Audi Q7 2007 Operating instructions

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Repair Manual
Audi Q7 2007 ➤
Fuel Injection and Ignition
Engine ID CJTB CJTC CNA
A
CJW
B
CJW
C
CJW
E
CTW
A
CTW
B
Edition 02.2015
Service
Service Department. Technical Information

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2015 Audi AG, Ingolstadt D3E802B262D

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.
Contents
24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety Precautions and Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 OBD General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety Precautions, Test and Measuring Instruments during Test Drive . . . . . . . . . . . . . . 2
1.3 Safety Precautions, Vehicles with Start/Stop System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Fuel System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Injection System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Pressure, Reducing in High Pressure Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 Fuel System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Connection Diagram - Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Intake Flap Control Vacuum Actuator, Removing and Installing . . . . . . . . . . . . . . . . . . . . 9
3 Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Component Locations - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Overview - Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Engine Covers, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.5 Air Filter Element, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.6 Air Filter Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.7 Overview - Intake Manifold Lower Section, Fuel Rail and Fuel Injectors . . . . . . . . . . . . . . 30
3.8 Intake Air Temperature Sensor G42 / Manifold Absolute Pressure Sensor G71 , Removing
and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.9 Throttle Valve Control Module J338 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 34
3.10 Control Valve Control Unit J808 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 36
3.11 Intake Manifold Lower Section with Fuel Rail, Removing and Installing . . . . . . . . . . . . . . 36
3.12 Fuel Injectors, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.13 Fuel Pressure and Residual Pressure before High Pressure Pump, Checking . . . . . . . . . . 42
3.14 Overview - High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.15 High Pressure Line, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.16 High Pressure Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.17 Overview - Heated Oxygen Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.18 Heated Oxygen Sensors G39 / G108 / G130 / G131 , Removing and Installing . . . . . . . . 53
4 Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.1 Wiring and Components, Checking with Test Box Kit - 105 Pin Test Box Kit VAG1598/42
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.2 Engine Control Module J623 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1 General Information and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.1 Ignition System General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.2 Safety Precautions, Test and Measuring Instruments during Test Drive . . . . . . . . . . . . . . 65
1.3 Fuel Injection and Ignition System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2 Ignition, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.1 Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.2 Overview - Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.3 Ignition Coils with Power Output Stages, Removing and Installing . . . . . . . . . . . . . . . . . . 69
2.4 Knock Sensor 1 G61 / Knock Sensor 2 G66 , Removing and Installing . . . . . . . . . . . . . . . . 70
2.5 Camshaft Position Sensor G40 / Camshaft Position Sensor 2 G163 , Removing and
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.6 Engine Speed Sensor G28 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
Contents i

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4 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
ii Contents

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24 – Multiport Fuel Injection
1 Safety Precautions and Clean Work‐
ing Conditions
(Edition 02.2015)
⇒ “1.1 OBD General Information”, page 1
⇒ “1.2 Safety Precautions, Test and Measuring Instruments dur‐
ing Test Drive”, page 2
⇒ “1.3 Safety Precautions, Vehicles with Start/Stop System”,
page 2
⇒ “1.4 Fuel System Safety Precautions”, page 2
⇒ “1.5 Injection System Safety Precautions”, page 4
⇒ “1.6 Pressure, Reducing in High Pressure Area”, page 5
⇒ “1.7 Fuel System, Checking for Leaks”, page 6
1.1 OBD General Information
♦ The engine control module is equipped with On Board Diag‐
nostics (OBD). Before repairs such as fault finding, check the
DTC memory first. The vacuum hoses and connections must
also be checked (unmetered air).
♦ Fuel hoses in engine compartment must only be secured with
spring clamps. The use of clamps or screw-type clamp is not
permissible.
♦ For the electric components to work properly, a voltage of at
least 11.5 Volts is required.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine, will not be burnt in the engine and dam‐
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.
♦ If it is difficult to disconnect the connectors, use a Reversing
Light Switch Connector Release Tool - T40138- .
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
1. Safety Precautions and Clean Working Conditions 1

