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Service
Workshop Manual
Audi TT 2007 ➤
Fuel supply system, diesel engines
Engine ID
Edition 06.2010
CBBBCFG
B
Service Department. Technical Information
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
20 - Fuel supply 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.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A005TT02320
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Using testers and measuring instruments during a road test . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Removing and installing components from a full or partly full fuel tank . . . . . . . . . . . . . . . . 2
1.5 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Rules for cleanliness when working on fuel supply system and injection system . . . . . . . . 3
2.2 Test conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Fuel tank with attached components - vehicles with four-wheel drive . . . . . . . . . . . . . . . . 5
1.1 Fuel tank with attached components - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 8
2 Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive . . . . . . . . . . . . 14
2.1 Fuel delivery unit and fuel gauge senders - exploded view . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Fuel system pressurisation pump G6 - electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 Checking fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.6 Checking fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.7 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.8 Suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.9 Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3 Supplementary fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1 Supplementary fuel pump V393 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2 Removing and installing supplementary fuel pump V393 . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.1 Fuel filter - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2 Removing and installing fuel filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5 Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7 Accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.1 Accelerator pedal module - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.2 Removing and installing accelerator pedal module with accelerator position senders . . . . 45
Contents i
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Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
ii Contents
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Fuel supply system, diesel engines - Edition 06.2010
00 – Technical data
1 Safety precautions
Overview
♦ ⇒ “1.1 Working on the fuel system”, page 1
♦ ⇒ “1.2 Using testers and measuring instruments during a road
test”, page 2
♦ ⇒ “1.3 Working on vehicles with start/stop system”,
page 2
♦ ⇒ “1.4 Removing and installing components from a full or partly
full fuel tank”, page 2
♦ ⇒ “1.5 Removing and installing fuel tank”, page 2
1.1 Working on the fuel system
When working on the fuel system note the following warnings:
Audi TT 2007 ➤
WARNING
Risk of injury - fuel system operates under pressure.
♦ Wrap a cloth around the connection before opening the
fuel system. Then release pressure by carefully loosening
the connection.
The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
Observe the following points to prevent personal injuries and
damage to the injection and glow plug system:
♦ Always switch off the ignition before connecting or discon‐
necting tester cables or electrical wiring for the injection or
glow plug system.
♦ Always switch off ignition before washing engine.
♦ Faults are stored in the engine control units if electrical con‐
nectors were unplugged and the engine was started: Inter-
rogate event memory in Guided Functions ⇒ Vehicle
diagnostic tester .
Caution
To prevent damage to the electronic components when dis‐
connecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery.
Disconnect battery ⇒ Electrical system; Rep. Gr. 27 .
1. Safety precautions 1
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Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
1.2 Using testers and measuring instru‐
ments during a road test
Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
Accidents can be caused if the driver is distracted by test
equipment while road-testing, or if test equipment is not prop‐
erly secured.
Persons sitting in the front passenger's seat could be injured if
the airbag is triggered in an accident.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Test equipment must always be secured on the rear seat
with a strap and operated from the rear seat by a second
person.
1.3 Working on vehicles with start/stop sys‐
tem
When performing repairs on vehicles with start/stop system, note
the following:
WARNING
Risk of injury due to automatic engine start on vehicles with
start/stop system.
♦ On vehicles with activated start/stop system (this is indi‐
cated by a message in the instrument cluster display), the
engine may start automatically on demand.
♦ Therefore it is important to ensure that the start/stop sys‐
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).
1.4 Removing and installing components from a full or partly full fuel tank
When removing and installing components from a full or partly full
fuel tank, note the following:
♦ Fuel tank must not be full. The amount of fuel which can be
left in the fuel tank is indicated in the corresponding procedure
description. Drain fuel tank if necessary ⇒ page 6 .
♦ Before commencing work, switch on exhaust extraction sys‐
tem and place an extraction hose close to the sender opening
in the fuel tank to extract escaping petrol fumes. If no exhaust
extraction system is available, a radial fan with a displacement
of at least 15 m3/h can be used (the fan motor must be clear
of the air stream).
♦ Avoid skin contact with fuel. Wear fuel-resistant gloves.
1.5 Removing and installing fuel tank
♦ Fuel tank must be empty to reduce weight. Drain fuel tank if
necessary ⇒ page 6 .
2 Rep. Gr.00 - Technical data
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Fuel supply system, diesel engines - Edition 06.2010
2 General repair instructions
Overview
♦ ⇒ “2.1 Rules for cleanliness when working on fuel supply sys‐
tem and injection system”, page 3
♦ ⇒ “2.2 Test conditions”, page 3
♦ ⇒ “2.3 Contact corrosion!”, page 3
2.1 Rules for cleanliness when working on fuel supply system and injection system
Even small amounts of dirt can cause malfunctions. For this rea‐
son, please observe the following rules when working on the fuel
supply system and injection system:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal off open pipes/lines and connections immediately with
clean plugs, e.g. from engine bung set -VAS 6122- .
♦ Place parts that have been removed on a clean surface and
cover them over. Use only lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have not been stored in their packing (e.g. in tool boxes
etc.).
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
Audi TT 2007 ➤
2.2 Test conditions
• Battery voltage at least 12.5 V
• Fuel pump fuse OK ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
• Fuel pump relay -J17- OK ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.
• Fuel pump control unit -J538- Ok; checking in Guided Fault
Finding ⇒ vehicle diagnostic tester .
•
Fuel tank at least 1/4 full.
• Fuel filter OK.
• Fuel lines OK (not obstructed or crushed).
2.3 Contact corrosion!
Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
used.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
2. General repair instructions 3
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Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Note the following:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend the use of Audi accessories.
♦ Damage caused by contact corrosion is not covered under
warranty.
