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Audi 5 cylinder turbo

First, remove the intake hose. Next, detach the throttle body. Finally, remove the injectors' cooling duct.

Removing mechanical injector

Remove mechanical injectors and distributor.

Remove the MAF air plate and secure the moving component with a plastic strap.

Bend the injector ventilation pipe to allow the installation of the fuel rail.

Injector sleeves

Carefully unscrew the injector sleeves, ensuring caution as the sleeves consist of three parts that may fall into the engine.

The plastic component can be removed using the thread tap.

We only need this part. Reinstall it using engine sealant.

Install additional O-rings on the injectors. Lubricate the O-rings, then insert the injectors into the sleeves until they click into place.

The O-ring on the injector tip must be properly seated.

Connect injector harness.

Fuel rail

Lubricate the O-rings with water and position the rail appropriately.

Bend the metal brackets of the rail and drill a hole in each bracket to insert the screw that will secure it to the intake manifold.

Ensure the injectors are fully inserted without any misalignment.

Throttle body

Install the throttle body. Trim the body as necessary to ensure a proper fit. Refer to the attached photo for guidance.

Fuel lines and filter

The fuel lines are now ready for installation.

The metal cylinder with three fittings serves as both a fuel filter and a pressure regulator, necessitating the removal of the old original unit.

  • Connect the feeding line from the fuel pump to the "IN" fitting.
  • Attach the return line, which goes back to the tank, directly to the unnamed central fitting.
  • Connect the main line leading to the fuel rail to the "OUT" fitting.

Utilize the three black junctions included in the kit to connect the rubber line to the filter/pressure regulator, ensuring they are securely mounted.

Once the fuel lines are installed, cycle the ignition on and off 5-6 times without engaging the starter to build pressure in the fuel lines.

Thoroughly inspect for any potential leaks.

The fitting features a cone-shaped seal that tightens under fuel pressure. If you notice a leak, try gently moving the fitting back and forth. If it continues to leak, remove it and apply a small amount of oil to the sealing parts.

MAP

The precise placement of the MAP sensor is crucial for optimal engine performance. Please position the MAP sensor exactly as shown on the photo

Drill a 13mm hole for the sensor and an 8mm hole for the securing bolt. Apply grease to the drill tip to capture debris. It is recommended to clean the intake manifold thoroughly after drilling to ensure no metal debris remains.

Apply a sealant to fill the hole, ensuring an adequate amount of sealing paste is used due to the rough surface of the intake manifold.

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

Never install the sensor with the wires facing upwards to prevent water from running along the cable, which could lead to connector flooding and subsequent oxidation.

Secure the sensor using the screw. Apply sealant to the threads to prevent air leaks and ensure the sensor remains securely fastened.

Warning

Installing a MAP sensor in place of a cold start injector is strictly prohibited.

Idle valve

Clean the valve internals using carburetor cleaner and lubricate them with oil. Avoid using WD-40, as it is not a good lubricant. Bicycle chain lubricant is well suitable for this purpose.

Air ducts

Reinstall the rear air ducts, hoses, and other previously removed components

ECU and wiring

Warning

Disconnect the battery when servicing the electrical system. Reconnect the battery only when the engine needs to be started.

The ECU is designed to be dust and splash-resistant but is not suitable for continuous exposure to water or pressurized water. It is recommended to install it in a dry and secure location. Ensure that the ECU is not installed with the cable facing upwards, as this may allow water and moisture to enter the unit.

Warning

Wire colors may change without prior notice. If wires have text labels, use these labels to identify the purpose of each wire.

This is the wiring.

Put the wiring this way:

AFS emulator

The emulator is needed only for a stock on-board computer. If you don't have one - skip this step.

A stock computer will still show inaccurate fuel consumption, so it is better to install our on-board computer instead.

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.

RPM signal

Сonnect AN wire to the Tachometer output of the stock ECU (Pin 7 of MC1 ECU)

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 your vehicle lacks a lambda sensor or if the existing sensor is malfunctioning, it is recommended to install a universal Bosch sensor, either model 0258986507 or 0258006537.

The original lambda probe features three wires: ECU signal, ECU ground, and heater +12V. It does not include a heater ground wire, as the exhaust pipe serves as the ground.

The new lambda probe is designed with two separate heater wires, and the heater is isolated from the sensor housing, providing a more robust design.

Connection diagram:

  • White wires: Connect one to the lambda heating connector or the fuel pump supply, and the other to the car chassis.
  • Black: Connects to the LAMBDA wire of the ECU
  • Gray: Connects to the ground point of the ECU

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

IAT wire is connected in parallel to the stock 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.

LPG

Connect the EXT wire to the gas supply valve and activate the LPG mode by EXT input in the settings. The ECU will then adjust to operate on gas fuel.

For carburetted LPG systems, it is unnecessary to disconnect the power from the gasoline injectors. Simply select the Turn off injection option, and the fuel supply will be interrupted by the signal from the EXT. Connect the EXT wire to the gas supply valve and activate the LPG mode by EXT input in the settings. The ECU will then adjust to operate on gas fuel.

Air conditioner

Connect the AC (or EXT) wire to the air conditioner clutch wire. This connection is essential for maintaining the idle RPM when the air conditioner is engaged.

K-Line

To connect the K-Line cable, you will need to prepare three wires: Typically, the Bluetooth interface is used to connect to the ECU. However, in rare instances where the Bluetooth connection proves unreliable, the K-Line can be utilized as an alternative.

To connect the K-Line cable, you need 3 wires:

  • 12V
  • Ground
  • K-line

Pinout of the K-Line cable:

Pinout of the car OBD2 connector

Other wires

This manual does not mention certain additional wires, which are reserved for future use. Please ensure that any unused wires are isolated and concealed within the harness.

Additional info

Stock ECU wiring diagram

Stock IAT sensor

MAP sensor pinout

Invent Jetronic ECU pinout
8 7 6 5 4 3 2 1
A IDLE INJ1 INJ2 INJ3 INJ4 INJ5 INJ6 X1**
B +12V CLT TPS AN KLINE EMUL IDLE SW FULL SW
C GND 5V OUT IAT MAP LAMBDA EXT DH AC*

() - available in version 2.3 (*) - available in version 2.5

3-wire IAC valve

This valve contains two windings: one for opening and another for closing.

An external circuit is necessary to connect this valve. A MOSFET capable of handling over 5A of current and more than 55V of voltage is used (for example IRFZ44)

The dotted line represents the IAC case

Abbreviations

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