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with respect to the correctness of information in this document. Copyright by AUDI AG.
1.2 Safety Precautions, Test and Measuring
Instruments during Test Drive
If testing equipment must be used during a road test, observe the
following:
WARNING
Distraction and testing equipment that is not secured properly
can cause accidents.
The passenger airbag could pose a risk if it deploys in a colli‐
sion.
• Operating testing equipment while driving is a distraction.
• Testing equipment that is not secured properly increases
the risk of injury.
♦ Always secure testers on the rear seat with a strap and
have a second person on the rear seat operate them.
1.3 Safety Precautions, Vehicles with Start/
Stop System
WARNING
There is a risk of injury if the engine starts automatically in ve‐
hicles with the Start/Stop System.
♦ For vehicles with an activated Start/Stop System (recog‐
nizable from a notification in the instrument cluster), the
motor can be started automatically if needed.
♦ Make sure that the start/stop system is deactivated when
working on the vehicle (turn off the ignition, turn on the
ignition when necessary).
1.4 Fuel System Safety Precautions
WARNING
♦ The injection system is separated into a high-pressure
section (maximum approximately 120 bar (1740 psi)) and
a low-pressure section (approximately 6 bar (87 psi)).
♦ Before opening the high pressure area, the fuel pressure
must be reduced in the high pressure area. Refer to
⇒ “1.6 Pressure, Reducing in High Pressure Area”,
page 5 .
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
2 Rep. Gr.24 - Multiport Fuel Injection

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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.
WARNING
There is a risk of injury because the fuel is under pressure.
♦ Place clean rags around the connection before opening
the system. Then release pressure by carefully loosening
the connection.
♦ Wear safety gloves.
♦ Wear protective eyewear.
Very hot fuel can cause burns.
♦ The temperature of the fuel lines may reach 100 °C (212
°F) after stopping the engine. Let the fuel cool down before
opening any line connections otherwise there is a danger
of scalding.
♦ Wear safety gloves.
♦ Wear protective eyewear.
WARNING
Danger due to leaking 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 Transfer Fuel Pump - G6- must
be disconnected before opening the fuel system.
Caution
Risk of destroying electronic components when disconnecting
the battery.
♦ Make sure to complete the steps for disconnecting the
battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ;
Battery; Battery, Disconnecting and Connecting .
– Procedures before opening high pressure fuel injection sys‐
tem. Refer to
⇒ “1.6 Pressure, Reducing in High Pressure Area”,
page 5 .
To prevent personal injury and damage to the injection and igni‐
tion system, observe the following:
♦ Individuals with a pacemaker must not stay in the danger area
of high voltage systems, for example ignition systems, xenon
light.
♦ Fuel lines must not be opened when engine is running.
♦ The ignition must be switched off before connecting or dis‐
connecting injection and ignition system wiring or tester ca‐
bles.
♦ Wash the engine only when the ignition is turned off.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
1. Safety Precautions and Clean Working Conditions 3

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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.
Even very small particles of dirt can cause a fault. When working
on the fuel supply and fuel injection system, observe the following
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.
♦ Seal off all open lines and connections with clean plugs.
♦ Place the removed parts on a clean surface and cover them.
Only use lint-free cloths.
♦ Carefully cover or seal opened components if repairs are not
performed immediately.
♦ Install only clean parts: remove the replacement parts from
their packaging just before installing them. Do not use parts
that have been stored loose (for example, in tool boxes etc.).
♦ If the system is open: do not work with compressed air. If pos‐
sible do not move vehicle.
♦ Protect any disconnected connectors from dirt and moisture
and connect them only when they are completely dry.
Delete any DTC memory entries that occurred during testing or
assembly. Refer to Vehicle Diagnostic Tester , Guided Func-
tions, Check DTC memory , and then Generate readiness
code.
1.5 Injection System Safety Precautions
To reduce the risk of personal injury and/or damage to the fuel
injection and ignition system, always observe the following:
♦ Individuals with a pacemaker must not stay in the danger area
of high voltage systems, for example ignition systems, xenon
light.
♦ The ignition must be switched off before connecting or dis‐
connecting injection and ignition system wiring or tester ca‐
bles.
♦ For reasons of safety, disconnect the battery before opening
the fuel system because the fuel pump is activated by the door
contact switch in the driver door.
♦ Fuel lines must not be opened when engine is running.
♦ Wash the engine only when the ignition is turned off.
♦ Disconnect the connectors from the ignition coils if the engine
is supposed to be driven by the cranking speed so that the
engine cannot start (for example, when performing a com‐
pression test). Refer to
⇒ “2.3 Ignition Coils with Power Output Stages, Removing and
Installing”, page 69 .
♦ Also remove the fuse for the Fuel Pump Control Module -
J538- . Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐
ponent locations.
♦ If the connectors were disconnected and the engine was star‐
ted, then malfunctions have been stored in the engine control
module DTC memory.
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
4 Rep. Gr.24 - Multiport Fuel Injection