4 Rep. Gr.00 - Technical data
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Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
20 – Fuel supply system
1 Fuel tank with attached components
- vehicles with four-wheel drive
⇒ “1.1 Fuel tank with attached components - exploded view”, page
5
⇒ “1.2 Draining fuel tank”, page 6
⇒ “1.3 Removing and installing fuel tank with attached compo‐
nents”, page 8
1.1 Fuel tank with attached components - exploded view
1 - Nut
❑ 23 Nm
2 - Heat shield for fuel tank
❑ With support bracket
3 - Fuel return line
❑ Blue
❑ From fuel filter
❑ Do not kink
❑ Clip onto fuel tank
4 - Fuel supply line
❑ Black
❑ To fuel filter
❑ Do not kink
❑ Clip onto fuel tank
5 - Electrical connector
❑ For fuel system pressur‐
isation pump -G6- and
fuel gauge sender -G-
6 - Protective plate
❑ For fuel filler neck
7 - Filler cap
❑ Secured to tank flap unit
8 - Earth connection
❑ To eliminate electrostat‐
ic charge
❑ Installation position
⇒ page 6
❑ Make sure that connec‐
tor is securely fitted
❑ After installation, use an
ohmmeter to check the electrical connection between the protective plate -item 6- on the fuel filler neck
and a bare metal part on the body. Specification: approx. 0 Ω
9 - Bolt
❑ 11 Nm
1. Fuel tank with attached components - vehicles with four-wheel drive 5
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Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
10 - Pop rivet
11 - Fuel tank
❑ Removing and installing ⇒ page 8
12 - Electrical connector
❑ For fuel gauge sender 2 -G169-
13 - Securing strap
❑ Installation position: Fixing point (hole) points in direction of travel
Earth connection for fuel filler neck and protective plate
– The connections -2- and -4- on filler neck must be free from
corrosion to ensure earth connection to body is not impaired.
– Position the earth connection as illustrated -1-.
– Ensure that connectors -arrows- for earth connection are prop‐
erly seated on protective plate -5- and on fuel filler neck -3-.
WARNING
Risk of explosion caused by electrostatic discharge.
♦ After installation, use an ohmmeter to check the electrical
connection between the metal ring on the fuel filler neck
and a bare metal part on the body:
• Specification: approx. 0 Ω
1.2 Draining fuel tank
Special tools and workshop equipment required
♦ Wrench -T10202-
♦ Fuel extractor -VAS 5190-
6 Rep. Gr.20 - Fuel supply system
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Fuel supply system, diesel engines - Edition 06.2010
Procedure
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .
– Release the tank flap.
– Detach tapered adapter -2- from shaft end -1- of fuel extractor
-VAS 5190- .
– Use insulating tape to mark the extraction hose -arrow- at a
distance of -a- = 1,370 mm from the end of the hose.
– Remove filler cap from fuel filler neck.
– Screw shaft end of fuel extractor -VAS 5190- onto fuel filler
neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
Audi TT 2007 ➤
Note
♦
The procedure when using a fuel extractor without shaft end
is basically the same.
♦
In this case, make a mark -arrow- on the extraction hose at
distance -a- = 1,305 mm from the end of the hose using insu‐
lating tape. The extraction hose has been properly inserted
when the affixed mark is level with the edge of the filler neck.
♦
If hose is difficult to insert, apply a thin coat of engine oil. DO
NOT use silicone-based lubricant.
– Drain fuel tank as much as possible through fuel filler neck.
– Carefully remove extraction hose.
TT Coupé:
– Remove rear seat bench ⇒ Rep. Gr. 72 .
TT Roadster:
– Remove back panel side trim (left-side) ⇒ Rep. Gr. 70 .
All vehicles (continued):
– Unclip the retaining tabs -arrows- for the flange cover (left-
side).
1. Fuel tank with attached components - vehicles with four-wheel drive 7
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Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
– Unplug electrical connector -1- at flange.
– Disengage electrical connector -2- and move it clear to the
side.
– Unscrew locking ring using wrench -T10202- .
– Carefully pull fuel gauge sender 2 -G169- -item 1- with suction-
jet pump just slightly out of aperture in fuel tank.
Note
When removing, make sure you do not bend float arm of fuel
gauge sender 2 -G169- .
– Extract fuel from left fuel tank chamber through fuel tank open‐
ing using fuel extractor -VAS 5190- .
– Push hose into right-hand chamber of fuel tank and extract
remaining fuel.
– Re-install fuel gauge sender 2 -G169- ⇒ page 29 ; observe
notes on procedure for connecting battery.
1.3 Removing and installing fuel tank with attached components
Special tools and workshop equipment required
♦ Engine and gearbox jack -V.A.G 1383 A-
8 Rep. Gr.20 - Fuel supply system
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♦ Hook -3004-
Removing
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .
– Release the tank flap.
WARNING
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
Risk of accident caused by weight of fuel tank
♦ Fuel tank must be empty when it is removed.
– Drain fuel tank ⇒ page 6 .
TT Coupé:
– Remove rear seat bench ⇒ Rep. Gr. 72 .
TT Roadster:
– Remove back panel trim (right and left) ⇒ Rep. Gr. 70 .
All vehicles (continued):
– Unclip the retaining tabs -arrows- for the flange cover (right-
side).
– Unplug electrical connector -arrow- at flange.
1. Fuel tank with attached components - vehicles with four-wheel drive 9
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Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
– Unclip the retaining tabs -arrows- for the flange cover (left-
side).
– Unplug electrical connector -1- at flange.
– Unplug electrical connector -2- for Haldex coupling.
– Clean area around fuel filler neck.
– Remove filler cap -arrow- from fuel filler neck.
– Seal opening of fuel filler neck with a piece of clean foam or
similar to prevent dirt from dropping into the tank.
– Remove rear right wheel housing liner ⇒ Rep. Gr. 66 .
– Detach electrical wire -1- for ABS speed sensor from bracket
on fuel filler neck.
– Remove bolts -2- and -3- for fuel filler neck.
– Move overflow hose -4- on fuel filler neck clear.
