fuel pressure AUDI A4 2000 B5 / 1.G AWM Engine Motronic Injection System Servicing Workshop Manual

24-2

It is possible that the control module will
recognize a malfunction and store a DTC during
some tests. After completing all tests and
repairs, DTC memory should therefore be
checked and erased if necessary. Readiness
code must be generated after DTC memory is
erased Page 01
-84
.

Always switch ignition off before cleaning
engine.
The battery should only be disconnected and
reconnected when the ignition is turned off,
since otherwise the Engine Control Module
(ECM) can be damaged.

WARNING!

Fuel system is under pressure! Before
opening system, place rags around the
connection point. Then release pressure by
carefully loosening connection.
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24-4
Technical data

Engine identification

AWM (1.8 L / 5V/ 125 kW-engine)
Idle speed
Engine speed cannot be adjusted, it is regulated by idle
stabilization
Front Wheel Drive
(FWD)
All Wheel Drive (AWD)
740 to 860 RPM
760 to 880 RPM
Engine speed (RPM) limitation
via fuel injector shut-off
about 6800 RPM
Fuel pressure at idle speed Vacuum hose
connected
about 3.5 bar positive pressure

Vacuum hose
disconnected
about 4.0 bar positive pressure
Residual pressure after 10 min. at least 2.5 bar positive pressure
Fuel injectors Injection stream Dual-hole nozzle / same for all
injectors

Injection quantity (30 s)
135 10 ml

Resistance
(room temperature)
12 to 13
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24-7


Repair Manual, 1.8 Liter 4
-Cyl. 5V Turbo Engine
Mechanical, Engine Code(s): AWM, Repair Group 26; Secondary Air Injection (AIR) system, checking

6 -
Fuel pressure regulator
Checking Page 24
-32
7 -
Engine Speed (RPM) sensor -G28-
Checking Page 28
-27
8 -
Secondary Air Injection (AIR) solenoid
valve-N112-
Installation location Fig. 4
, Page
24
-14

Checking:Green harness connector
9 -
Bracket for harness connectors Component location Fig. 1
, Page
24
-13

Accessible with coolant expansion tank
unbolted and swung to the side.
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24-32

System pressure, fuel pressure
regulator and residual pressure,
checking


Note:
Fuel pressure regulator regulates fuel pressure
according to intake manifold pressure. This
ensures that the pressure drop at the fuel
injectors remains the same for each speed and
load range of the engine.

Special Tools and Equipment

Test requirements:
Repair Manual, Fuel Supply System, Repair Group 20

VAG1318V.A.G 1318 with V.A.G 1318/11 adapter, V.A.G 1318/12 pressure
hose with connectors and V.A.G 1318/13 adapter Fuel Pump (FP) relay OK; checking Page 24
-52
.
Fuel Pump (FP) OK, checking: Fuel filter OK Battery voltage at least 12.7 V Vehicles with automatic transmission Selector lever in P or N.
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24-33

Checking system pressure

- Open fuel filler flap briefly (pressure release).

WARNING!
Fuel system is under pressure! Before opening system, place rags
around the connection point. Then release pressure by carefully
loosening connection. - Remove engine cover (arrows).

- Open threaded connection (arrow) and catch exiting fuel using a rag.
- Connect VAG1318 pressure gauge in supply line using adapters
1318/11, 1318/12 and 1318/13.
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24-34


- Open shut-off valve of pressure gauge. The lever points in the direction
of flow.
- Start engine and let run at idle.
- Measure fuel pressure.

Specification: about 3.5 bar positive pressure

- Disconnect vacuum hose at fuel pressure regulator.

Fuel pressure must rise to about 4.0 bar positive pressure.
- Switch ignition off.
- Check for proper seal and residual pressure by observing pressure
drop on pressure gauge.
After 10 minutes, there must be at least 2.5 bar positive pressure
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24-35
If residual pressure sinks below 2.5 bar positive
pressure:

- Start engine and let run at idle.

If pressure does not drop now:
If pressure drops again:
If pressure does not drop now: - Wait until pressure has dropped, and then switch off ignition.
Simultaneously close shut-off valve of VAG1318 pressure gauge (lever
perpendicular to direction of flow -arrow-).
- Observe pressure drop on pressure gauge.
- Test check-valve on Fuel Pump (FP).
- Open shut-off valve of pressure gauge. The lever points in the direction
of flow.
- Start engine and let run at idle.
- Wait until pressure has dropped, and then switch off ignition.
Simultaneously clamp return line (with blue marking) completely
closed.
- Replace fuel pressure regulator
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24-36
If pressure drops again:

- Check wire connections, O-rings at fuel
distributor and fuel injectors for proper seal.

- Check whether pressure gauge is properly
sealed.

Note:
Before disconnecting pressure gauge, release
pressure by opening shut-off valve. Hold a
container in front of connection for this.
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24-43


4 -
O-ring
Removing and installing Page 24
-45
Always replaceCoat with clean engine oil
5 -
Fuel distributor
6 -
Fuel supply line Tighten to 25 Nm
7 -
Fuel return line
8 -
Harness connector for injectors4x
9 -
Socket head bolt- 10 Nm
10 -
Fuel pressure regulator
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24-44


Repair Manual, 1.8 Liter 4
-Cyl. 5V Engine
Mechanical, Engine Code(s): AWM, Repair Group 15; Cylinder head, removing and installing; Intake manifold, removing and installing
11 -
O-ring
Always replace
12 -
O-ring Always replace
13 -
Retaining clip For fuel pressure regulator
14 -
Retaining clip Make sure clip is correctly seated on fuel
injector and fuel rail
15 -
Intake manifold With throttle valve control module -J338-with Intake Air Temperature (IAT) sensor -
G42- Removing
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