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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.
Caution
Risk of destroying electronic components when disconnecting
the battery.
♦ Follow the steps for disconnecting the battery.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
1.6 Pressure, Reducing in High Pressure
Area
Note the following when working on the fuel system:
WARNING
♦ The injection system is separated into a high-pressure
section (maximum approximately 120 bar (1740 psi)) and
a low-pressure section (approximately 6 bar (87 psi)).
♦ Before opening the high pressure area, the fuel pressure
must be reduced in the high pressure area.
WARNING
There is a risk of injury because the fuel is under pressure.
♦ Place clean rags around the connection before opening
the system. Then release pressure by carefully loosening
the connection.
♦ Wear safety gloves.
♦ Wear protective eyewear.
Very hot fuel can cause burns.
♦ The temperature of the fuel lines may reach 100 °C (212
°F) after stopping the engine. Let the fuel cool down before
opening any line connections otherwise there is a danger
of scalding.
♦ Wear safety gloves.
♦ Wear protective eyewear.
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.
♦ The fuel lines will continue to be filled with fuel, but will no
longer be under high pressure. Wear protective eyewear
and protective clothing when opening the fuel system.
♦ Before opening the high pressure system, place a cloth
around the connection.
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
1. Safety Precautions and Clean Working Conditions 5

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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.
WARNING
Danger due to leaking 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 Transfer Fuel Pump - G6- must
be disconnected before opening the fuel system.
Caution
Risk of destroying electronic components when disconnecting
the battery.
♦ Make sure to complete the steps for disconnecting the
battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ;
Battery; Battery, Disconnecting and Connecting .
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
• Delete any DTC memory entries that occurred during testing
or assembly. Refer to Vehicle Diagnostic Tester , Guided
Functions, Check DTC memory , and then Generate read-
iness code.
1.7 Fuel System, Checking for Leaks
– Let the engine run a few minutes at a moderate RPM.
– Switch off the ignition.
– Check the entire fuel system for leaks.
– Replace the part if there are leaks in spite of correct tightening
specifications.
– Perform a road test and press the accelerator pedal all the way
down at least one time.
– Check the high pressure area again for leaks.
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
6 Rep. Gr.24 - Multiport Fuel Injection

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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.
2 Vacuum System
⇒ “2.1 Connection Diagram - Vacuum System”, page 7
⇒ “2.2 Vacuum System, Checking”, page 9
⇒ “2.3 Intake Flap Control Vacuum Actuator, Removing and In‐
stalling”, page 9
2.1 Connection Diagram - Vacuum System
Note
♦ Follow the guidelines for clean working conditions. Refer to
⇒ “1 Safety Precautions and Clean Working Conditions”, page
1 .
♦ Before testing or performing a repair, check all air guide pipes
and hoses and all vacuum lines for leaks and secure seating.
Caution
There is a risk that an engine malfunction may occur.
♦ When routing the vacuum lines, make sure they are not
kinked, twisted or pinched.
Note
♦ Red = vacuum diaphragm supply line.
♦ Blue = control line to the intake manifold runner control vac‐
uum actuator.
♦ Orange = control line to the left secondary air injection com‐
bination valve.
♦ Brown = control line to the right secondary air injection com‐
bination valve.
♦ Green = control line for switchable coolant pump.
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
2. Vacuum System 7