TT Roadster:
– Remove diagonal struts ⇒ Rep. Gr. 42 .
10 Rep. Gr.20 - Fuel supply system
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Fuel supply system, diesel engines - Edition 06.2010
All vehicles (continued):
Caution
Risk of damage to flexible joints in front exhaust pipe
♦ The flexible joints in the front exhaust pipe must not be
bent more than 10°.
♦ Before slackening clamp on exhaust pipe, secure front
section of exhaust system to underbody of vehicle with a
chain.
– Separate exhaust system at clamp -arrows-.
– Secure front section of exhaust system with a chain. To do so,
engage hooks -3004- into openings on underside of vehicle
(remove plugs if fitted).
– Push the clamp back in order to separate the exhaust system.
Note
Audi TT 2007 ➤
A second person will be required for detaching rear section of
exhaust system.
– Disengage rear silencer at the rubber mountings and remove
rear section of exhaust system.
– Remove propshaft ⇒ Rear final drive 02D/0AV; Rep. Gr. 39 .
WARNING
Risk of injury - fuel system operates under pressure.
♦ Wrap a clean cloth around the connection before opening
the fuel system. Then release pressure by carefully loos‐
ening the connection.
♦ Wear protective gloves.
♦ Wear safety goggles.
The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
– Press release tab and disconnect fuel supply pipe -1- and re‐
turn pipe -2- at front right of fuel tank.
1. Fuel tank with attached components - vehicles with four-wheel drive 11
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
WARNING
Risk of accident caused by weight of fuel tank
♦ Fuel tank must be empty when it is removed.
– First remove bolts -2, 5, 6-.
– If fitted, unhook wiring harness -arrows- and move it clear.
– Position engine and gearbox jack -V.A.G 1383 A- below vehi‐
cle to support tank.
– Remove bolts -1, 3, 4, and 7-.
– Then lower fuel tank using engine and gearbox jack -V.A.G
1383 A- , simultaneously guiding fuel tank down by hand.
– Remove fuel tank downwards (turning it sideways as re‐
quired).
– In addition, a 2nd mechanic will be required to guide the fuel
filler neck on trailing arm out by hand.
Installing
• Tightening torques ⇒ page 5
Installation is carried out in the reverse order; note the following:
– Position fuel tank with securing straps on underbody, using
engine and gearbox jack -V.A.G 1383 A- .
– Attach wiring harness at top of fuel tank.
– When installing fuel tank, make sure that the fuel filler neck is
correctly inserted into the opening on the body.
– Secure fuel tank by first tightening bolts at points -1, 3, 4, 7-,
then at points -2, 5, 6-.
12 Rep. Gr.20 - Fuel supply system
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Fuel supply system, diesel engines - Edition 06.2010
– The connections -2- and -4- on filler neck must be free from
corrosion to ensure earth connection to body is not impaired.
– Tighten bolts -2- and -4- for fuel filler neck.
– Check the earth wiring at both ends for traces of oxidation and
remove oxidation if necessary.
– Position the earth connection as illustrated -1-.
– Ensure that connectors -arrows- for earth connection are prop‐
erly seated on protective plate -5- and on fuel filler neck -3-.
WARNING
Risk of explosion caused by electrostatic discharge.
♦ After installation, use an ohmmeter to check the electrical
connection between the metal ring on the fuel filler neck
and a bare metal part on the body:
• Specification: approx. 0 Ω
– Attach electrical wire for ABS speed sensor to bracket on fuel
filler neck.
– Install rear right wheel housing liner ⇒ Rep. Gr. 66 .
– Install propshaft ⇒ Rear final drive 02D/0AV; Rep. Gr. 39 .
– Install rear section of exhaust system ⇒ Rep. Gr. 26 .
– Install diagonal struts ⇒ Rep. Gr. 42 .
TT Coupé:
– Install rear seat bench ⇒ Rep. Gr. 72 .
TT Roadster:
– Install back panel trim (right and left) ⇒ Rep. Gr. 70 .
Audi TT 2007 ➤
1. Fuel tank with attached components - vehicles with four-wheel drive 13
Page 18
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
2 Fuel delivery unit and fuel gauge
senders - vehicles with four-wheel
drive
⇒ “2.1 Fuel delivery unit and fuel gauge senders - exploded view”,
page 14
⇒ “2.2 Fuel system pressurisation pump G6 - electrical test”, page
16
⇒ “2.3 Removing and installing fuel delivery unit”, page 18
⇒ “2.4 Checking fuel gauge sender G ”, page 22
⇒ “2.5 Removing and installing fuel gauge sender G ”,
page 24
⇒ “2.6 Checking fuel gauge sender 2 G169 ”, page 25
⇒ “2.7 Removing and installing fuel gauge sender 2 G169 ”, page
27
⇒ “2.8 Suction-jet pump”, page 31
⇒ “2.9 Removing and installing suction-jet pump”, page 31
2.1 Fuel delivery unit and fuel gauge senders - exploded view
1 - Fuel gauge sender -G-
❑ Checking resistance
values ⇒ page 22
❑ Removing and installing
⇒ page 24
2 - Fuel delivery unit with
flange
❑ Checking fuel system
pressurisation pump G6- (electrical test)
⇒ page 16
❑ Removing and installing
⇒ page 18
❑ Put at least 5 litres of
fuel into tank after instal‐
ling
3 - Seal
❑ Renew
❑ Install dry
4 - Fuel supply line
❑ Black
❑ To fuel filter
❑ Do not kink
❑ Attached to connection
marked “V” on flange
❑ To disconnect from
flange, press release
tab on connection
5 - Fuel return line
❑ Blue
❑ From fuel filter
❑ Do not kink
14 Rep. Gr.20 - Fuel supply system
Page 19
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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.
