -K132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking throttle valve control unit -J338 . . . . . . . . . . . . . . . . . . . . . . . . . .

27、 . . . . . . . . . . . . . . . . . . . . . . . . . .24-17524-17624-177- Performing adaption of throttle valve control unit24-178- Checking angle sender for throttle valve actuator24-185- Checking accelerator position sender24-192- Adapting kickdown function24-199- Checking brake light switch and bra

28、ke pedal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking clutch pedal switch -F36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Testing Cruise Control System (CCS) . . . . .

29、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking auxiliary signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking engine speed signal . . . . . . . . .

30、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking wiring for crash signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Check the data exchange between engine

31、control unit and other CAN-control units . . . . . . . . . . . . . . .Vacuum diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-20424-21124-21824-22524-22624-22724-22924-23928Ignition systemPageChe

32、cking ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

33、8-128-1- Safety precautions28-2- Technical data28-3- Checking ignition coils with output stages28-4- Checking power supply relay for Motronic system -J27128-14- Checking engine speed sender -G2828-23- Checking intake air temperature sensor -G4228-28- Checking coolant temperature sender -G62 . . . .

34、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking control unit power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking knock control stop . . . . . . . . . . . . . . .

35、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-3428-4028-44- Checking knock sensors28-48- Checking Hall sender -G40- Checking misfire detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-5328-60Self-diagnosisTechnical data of self-diagnosisFeatures Data transfer between control unit and vehicle diagnostic, testing and information syst

37、em VAS 5051 is carried out in ”self-diagnosis” mode. Fault memory: Non-volatile and volatile memories Non-volatile and volatile memoriesSafety precautionsNote the following points if testers and measuring instruments have to be used during a road test:Important: Always attach testers and measuring i

38、nstruments to the back seat and have a second person operate them from there. If test equipment were operated from the front passenger seat, the person sitting there could be injured if the front passenger airbag were triggered in the event of an accident.01-1Connect vehicle diagnostic, testing and

39、information system VAS 5051 and select functionsTest requirements:Fuses for engine electronics OK Current Flow Diagrams, Electrical Fault-finding and Fitting Loca- tions binderBattery voltage at least 12.7 VV.A.S 5051/1POLA01?0060Earth connections on engine and gearbox OK.Procedure Switch ignition o

40、ff. Connect up vehicle diagnostic, testing and information system VAS 5051 with diagnostic wire VAS 5051/1.Important:Note the safety precautions Page 01-1.Note:A fault message appears on the display: Operating instructions of vehicle diagnostic, testing and information system VAS 505101-2VAS 5051A87

41、?0312Display on VAS 5051: Press the ”vehicle self-diagnosis” key.1A01?0120Display on VAS 5051:Note:The automatic test sequence is carried out by pressing ”00 - Interro- gate fault memory - Total system” in selection -1-, i.e. the fault mem- ories of all vehicle systems with self-diagnosis capability

42、 are interro- gated.01-31A01?0120Display on VAS 5051:Depending on which function is required ”Diagnostic functions” table, Page 01-6: Switch the ignition on. or Start the engine. Select vehicle system ”01 - Engine electronics” in selection -1-.12A01?0121 Wait until the next display appears.Display o

43、n VAS 5051:1-Controlunitidentification oftheengine controlunitPage01-5 2 - Control unit identification of the immobiliser Page 01-501-4Control unit identification Engine control unit (example)01 - Engine electronicsVehicle system8E0909018.Part-No.; assignment Parts List1.8L 1) R4/5VT 2) G 3) 0003 4)

44、1) Engine capacity2) In line engine, 4 cylinders, 5 valves, turbo3) G = cruise control system activated no display = no cruise control system or cruise control system not activated4) Control unit data status (software type)Code 11501:Code of control unit (check Page 01-74)Dealership No. 12345Worksho

45、p code of VAS 5051 with which encoding was last performedControl unit identification, immobiliser (example)WAUZZZ8EZ1A054321 1) AUZ7Z0X1137197 2)1) 17-digit vehicle identification no. (Chassis number)2) 14-digit ident no. for immobiliser01-51A01?0122 Press the key.Display on VAS 5051:1 - Selection o

46、f diagnostic functions:Diagnostic functionsIgnition on, engine stoppedEngine idlingVehicle runningPage02Interrogating fault memorynoyesyes01-703Final control diagnosisyesnono01-4204Basic settingnoyesno01-6505Erasing fault memoryyesyesyes01-706End of outputyesyesyes01-1107Encoding control unityesnono

47、01-7408Reading measured value blockyesyesyes01-7809Reading individual measured valuenonono-10Adaptionnonono-11Log-in procedureyesnono24-22401-6Interrogating and erasing fault memoryInterrogating fault memory Connect vehicle diagnostic, testing and information system VAS 5051 Page 01-2 and select veh

48、icle system ”01 -Engine elec- tronics” in the selection. When doing this, the engine should be id- ling.Note:1A01?0122If the engine will not start, crank it for at least 5 seconds with the starter and then always leave the ignition on.Display on VAS 5051: Under -1- select diagnostic function ”02 - I

49、nterrogate fault memory”.01-721A87?0316Display on VAS 5051:1- - Content of the fault memory: 0 Faults recognised or X Faults recognised2- - Faults Fault code Fault location Fault type1A01?0122A - If faults were recognised: Print out the screen content or the self-diagnosis report. Exit function ”02

50、- Interrogate fault memory” by pressing the key. Display on VAS 5051: Rectify the fault(s) as specified in fault table Page 01-12. Reselect diagnostic function ”02 - Interrogate fault memory” and erase the fault memory Page 01-9. Select the diagnostic function ”06 - End output” in the selection Page

51、 01-11.01-8B - If no fault was recognised: Select the diagnostic function ”06 - End output” in the selection Page 01-11.Erasing fault memoryNote:If it is not possible to erase fault memory, interrogate it once again and rectify faults.Preconditions:1A01?0122Faultmemory interrogated Page 01-7. All fa

52、ults rectified.After fault memory has been successfully interrogated: Display on VAS 5051: Under -1- select diagnostic function ”05 - Erase fault memory”.01-912A87?0320Display on VAS 5051:1- - No display (before erasing) or Fault memory erasedNote:The following message appears in display zone -1-: ”

53、Fault memory not yet interrogated”, if the operational sequence was not adhered to exactly. The fault memory can only be erased, if the fault memory has been interrogated beforehand.2- - Note:Is the function to be carried out? Note: Data will be erased! Press the ”O(jiān)K”-key in display -2-. Exit function ”05 - Erase fault memory” by pressing the key. Interrogate fault memory again after carrying out the repairs.Note:This erases faults that have been stored whilst the fault was being rectified, for example, faults that have arisen a