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1 - Secondary Air Injection Sol‐
enoid Valve - N112-
2 - Intake Manifold Runner
Control Valve - N316-
3 - Secondary Air Injection Sol‐
enoid Valve 2 - N320-
Note
Depending on the version, not in‐
stalled on USA vehicles.
4 - To the Brake Booster
5 - Distribution Piece with Clo‐
sure Cap
6 - Left Secondary Air Injection
Combination Valve
❑ Checking. Refer to ⇒
Engine Mechanical;
Rep. Gr. 26 ; Secondary
Air System; Secondary
Air Injection Combina‐
tion Valves, Checking
Function and for Leaks .
❑ Removing and instal‐
ling. Refer to ⇒ Engine
Mechanical; Rep. Gr.
26 ; Secondary Air Sys‐
tem; Left Secondary Air
Injection Combination
Valve, Removing and
Installing .
7 - Check Valve
8 - Vacuum Pump
9 - Cylinder Head Coolant
Valve - N489-
10 - Vacuum Actuator
❑ For intake manifold flap at cylinder bank 2 (left)
❑ Removing and installing. Refer to
⇒ “2.3.2 Intake Flap Control Vacuum Actuator, Removing and Installing, Cylinder Bank 2 (Left)”,
page 10 .
11 - Coolant Pump
12 - Check Valve
13 - Vacuum Actuator
❑ For intake manifold flap at cylinder bank 1 (right)
❑ Removing and installing. Refer to
⇒ “2.3.1 Intake Flap Control Vacuum Actuator, Removing and Installing, Cylinder Bank 1 (Right)”, page
9 .
14 - Right Secondary Air Injection Combination Valve
❑ Checking. Refer to ⇒ Engine Mechanical; Rep. Gr. 26 ; Secondary Air System; Secondary Air Injection
Combination Valves, Checking Function and for Leaks .
❑ Removing and installing. Refer to ⇒ Engine Mechanical; Rep. Gr. 26 ; Secondary Air System; Right
Secondary Air Injection Combination Valve, Removing and Installing .
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
8 Rep. Gr.24 - Multiport Fuel Injection

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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.
2.2 Vacuum System, Checking
Special tools and workshop equipment required
♦ Hand Vacuum Pump - VAS6213-
Procedure
– Check all vacuum lines in the vacuum system for:
♦ Cracks
♦ Damage caused by animals
♦ Pinching
♦ Porous locations and other leaks
– Check the vacuum lines leading both to and from the solenoid
valve to the respective component.
– If there is a fault, check the vacuum lines for the named com‐
ponent, but also all the vacuum lines to the other components.
– If using the Hand Vacuum Pump - VAS6213- and does not
produce any vacuum or if the vacuum drops again right away,
then check the hand vacuum pump and the connection hoses
for leaks.
2.3 Intake Flap Control Vacuum Actuator,
Removing and Installing
⇒ “2.3.1 Intake Flap Control Vacuum Actuator, Removing and In‐
stalling, Cylinder Bank 1 (Right)”, page 9
⇒ “2.3.2 Intake Flap Control Vacuum Actuator, Removing and In‐
stalling, Cylinder Bank 2 (Left)”, page 10
2.3.1 Intake Flap Control Vacuum Actuator,
Removing and Installing, Cylinder Bank
1 (Right)
Special tools and workshop equipment required
♦ Commercially available Torx socket wrench or Bit 10 with ball
head
♦ Commercially available -Magnetic Rod-
Removing
– Remove the front engine cover. Refer to
⇒ “3.4 Engine Covers, Removing and Installing”, page 27 .
– Disconnect the secondary air injection hose -1- at the sepa‐
rating point -2- and free up the bracket.
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
2. Vacuum System 9