Fuel supply system, diesel engines - Edition 06.2010
❑ Attached to connection marked “R” on flange
❑ To disconnect from flange, press release tab on connection
6 - Electrical connector
❑ For fuel system pressurisation pump -G6- and fuel gauge sender -G-
7 - Locking ring
❑ Remove and install using wrench -T10202❑ 110 Nm
8 - Supply pipe for suction-jet pump
❑ From fuel pump to suction-jet pump
❑ Press release tab on pipe connector to disconnect
9 - Electrical connector
❑ For fuel gauge sender 2 -G169-
10 - Locking ring
❑ Remove and install using wrench -T10202❑ 110 Nm
11 - Seal
❑ Renew
❑ Install dry
12 - Fuel gauge sender 2 -G169-
❑ Only available together with -item 13-.
❑ Checking resistance values ⇒ page 25
❑ Removing and installing ⇒ page 27
❑ Installation position ⇒ page 30
13 - Suction-jet pump
❑ Only available together with -item 12-.
❑ Removing and installing ⇒ page 31
14 - Fuel supply pipe
❑ From suction-jet pump to fuel delivery unit
❑ Inserted in baffle housing of fuel delivery unit
Audi TT 2007 ➤
2. Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive 15
Page 20
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
2.2 Fuel system pressurisation pump -G6- - electrical test
Special tools and workshop
equipment required
♦ Remote control -
V.A.G 1348/3 A- with
adapter cable V.A.G 1348/3-3-
♦ Hand-held multimeter -
V.A.G 1526C-
♦ Auxiliary measuring set -
V.A.G 1594C-
Procedure
Observe test conditions ⇒ page 3 .
TT Coupé:
– Remove rear seat bench ⇒ Rep. Gr. 72 .
TT Roadster:
– Remove back panel side trim (right-side) ⇒ Rep. Gr. 70 .
16 Rep. Gr.20 - Fuel supply system
Page 21
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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.
Fuel supply system, diesel engines - Edition 06.2010
All vehicles (continued):
– Unclip retaining tabs -arrows- for flange cover.
– Unplug electrical connector -arrow- at flange.
Audi TT 2007 ➤
– Connect remote control -V.A.G 1348/3 A- with adapter cable
-V.A.G 1348/3-3- to contact -1- using a test lead from auxiliary
measuring set -V.A.G 1594C- .
– Tape off 2nd connector contact of the adapter cable -
V.A.G 1348/3-3- with insulating tape -arrow- to prevent short
circuits.
– Connect contact -5- to the body (earth) using a test lead from
auxiliary measuring set -V.A.G 1594C- .
– Connect crocodile clip to positive (+) terminal of battery.
– Press remote control button.
• Pump should start running audibly.
Note
The fuel pump runs very quietly. Where possible, avoid noisy sur‐
roundings for this test.
2. Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive 17
Page 22
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
If no noise can be heard from pump:
– Remove fuel delivery unit ⇒ page 18 .
– Check that the electrical wires between flange and fuel pump
are connected and test for continuity.
If no fault is found in wiring, fuel pump is defective. Renew fuel
delivery unit.
– Install fuel delivery unit ⇒ page 20 .
2.3 Removing and installing fuel delivery unit
Special tools and workshop equipment required
♦ Wrench -T10202-
Removing
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .
TT Roadster:
Caution
• On the TT Roadster, the fuel tank must first be removed
before removing the fuel delivery unit.
– Removing fuel tank ⇒ page 8 .
18 Rep. Gr.20 - Fuel supply system
Page 23
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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.
Fuel supply system, diesel engines - Edition 06.2010
TT Coupé:
WARNING
Large amounts of fuel can escape.
♦
The fuel tank must not be more than 1/3 full when remov‐
ing the fuel delivery unit, otherwise a large amount of fuel
will escape.
– Drain fuel tank if necessary ⇒ page 6 .
– Remove rear seat bench ⇒ Rep. Gr. 72 .
– Unclip the retaining tabs -arrows- for the flange cover (right-
side).
Audi TT 2007 ➤
– Unplug electrical connector -arrow- at flange.
– Mark fuel supply line -1- and fuel return line -2-.
WARNING
The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the fuel lines and the fuel can reach a
temperature of 100 °C. Allow the fuel to cool down before
disconnecting the lines - danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
Risk of injury - fuel system operates under high pressure.
♦ To reduce the pressure in the fuel system, wrap a clean
cloth around the connection and carefully loosen the con‐
nection.
– Detach both pipes from flange (press release tabs).
2. Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive 19
Page 24
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
TT Roadster:
– With fuel tank removed, mark fuel supply line -1- and fuel re‐
turn line -2-.
– Detach both pipes from flange (press release tabs).
TT Coupé:
WARNING
Large amounts of fuel can escape.
♦
The fuel tank must not be more than 1/3 full when remov‐
ing the fuel delivery unit, otherwise a large amount of fuel
will escape.
All vehicles (continued):
– Unscrew locking ring using wrench -T10202- .
– Take flange (right-side) and seal of fuel delivery unit out of
opening in fuel tank and move clear, leaving pipes connected.
– In opening in fuel tank, press release tab to disconnect supply
pipe -1- to suction-jet pump.
– Detach fuel supply pipe -2- from fuel delivery unit.
– Remove fuel delivery unit.
Note
♦
When removing fuel delivery unit, make sure you do not bend
float arm of fuel gauge sender -G- .
♦
Keep in mind that the fuel delivery unit still contains fuel.
Installing
• Tightening torque ⇒ page 14
Installation is carried out in the reverse order; note the following:
Note
♦
Renew seal.
♦
Take care not to bend the fuel gauge sender -G- when fitting
the fuel delivery unit.
♦
Ensure that fuel hoses are securely seated.
20 Rep. Gr.20 - Fuel supply system
Page 25
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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.
Fuel supply system, diesel engines - Edition 06.2010
– Insert fuel delivery unit in fuel tank with flange still detached.
– Push fuel supply pipe -2- into hole in fuel delivery unit so that
it engages audibly.
– Connect ends of supply pipe -1- leading to suction-jet pump
together so that they engage audibly.
