Audi TT 33 User Manual
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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
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.
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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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
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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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 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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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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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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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
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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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
– 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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with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ 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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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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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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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
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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