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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.
– Remove the bolts -2 and 3- and then remove the Intake Mani‐
fold Runner Position Sensor - G336- .
– Unclip the actuator rod -2- from the ball head vacuum actuator.
– Remove the vacuum hose -1-, and remove the vacuum ac‐
tuator.
Installing
Install in reverse order of removal and note the following:
The shaft for the intake manifold flaps and the bracket on the In‐
take Manifold Runner Position Sensor 2 - G512- are rectangular.
• When installing pay attention that the bracket on the Intake
Manifold Runner Position Sensor - G336- is positioned per‐
pendicular on the shaft for the intake manifold flaps on the
intake manifold flaps.
Note
♦ Replace seals.
♦ Secure all hose connections with standard production hose
clamps. Refer to the Parts Catalog.
– Install the engine cover. Refer to
⇒ “3.4 Engine Covers, Removing and Installing”, page 27 .
Tightening Specifications
♦ Refer to
⇒ “3.7 Overview - Intake Manifold Lower Section, Fuel Rail and
Fuel Injectors”, page 30 .
2.3.2 Intake Flap Control Vacuum Actuator,
Removing and Installing, Cylinder Bank
2 (Left)
Special tools and workshop equipment required
♦ Hose Clamps - Up To 25mm - 3094-
♦ Hose Clip Pliers - VAS6362-
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
10 Rep. Gr.24 - Multiport Fuel Injection

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.
♦ Commercially available Torx socket wrench or Bit 10 with ball
head
♦ Commercially available -Magnetic Rod-
Removing
– Remove the front noise insulation -1-. Refer to ⇒ Body Exte‐
rior; Rep. Gr. 66 ; Noise Insulation; Noise Insulation Removing
and Installing .
WARNING
There is a risk of injury if the radiator fan turns on by itself.
♦ The coolant fan can come on even when the ignition is
turned off, for example, caused by the heat still in the en‐
gine compartment.
– Clamp off the coolant hoses -arrows- with the Hose Clamps -
Up To 25mm - 3094- .
– Remove the bolt -1-.
Note
The coolant hoses remain connected.
– Remove the front engine cover. Refer to
⇒ “3.4 Engine Covers, Removing and Installing”, page 27 .
– Open the clamp -1- and remove the vacuum hose from the
vacuum pump.
Note
Ignore the -arrows-.
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
2. Vacuum System 11

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.
– Clamp off the coolant hoses -1- with the Hose Clamps - Up To
25mm - 3094- and remove them from the coolant pipes on the
supercharger by loosening the hose clamps.
– Remove the bolt -2-.
– Disconnect the connector -1- on the Engine Coolant Temper‐
ature Sensor - G62- .
Note
Ignore item -2- and -arrow-.
– Remove the bolt -2- and bracket -3-.
– Move the coolant pipe -1- to the side.
– Remove the bolts -2 and 3- and then remove the Intake Mani‐
fold Runner Position Sensor 2 - G512- .
Note
It is recommended to use a magnate to prevent the bolt from fall‐
ing.
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
12 Rep. Gr.24 - Multiport Fuel Injection

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.
– Unclip the actuator rod -1- from the ball head vacuum actuator
-2-.
– Remove the vacuum hose -3-, and remove the vacuum ac‐
tuator.
Installing
Install in reverse order of removal and note the following:
The shaft for the intake manifold flaps and the bracket on the In‐
take Manifold Runner Position Sensor 2 - G512- are rectangular.
• When installing pay attention that the bracket on the Intake
Manifold Runner Position Sensor - G336- is positioned per‐
pendicular on the shaft for the intake manifold flaps on the
intake manifold flaps.
Note
♦ Replace seals.
♦ Secure all hose connections with standard production hose
clamps. Refer to the Parts Catalog.
– Install the engine cover. Refer to
⇒ “3.4 Engine Covers, Removing and Installing”, page 27 .
– Check the coolant level. Refer to ⇒ Fuel Injection and Ignition;
Rep. Gr. 19 ; Cooling System, Coolant, Draining and Filling .
Tightening Specifications
♦ Refer to
⇒ “3.7 Overview - Intake Manifold Lower Section, Fuel Rail and
Fuel Injectors”, page 30
♦ Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Noise Insulation;
Overview - Noise Insulation .
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
2. Vacuum System 13