Note
Audi TT 2007 ➤
The fuel delivery unit is shown without the fuel tank in the next
two illustrations.
– Install new seal for flange (seal must be installed dry).
– Insert guide tubes -1- and -2- on flange into corresponding
holes -arrows- in fuel delivery unit.
– Make sure that electrical wiring -1- and fuel supply line -3- are
positioned as shown so they do not obstruct lever -2- of fuel
gauge sender.
2. Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive 21
Page 26
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
– Press flange down against spring pressure, and turn flange to
installation position.
• Lug -2- on flange points towards arrow marking, and must be
between tabs -1- and -3- on fuel tank.
Note
The -arrow- points in direction of travel.
– Tighten locking ring.
TT Coupé:
– Install rear seat bench ⇒ Rep. Gr. 72 .
TT Roadster:
– Install fuel tank ⇒ page 12 .
All vehicles (continued):
– Put at least 5 litres of fuel into tank after installing fuel delivery
unit.
2.4 Checking fuel gauge sender -G-
Special tools and workshop equipment required
♦ Hand-held multimeter -V.A.G 1526C-
♦ Auxiliary measuring set -V.A.G 1594C-
22 Rep. Gr.20 - Fuel supply system
Page 27
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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.
Fuel supply system, diesel engines - Edition 06.2010
Procedure
TT Coupé:
– Remove rear seat bench ⇒ Rep. Gr. 72 .
TT Roadster:
– Remove back panel side trim (right-side) ⇒ Rep. Gr. 70 .
All vehicles (continued):
– Unclip the retaining tabs -arrows- for the flange cover (right-
side).
– Unplug electrical connector -arrow- at flange.
Audi TT 2007 ➤
2. Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive 23
Page 28
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
– Connect multimeter (resistance test) between contacts -2- and
-3-.
Fuel gauge sender -G- installed:
• Sender at lower stop: approx. 270 Ω.
• Sender at upper stop: approx. 70 Ω.
Note
♦
To test the maximum and minimum resistance values for “tank
full” and “tank empty”, remove the fuel delivery unit
⇒ page 18 and move the sender float all the way to its top or
bottom position.
♦
If the resistance is 0 Ω, there is a short circuit. If the resistance
is ∞ Ω, there is an open circuit in the wiring.
♦
The following values are obtained with the fuel gauge sender
-G- removed, due to the greater travel of the float arm:
Fuel gauge sender -G- removed:
• Sender at lower stop: approx. 290 Ω.
• Sender at upper stop: approx. 60 Ω.
– Connect multimeter (resistance test) between contacts -3- and
-4-.
Fuel gauge sender -G- installed or removed:
• Sender in any position: approx. 340 Ω.
Installation is carried out in the reverse order; note the following:
TT Coupé:
– Install rear seat bench ⇒ Rep. Gr. 72 .
TT Roadster:
– Install back panel side trim (right-side) ⇒ Rep. Gr. 70 .
2.5 Removing and installing fuel gauge
sender -G-
Removing
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .
TT Roadster:
Caution
• On the TT Roadster, the fuel tank must first be removed
before removing the fuel delivery unit.
– Removing fuel tank ⇒ page 8 .
All vehicles (continued):
– Remove fuel delivery unit ⇒ page 18 .
24 Rep. Gr.20 - Fuel supply system
Page 29
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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.
Fuel supply system, diesel engines - Edition 06.2010
– Use screwdriver to release retaining tabs -arrows- and lift out
fuel gauge sender -G- .
Caution
Risk of damage.
♦ First release retainer tabs on connector contact before
detaching electrical connectors on fuel gauge sender -G- .
Audi TT 2007 ➤
– Release retainer tabs on electrical connectors -1 ... 3- and then
detach electrical connectors.
Installing
Installation is carried out in the reverse order; note the following:
– Insert fuel gauge sender -G- into guides on fuel delivery unit
and press upwards until it clicks into place.
– Plug in electrical connectors and check that they have engag‐
ed properly.
– Install fuel delivery unit ⇒ page 20 .
2.6 Checking fuel gauge sender 2 -G169-
Special tools and workshop equipment required
♦ Hand-held multimeter -V.A.G 1526C-
2. Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive 25
Page 30
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
♦ Auxiliary measuring set -V.A.G 1594C-
Procedure
TT Coupé:
– Remove rear seat bench ⇒ Rep. Gr. 72 .
TT Roadster:
– Remove back panel side trim (left-side) ⇒ Rep. Gr. 70 .
All vehicles (continued):
– Unclip the retaining tabs -arrows- for the flange cover (left-
side).
– Unplug electrical connector -1- at flange.
Note
Disregard -item 2-.
26 Rep. Gr.20 - Fuel supply system
Page 31
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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.
Fuel supply system, diesel engines - Edition 06.2010
– Connect multimeter (resistance test) between contacts -1- and
-2-.
With fuel gauge sender 2 -G169- installed:
• Sender at lower stop: approx. 270 Ω.
• Sender at upper stop: approx. 70 Ω.
Note
♦
In order to test the maximum and minimum values for “tank
full” and “tank empty”, remove the fuel gauge sender 2 -G169-
⇒ page 27 and move the float all the way to its top or bottom
position.
♦
If the resistance is 0 Ω, there is a short circuit. If the resistance
is ∞ Ω, there is an open circuit in the wiring.
♦
The following values are obtained with the fuel gauge sender 2
-G169- removed, due to the greater travel of the float arm:
With fuel gauge sender 2 -G169- removed:
• Sender at lower stop: approx. 286 Ω.
• Sender at upper stop: approx. 50 Ω.
– Connect multimeter (resistance test) between contacts -2- and
-3-.
With fuel gauge sender 2 -G169- installed or removed:
• Sender in any position: approx. 340 Ω.
Installation is carried out in the reverse order; note the following:
TT Coupé:
– Install rear seat bench ⇒ Rep. Gr. 72 .
