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Audi 5 cylinder turbo

The first thing to do is to remove the intake hose. Then, remove throttle body.

Remove injectors cooling duct.

Removing mechanical injector

Remove mechanical injectors and distributor.

Remove MAF air plate. Secure moving part with plastic strap.

Bend injector ventilation pipe, because it will prevent the fuel rail installation.

Injector sleeves

Unscrew injector sleeves. Be careful, sleeves have 3 parts, which can fall into the engine.

Plastic part can be extracted with the thread tap

We need this part only. Install it back using engine sealant.

Install additional o-rings on the injectors. Lubricate o-rings, and insert injectors into sleeves until click.

O-ring on injector tip should sit into it's place.

Connect injector harness.

Fuel rail

Lubricate o-rings with water, and fit rail into place. Mark and drill holes for securing the rail.

Throttle body

Install throttle body. You should cut the body to fit it.

Fuel lines and filter

Now the fuel lines can be mounted

The metal cylinder with three fittings is a fuel filter combined with a pressure regulator, you will need to get rid of the old original one.

The delivery line that goes from the fuel pump is connected to the "IN" fitting. The return line that goes back to the tank is connected directly to the unnamed central fitting. The main line that goes to the fuel rail is connected to the "OUT".

Use the the three black junctions provided with the kit to connect the rubber line to the filter/pressure regulator and ensure that they are properly mounted.

After the fuel lines are installed, turn on and off the ignition (without powering the starter) 5-6 times, to build pressure in the fuel lines.

Check carefully for any leaks.

MAP

MAP sensor location is really important to ensure a great engine operation. Locate MAP sensor exactly as shown on photo.

Drill 13mm hole for the sensor and 8mm for the bolt that will secure it. Cover the drill tip with grease to catch the debris, it is reccomended to clean the intake manifold after drilling the hole to ensure that no metal debris is left in it.

Seal hole with a sealant. Sufficient sealing paste must be applied because the surface of the intake manifold is rough.

Secure sensor with included screw. Apply sealant to the thread, to prevent air leaks and unscrewing.

Never install any sensor with the wires upwards, water will flow off the cable and shortcircuit the sensor.

Idle valve

Clean valve internals with carburettor cleaner, and lubricate with the oil. Don't use WD40, it is not lubricant.

Air ducts

Install back air ducts, hoses, etc.

ECU and wiring

Warning

Disconnect battery when working with the electrical system. Connect battery back only when engine have to be started.

ECU is dust and splashproof. It cannot withstand continuous water contact or pressurized water, so it is reccomended to install it in a dry and safe place. Do not install ECU with cable upwards. In this case, water and moisture will flow off the cable into ECU.

Warning

Wire colors are not fixed, and can be changed. Wires are labeled. Refer to labels to determine wire purpose.

This is the wiring.

Put the wiring this way:

AFS emulator

AFS emulator is needed only for stock trip computer. If you don't have stock trip computer - skip this step.

AFS wires are hidden here:

Cut the middle wire from the connector, and connect to the EMUL wire.

Hall sensor

Find the hall sensor connector on the ignition distributor.

Connect DH wire in parallel to the central wire of hall sensor connector.

Ignition amplifier

Connect AN wire to the middle pin of the ignition amplifier.

If you have different amplifier, not like on photo, you should connect AN wire to the control pin. You should find thin wire, connected from the amplifier to the stock ECU. Refer to the stock wiring diagram at the end of this document.

Lambda sensor

Connect the LAMBDA wire to the signal wire of the lambda probe (see on photo).

Attention! Make sure to disconnect the lambda from the stock ECU to avoid interference.

If you don't have lambda sensor, or your sensor is malfunctioning, you should install universal Bosch sensor 0258986507 or 0258006537

Connection diagram:

  • white wires - to the heating connector
  • black - signal to the ECU
  • gray - to the ECU ground

Throttle position switches

Disconnect stock connector, and check idle switch resistance. It should be 0..5 Ohm. If higher - switch is worn out, you should replace it.

Check FULL LOAD switch. It should engage at 55-60% throttle opening.

Connect IDLE SW in parallel to the idle switch wire

Connect FULL SW in parallel to the full throttle switch wire

Coolant temperature sensor

CLT wire is connected in parallel to the coolant temperature sensor

Intake air temperature sensor

CLT wire is connected in parallel to the air temperature sensor

Warning! IAT sensor should be functioning correctly. It is original sensor, it's not replaceable with ordinary resistive sensors. With IAT malfunctioning, ignition system will not work correctly.

Idle valve

Disconnect old idle valve connector, and connect new one, labeled IDLE.

Power

Connect power wires to the battery. Secure main relay near the battery.

Connect COIL +12 wire to the ignition coil +12V terminal. This wire is used for switching on the main relay.

Air conditioner

Connect EXT wire to the air conditioner clutch wire. It is used for maintaining idle RPM while air conditioner is operating.

K-Line

Normally, you will use Bluetooth interface to connect to the ECU. In rare cases, BT connection is unreliable, so you can use K-Line instead.

To connect K-Line cable, you should prepare 3 wires:

  • 12V
  • Ground
  • K-line

Pinout of the K-Line cable:

Pinout of the car OBD2 connector

Other wires

There are other wires, not mentioned in this manual. They are reserved for future use. Isolate and hide unused wires into the harness.

Additional info

Stock ECU wiring diagram

Stock IAT sensor

MAP sensor pinout

Invent Jetronic ECU pinout

View at the ECU connector

8 7 6 5 4 3 2 1
A IDLE INJ1 INJ2 INJ3 INJ4 INJ5 INJ6
B +12V CLT TPS AN KLINE EMUL IDLE SW FULL SW
C GND 5V OUT IAT MAP LAMBDA EXT DH AC*

(*) - АС input is available starting from ECU version 2.3

Abbreviations

  • MAP - absolute pressure sensor
  • TPS - throttle position sensor
  • IAT - sensor air temperature
  • CLT - coolant temperature sensor
  • DH - Hall sensor
  • AFS - airflow sensor
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