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.
3 Injection System
⇒ “3.1 Test Data”, page 14
⇒ “3.2 Component Locations - Overview”, page 14
⇒ “3.3 Overview - Air Filter”, page 25
⇒ “3.4 Engine Covers, Removing and Installing”, page 27
⇒ “3.4 Engine Covers, Removing and Installing”, page 27
⇒ “3.5 Air Filter Element, Removing and Installing”, page 27
⇒ “3.6 Air Filter Housing, Removing and Installing”, page 28
⇒ “3.7 Overview - Intake Manifold Lower Section, Fuel Rail and
Fuel Injectors”, page 30
⇒ “3.8 Intake Air Temperature Sensor G42 / Manifold Absolute
Pressure Sensor G71 , Removing and Installing”, page 34
⇒ “3.9 Throttle Valve Control Module J338 , Removing and In‐
stalling”, page 34
⇒ “3.10 Control Valve Control Unit J808 , Removing and Instal‐
ling”, page 36
⇒ “3.11 Intake Manifold Lower Section with Fuel Rail, Removing
and Installing”, page 36
⇒ “3.12 Fuel Injectors, Removing and Installing”, page 39
⇒ “3.13 Fuel Pressure and Residual Pressure before High Pres‐
sure Pump, Checking”, page 42
⇒ “3.14 Overview - High Pressure Pump”, page 45
⇒ “3.15 High Pressure Line, Removing and Installing”,
page 47
⇒ “3.16 High Pressure Pump, Removing and Installing”,
page 49
⇒ “3.17 Overview - Heated Oxygen Sensors”, page 52
⇒ “3.18 Heated Oxygen Sensors G39 / G108 / G130 / G131 ,
Removing and Installing”, page 53
3.1 Test Data
3.0L TFSI Engine
Idle speed Cannot be adjusted, it is regu‐
lated by idle stabilization
Fuel pressure before high-
pressure pump
3 to 6 bar (43 to 87 psi) pres‐
sure
Fuel pressure after high-pres‐
sure pump
30 to 125 bar (435 to 1812 psi)
pressure
3.2 Component Locations - Overview
Engine Compartment, Right Side
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
14 Rep. Gr.24 - Multiport Fuel Injection

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.
1 - Secondary Air Injection
Pump Motor - V101-
❑ Component location.
Refer to
⇒ Fig. ““ Secondary Air
Injection Pump Motor -
V101- Component Lo‐
cation”“ , page 25 .
2 - Charge Air Pressure Sen‐
sor - G31- / Intake Manifold
Temperature Sensor - G72-
❑ Component location.
Refer to
⇒ Fig. ““ Charge Air
Pressure Sensor -G31- /
Intake Manifold Tem‐
perature Sensor -G72-
Component Location”“ ,
page 23 .
3 - Ignition Coils, Cylinder
Bank 1
❑ Ignition Coil 1 with Pow‐
er Output Stage - N70-
❑ Ignition Coil 2 with Pow‐
er Output Stage - N127-
❑ Ignition Coil 3 with Pow‐
er Output Stage - N291-
❑ Removing and instal‐
ling. Refer to
⇒ “2.3 Ignition Coils with
Power Output Stages,
Removing and Instal‐
ling”, page 69 .
4 - Connectors
❑ For heated oxygen sen‐
sors
❑ Connector assignments. Refer to
⇒ Fig. ““Connectors for the Right Heated Oxygen Sensor in the Engine Compartment”“ , page 20 .
5 - Heated Oxygen Sensor - G39-
❑ With Oxygen Sensor Heater - Z19-
❑ Component location. Refer to
⇒ Fig. ““Component Location: Cylinder Bank 1 (right) Heated Oxygen Sensors”“ , page 21 .
❑ Component location: connector. Refer to
⇒ Fig. ““Connectors for the Right Heated Oxygen Sensor in the Engine Compartment”“ , page 20
❑ Removing and installing. Refer to
⇒ “3.18 Heated Oxygen Sensors G39 / G108 / G130 / G131 , Removing and Installing”, page 53 .
6 - Engine Control Module - J623-
❑ Component location. Refer to
⇒ Fig. ““ Engine Control Module -J623- Component Location”“ , page 19 .
❑ Removing and installing. Refer to
⇒ “4.2 Engine Control Module J623 , Removing and Installing”, page 58 .
7 - Camshaft Adjustment Valve 1 - N205-
❑ Component location. Refer to
⇒ Fig. ““Camshaft Position Sensor and Exhaust Camshaft Control Valve Cylinder Bank 1 (right)”“ , page
23 .
8 - Oxygen Sensor after Three Way Catalytic Converter - G130-
❑ With Heater For Oxygen Sensor 1 after Catalytic Converter - Z30-
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
3. Injection System 15