TT Roadster:
– Install back panel side trim (left-side) ⇒ Rep. Gr. 70 .
Audi TT 2007 ➤
2.7 Removing and installing fuel gauge sender 2 -G169-
Special tools and workshop equipment required
♦ Wrench -T10202-
Removing
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .
2. Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive 27
Page 32
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
TT Roadster:
Caution
• On the TT Roadster, the fuel tank must first be removed
before removing the fuel gauge sender 2 -G169- .
– Removing fuel tank ⇒ page 8 .
TT Coupé:
WARNING
Large amounts of fuel can escape.
♦
The fuel tank must not be more than 1/3 full when remov‐
ing the fuel gauge sender 2 -G169- , otherwise a large
amount of fuel will escape.
– Drain fuel tank if necessary ⇒ page 6 .
– Briefly open filler cap for fuel tank and close again.
– Remove rear seat bench ⇒ Rep. Gr. 72 .
– Unclip the retaining tabs -arrows- for the flange cover (left-
side).
– Unplug electrical connector -1- at flange.
– Disengage electrical connector -2- and move it clear to the
side.
28 Rep. Gr.20 - Fuel supply system
Page 33
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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.
Fuel supply system, diesel engines - Edition 06.2010
WARNING
Large amounts of fuel can escape.
♦
The fuel tank must not be more than 1/3 full when remov‐
ing the fuel gauge sender 2 -G169- , otherwise a large
amount of fuel will escape.
All vehicles (continued):
– Unscrew locking ring using wrench -T10202- .
– Carefully pull fuel gauge sender 2 -G169- -item 2- together
with suction-jet pump -1- just slightly out of opening in fuel
tank.
– Detach seal.
– Unclip suction-jet pump from flange -arrows-.
Note
Audi TT 2007 ➤
When removing, make sure you do not bend float arm of fuel
gauge sender 2 -G169- .
Installing
• Tightening torque ⇒ page 14
Installation is carried out in the reverse order; note the following:
Note
♦
Renew seal.
♦
When installing, make sure you do not bend float arm of fuel
gauge sender 2 -G169- .
– Carefully insert fuel gauge sender 2 -G169- into opening in fuel
tank.
– Clip suction-jet pump -1- onto flange, so that you hear it click
into place.
2. Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive 29
Page 34
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
– Install new seal for flange (seal must be installed dry).
Caution
Leakage risk
♦ The seal must not be pinched or damaged when installing
the flange.
– Press flange down against spring pressure and move flange
into installation position.
• Lug -2- on flange points towards arrow marking, and must be
between tabs -1- and -3- on fuel tank.
Note
The -arrow- points in direction of travel.
– Tighten locking ring.
TT Coupé:
– Install rear seat bench ⇒ Rep. Gr. 72 .
TT Roadster:
– Install fuel tank ⇒ page 12 .
30 Rep. Gr.20 - Fuel supply system
Page 35
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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.
Fuel supply system, diesel engines - Edition 06.2010
2.8 Suction-jet pump
On vehicles with four-wheel drive the fuel tank is divided into a
left and a right chamber. A so-called suction-jet pump -1- is used
for delivering the fuel from the left fuel tank chamber -3- to the
baffle housing of the fuel delivery unit -2- on the right.
Suction-jet pump: operation
The suction-jet pump operates according to the principle of fluid
entrainment: the stream of fuel from the electric fuel pump is
passed through a nozzle in the suction-jet pump, and is thus ac‐
celerated. The accelerated stream of fuel draws off the surround‐
ing fuel and delivers it to the baffle housing of the fuel delivery
unit.
Faults caused by defective suction-jet pump
Caution
The engine can stop due to fuel starvation if the suction-jet
pump is defective.
♦ If the suction-jet pump is defective, the engine can stop
due to fuel starvation when the tank is still 1/4 full.
Audi TT 2007 ➤
If the suction-jet pump is not working, up to 15 litres of fuel (up to
about 1/4 of tank capacity) may remain in the left chamber of the
tank, from where it cannot be drawn into the fuel delivery unit.
If the engine stops due to fuel starvation with the tank up to about
1
/4 full, proceed as follows:
– Check fuel system pressurisation pump -G6- ⇒ page 16 .
If fuel pump is OK, but no fuel is delivered:
– Put another 5 litres (approx.) of fuel into tank.
– Start engine.
If engine now starts:
– Renew suction-jet pump ⇒ page 31 .
2.9 Removing and installing suction-jet pump
Special tools and workshop equipment required
♦ Wrench -T10202-
Removing
Observe safety precautions ⇒ page 1 .
2. Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive 31
Page 36
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
Observe rules for cleanliness ⇒ page 3 .
TT Roadster:
Caution
• On the TT Roadster, the fuel tank must first be removed
before removing the suction-jet pump.
– Removing fuel tank ⇒ page 8 .
TT Coupé:
WARNING
Large amounts of fuel can escape.
♦
The fuel tank must not be more than 1/3 full when remov‐
ing the suction-jet pump, otherwise a large amount of fuel
will escape.
– Drain fuel tank if necessary ⇒ page 6 .
– Remove rear seat bench ⇒ Rep. Gr. 72 .
– Unclip the retaining tabs -arrows- for the flange cover (right-
side).
– Unplug electrical connector -arrow- at flange.
32 Rep. Gr.20 - Fuel supply system
Page 37
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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.
Fuel supply system, diesel engines - Edition 06.2010
– Mark fuel supply line -1- and fuel return line -2-.
WARNING
Risk of injury - fuel system operates under pressure.
♦ Wrap a clean cloth around the connection before opening
the fuel system. Then release pressure by carefully loos‐
ening the connection.
♦ Wear protective gloves.
♦ Wear safety goggles.
The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
Audi TT 2007 ➤
– Detach both pipes from flange (press release tabs).
– Unclip the retaining tabs -arrows- for the flange cover (left-
side).
– Unplug electrical connector -1- at flange.
– Disengage electrical connector -2- and move it clear to the
side.
2. Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive 33
Page 38
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
TT Roadster:
– With fuel tank removed, mark fuel supply line -1- and fuel re‐
turn line -2-.
– Detach both pipes from flange (press release tabs).
TT Coupé:
WARNING
Large amounts of fuel can escape.
♦
The fuel tank must not be more than 1/3 full when remov‐
ing the suction-jet pump, otherwise a large amount of fuel
will escape.
All vehicles (continued):
– Unscrew locking ring (right-side) using wrench -T10202- .
– Take flange (right-side) and seal of fuel delivery unit out of
opening in fuel tank and move clear, leaving pipes connected.
– In opening in fuel tank, press release tab to disconnect supply
pipe -1- to suction-jet pump.
– Detach fuel supply pipe -2- from fuel delivery unit.
– Unscrew locking ring (left-side) using wrench -T10202- .
34 Rep. Gr.20 - Fuel supply system
Page 39
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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.
Fuel supply system, diesel engines - Edition 06.2010
– Carefully pull fuel gauge sender 2 -G169- -item 2- together
with suction-jet pump -1- just slightly out of opening in fuel
tank.
– Detach seal.
– Unclip suction-jet pump from flange -arrows-.
Note
When removing, make sure you do not bend float arm of fuel
gauge sender 2 -G169- .
– Reach into fuel tank opening on left side of vehicle and pull out
suction-jet pump, with pipes pointing towards the left.
Installing
• Tightening torque ⇒ page 14
Installation is carried out in the reverse order; note the following:
Note
Audi TT 2007 ➤
♦
Renew seals.
♦
When installing, make sure you do not bend float arm of fuel
gauge sender 2 -G169- .
– Push suction-jet pump (with pipes attached) into fuel tank
opening on left side of vehicle.
– Reach into fuel tank opening on right side of vehicle and pull
suction-jet pump with pipes into the installation position.
– Push fuel supply pipe -2- into hole in fuel delivery unit so that
it engages audibly.
– Connect ends of supply pipe -1- leading to suction-jet pump
together so that they engage audibly.
2. Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive 35
Page 40
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
Note
The fuel delivery unit is shown without the fuel tank in the next
two illustrations.
– Install new seal for flange (seal must be installed dry).
– Insert guide tubes -1- and -2- on flange into corresponding
holes -arrows- in fuel delivery unit.
– Make sure that electrical wiring -1- and fuel supply line -3- are
positioned as shown so they do not obstruct lever -2- of fuel
gauge sender.
Caution
Leakage risk
♦ The seal must not be pinched or damaged when installing
the flange.
– Press flange down against spring pressure and move flange
into installation position.
• Lug -2- on flange points towards arrow marking, and must be
between tabs -1- and -3- on fuel tank.
Note
The -arrow- points in direction of travel.
36 Rep. Gr.20 - Fuel supply system
Page 41
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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.
Fuel supply system, diesel engines - Edition 06.2010
– Tighten locking ring.
– Carefully insert fuel gauge sender 2 -G169- into opening in fuel
tank.
– Clip suction-jet pump -1- onto flange -2-, so that you hear it
click into place.
Audi TT 2007 ➤
– Install new seal for flange (seal must be installed dry).
Caution
Leakage risk
♦ The seal must not be pinched or damaged when installing
the flange.
– Press flange down against spring pressure and move flange
into installation position.
• Lug -2- on flange points towards arrow marking, and must be
between tabs -1- and -3- on fuel tank.
Note
The -arrow- points in direction of travel.
– Tighten locking ring.
TT Coupé:
– Install rear seat bench ⇒ Rep. Gr. 72 .
TT Roadster:
– Install fuel tank ⇒ page 12 .
All vehicles (continued):
– Put at least 5 litres of fuel into tank after installing suction-jet
pump
2. Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive 37
Page 42
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
3 Supplementary fuel pump
⇒ “3.1 Supplementary fuel pump V393 - exploded view”,
page 38
⇒ “3.2 Removing and installing supplementary fuel pump V393 ”,
page 39
3.1 Supplementary fuel pump -V393- - exploded view
Caution
Running when dry causes irreparable damage to high-pres‐
sure pump.
♦ If the fuel filter, the fuel lines or the supplementary fuel
pump -V393- are renewed, it is important to bleed the fuel
system before the engine is started for the first time.
– Bleed fuel system ⇒ Rep. Gr. 23 ; Performing first fuel filling
after installing high-pressure pump .
1 - Electrical connector
2 - Bolt
❑ 9 Nm
3 - Bracket
4 - Bolt
❑ 20 Nm
5 - Rubber mounting
6 - Fuel supply hose
❑ From fuel filter
❑ White marking
7 - Bolt
❑ 9 Nm
8 - Bracket
9 - Supplementary fuel pump V393-
❑ Removing and installing
⇒ page 39
10 - Rubber mounting
11 - Fuel supply hose
❑ To high-pressure pump
❑ White marking
38 Rep. Gr.20 - Fuel supply system
Page 43
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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.
Fuel supply system, diesel engines - Edition 06.2010
3.2 Removing and installing supplementary
fuel pump -V393-
Removing
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .
– Disengage fuel hose -3- at bracket -arrow-.
– Press release tab and unplug electrical connector -1-.
– Remove bolts -2, 4- and detach bracket with supplementary
fuel pump.
– Detach electrical connector -1- from bracket.
– Unscrew bolts -2, 3, 5- and remove bracket -4-.
Audi TT 2007 ➤
– Move electrical wiring clear -arrow-.
– Take supplementary fuel pump -5- with rubber mountings
-4, 6- out of bracket -2-.
– Detach fuel hoses -1- and -3-.
Installing
• Tightening torque ⇒ page 38
Installation is carried out in the reverse order; note the following:
Note
Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
– Connect fuel hoses to fuel pipes and supplementary fuel pump
according to markings.