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.
❑ Component location. Refer to
⇒ Fig. ““Component Location: Cylinder Bank 1 (right) Heated Oxygen Sensors”“ , page 21 .
❑ Component location: connector. Refer to
⇒ Fig. ““Connectors for the Right Heated Oxygen Sensor in the Engine Compartment”“ , page 20
❑ Removing and installing. Refer to
⇒ “3.18 Heated Oxygen Sensors G39 / G108 / G130 / G131 , Removing and Installing”, page 53 .
9 - Secondary Air Injection Sensor 1 - G609-
❑ Component location. Refer to
⇒ Fig. ““ Secondary Air Injection Sensor 1 -G609- Component Location”“ , page 25 .
10 - Throttle Valve Control Module - J338-
❑ Component location. Refer to
⇒ Fig. ““ Throttle Valve Control Module -J338- Component Location”“ , page 22 .
❑ Removing and installing. Refer to
⇒ “3.9 Throttle Valve Control Module J338 , Removing and Installing”, page 34 .
11 - EVAP Canister Purge Regulator Valve 1 - N80-
12 - Engine Speed Sensor - G28-
❑ Component location. Refer to
⇒ Fig. ““ Engine Speed Sensor -G28- Component Location”“ , page 25 .
❑ Removing and installing. Refer to
⇒ “2.6 Engine Speed Sensor G28 , Removing and Installing”, page 71 .
13 - Knock Sensor 1 - G61-
❑ Component location. Refer to
⇒ Fig. ““Component Location Under the Intake Manifold Lower Section, Cylinder Bank 2 (left)”“ ,
page 22 .
❑ Component location: connector. Refer to
⇒ Fig. ““Connectors for the Right Heated Oxygen Sensor in the Engine Compartment”“ , page 20
❑ Removing and installing. Refer to
⇒ “2.4 Knock Sensor 1 G61 / Knock Sensor 2 G66 , Removing and Installing”, page 70 .
14 - Cylinder Bank 1 Fuel Injectors
❑ Cylinder 1 Fuel Injector - N30-
❑ Cylinder 2 Fuel Injector - N31-
❑ Cylinder 3 Fuel Injector - N32-
❑ Removing and installing. Refer to ⇒ “3.12 Fuel Injectors, Removing and Installing”, page 39 .
15 - Intake Manifold Runner Position Sensor - G336-
❑ Component location. Refer to
⇒ Fig. ““ Intake Manifold Runner Position Sensor -G336- Component Location”“ , page 22 .
16 - Camshaft Position Sensor - G40-
❑ Component location. Refer to
⇒ Fig. ““Camshaft Position Sensor and Exhaust Camshaft Control Valve Cylinder Bank 1 (right)”“ , page
23 .
❑ Removing and installing. Refer to
⇒ “2.5 Camshaft Position Sensor G40 / Camshaft Position Sensor 2 G163 , Removing and Installing”,
page 71 .
17 - Low Fuel Pressure Sensor - G410-
18 - Fuel Metering Valve - N290-
❑ Component location. Refer to ⇒ Fig. ““ Fuel Metering Valve -N290- Component Location”“ , page 21 .
19 - Charge Air Cooling Pump - V188-
❑ Component location. Refer to
⇒ Fig. ““ Charge Air Cooling Pump -V188- Component Location”“ , page 24 .
Engine Compartment, Left Side
Audi Q7 2007 ➤
Fuel Injection and Ignition - Edition 02.2015
16 Rep. Gr.24 - Multiport Fuel Injection