– Engage fuel hoses carefully in mounting bracket.
– Bleed fuel system ⇒ Rep. Gr. 23 ; Performing first fuel filling
after installing high-pressure pump .
3. Supplementary fuel pump 39
Page 44
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
4 Fuel filter
⇒ “4.1 Fuel filter - exploded view”, page 40
⇒ “4.2 Removing and installing fuel filter housing”, page 41
4.1 Fuel filter - exploded view
Caution
Running when dry causes irreparable damage to high-pres‐
sure pump.
♦ If the fuel filter, the fuel lines or the supplementary fuel
pump -V393- are renewed, it is important to bleed the fuel
system before the engine is started for the first time.
– Bleed fuel system ⇒ Rep. Gr. 23 ; Performing first fuel filling
after installing high-pressure pump .
Note
Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
40 Rep. Gr.20 - Fuel supply system
Page 45
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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.
1 - Bolt
❑ 9 Nm
2 - Nut
❑ 9 Nm
3 - Bolt
❑ 9 Nm
4 - Seal
❑ Renew
5 - Cover
❑ For filter housing
6 - Fuel return hose
❑ To fuel tank
❑ Blue marking
7 - Fuel supply hose
❑ From fuel tank
❑ White marking
8 - Bolt
❑ 5 Nm
9 - Fuel return hose
❑ From high-pressure
pump
❑ Blue marking
10 - Fuel supply hose
❑ From supplementary
fuel pump -V393-
❑ White marking
11 - Filter element
❑ Renewing ⇒ Mainte‐
nance tables
12 - Fuel filter housing
❑ Removing and installing ⇒ page 41
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
4.2 Removing and installing fuel filter hous‐
ing
Special tools and workshop equipment required
♦ Hose clip pliers -V.A.G 1921-
4. Fuel filter 41
Page 46
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
Removing
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .
– Mark positions of fuel hoses for re-installation.
– Detach fuel hoses -4, 5, 6, 7- from fuel filter.
– Remove bracket -arrow- for coolant hose at fuel filter.
– Slacken bolt -1- a few turns.
– Remove bolt -3- and nut -2-.
– Detach fuel filter housing -8-.
Installing
Installation is carried out in the reverse order; note the following:
Note
Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
– Engage fuel filter carefully on mounting bracket.
– Connect fuel hoses to fuel filter according to markings.
– Bleed fuel system ⇒ Rep. Gr. 23 ; Performing first fuel filling
after installing high-pressure pump .
42 Rep. Gr.20 - Fuel supply system
Page 47
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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.
Fuel supply system, diesel engines - Edition 06.2010
5 Bleeding fuel system
Caution
Running when dry causes irreparable damage to high-pres‐
sure pump.
♦ If the fuel filter, the fuel lines or the supplementary fuel
pump -V393- are renewed, it is important to bleed the fuel
system before the engine is started for the first time.
– Bleed fuel system ⇒ Rep. Gr. 23 ; Performing first fuel filling
after installing high-pressure pump .
Audi TT 2007 ➤
5. Bleeding fuel system 43
Page 48
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
6 Checking fuel system for leaks
Observe rules for cleanliness ⇒ page 3 .
A leaking fuel system can cause:
♦ Foam build-up or air bubbles in the supply pipe.
♦ Lack of power, misfiring.
♦ Starting problems.
Checking fuel system and fuel lines for leaks
– Check whether the seals on the flanges are damaged and
whether the union nuts on the fuel tank flanges are properly
tightened.
– Perform a visual check on all fuel lines, fuel tank components
and hose connections:
♦ Fuel lines to engine
♦ Fuel lines to fuel tank
♦ Fuel cooler
♦ Fuel filter
♦ Fuel tank
44 Rep. Gr.20 - Fuel supply system
Page 49
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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.
Fuel supply system, diesel engines - Edition 06.2010
7 Accelerator pedal module
⇒ “7.1 Accelerator pedal module - exploded view”, page 45
⇒ “7.2 Removing and installing accelerator pedal module with ac‐
celerator position senders”, page 45
7.1 Accelerator pedal module - exploded view
1 - Cover cap
2 - Bolt
❑ 9 Nm
3 - Electrical connector
4 - Accelerator pedal module
❑ With accelerator posi‐
tion sender -G79- and
accelerator position
sender 2 -G185-
❑ Removing and installing
⇒ page 45
Audi TT 2007 ➤
7.2 Removing and installing accelerator
pedal module with accelerator position
senders
Special tools and workshop equipment required
7. Accelerator pedal module 45
Page 50
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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.
Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
♦ For LHD vehicles: release tool -T10238-
♦ For RHD vehicles: release tool -T10240-
Removing
– Remove cover for steering column -arrows-.
– Pull out release tab -2- as far as stop in direction of -arrow-
and unplug electrical connector -1- at accelerator pedal mod‐
ule -3-.
– Use screwdriver to prise off cap -4-.
– Remove bolt -5-.
46 Rep. Gr.20 - Fuel supply system
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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.
Fuel supply system, diesel engines - Edition 06.2010
– Push release tool -T10238- (or release tool -T10240- for RHD
vehicles) fully into the slots provided, as illustrated -arrow-,
and take off accelerator pedal module.
Installing
• Tightening torque ⇒ page 45
Installation is carried out in the reverse order; note the following:
– Plug in electrical connector -2- at accelerator pedal module
-5-.
• The connector must audibly engage.
– Press accelerator pedal module onto retaining studs -6-.
– Insert centring pin -7- into hole in underbody.
– Secure accelerator pedal module with bolt -3- and press on
cap -4-.
Audi TT 2007 ➤
Note
Disregard -item 1-.
Vehicles with dual clutch gearbox:
– After renewing, perform kick-down adaption in “Guided Func‐
tions” mode ⇒ Vehicle diagnosis, testing and information sys‐
tem VAS 5051.
7. Accelerator pedal module 47
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