Audi TT 38 User Manual
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Service
Workshop Manual
Audi TT 2007 ➤
Fuel supply system, petrol engines
Engine ID
BUB BWA BPY
CDAACEPACESACET
CBRACDLACDLBCDMACCTACCZ
A
A
Edition 11.2010
Service Department. Technical Information
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.
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 A005TT01020
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, petrol engines - Edition 11.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Using testers and measuring instruments during a road test . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Removing and installing components from a full or partly full fuel tank . . . . . . . . . . . . . . . . 2
2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Test conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1 Fuel tank with attached components - rest-of-world vehicles with front-wheel drive . . . . . . 6
1.1 Fuel tank with attached components - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 8
2 Fuel tank with attached components - USA vehicles with front-wheel drive . . . . . . . . . . . . 14
2.1 Fuel tank with attached components - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 16
3 Fuel delivery unit and fuel gauge sender - all vehicles with front-wheel drive . . . . . . . . . . 22
3.1 Fuel delivery unit and fuel gauge sender - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2 Checking fuel pump (electrical test) - vehicles with TFSI engine . . . . . . . . . . . . . . . . . . . . 23
3.3 Checking fuel pump control unit J538 - vehicles with TFSI engine . . . . . . . . . . . . . . . . . . 25
3.4 Removing and installing fuel pump control unit J538 - vehicles with TFSI engine . . . . . . . . 25
3.5 Checking fuel pump delivery rate - vehicles with TFSI engine . . . . . . . . . . . . . . . . . . . . . . 27
3.6 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.7 Adapting fuel pump after renewing fuel delivery unit - vehicles with TFSI engine with toothed
belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.8 Checking fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.9 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4 Fuel tank with attached components - rest-of-world vehicles with four-wheel drive . . . . . . 39
4.1 Fuel tank with attached components - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2 Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.3 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 42
5 Fuel tank with attached components - USA vehicles with four-wheel drive . . . . . . . . . . . . 48
5.1 Fuel tank with attached components - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.2 Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 51
6 Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive . . . . . . . . . . 57
6.1 Fuel delivery unit and fuel gauge senders - exploded view . . . . . . . . . . . . . . . . . . . . . . . . 57
6.2 Checking fuel pump (electrical test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.3 Checking fuel pump control unit J538 - vehicles with TFSI engine . . . . . . . . . . . . . . . . . . 61
6.4 Removing and installing fuel pump control unit J538 - vehicles with 1.8 ltr./2.0 ltr. TFSI
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.5 Removing and installing fuel pump control unit J538 - vehicles with 2.5 ltr. TFSI engine . . 62
6.6 Checking fuel pump delivery rate - vehicles with 1.8 ltr./2.0 ltr. TFSI engine . . . . . . . . . . . . 64
6.7 Checking fuel pump delivery rate - vehicles with 2.5 ltr. TFSI engine . . . . . . . . . . . . . . . . 68
6.8 Checking fuel pump delivery rate - vehicles with 3.2 ltr. MPI engine . . . . . . . . . . . . . . . . . . 70
6.9 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.10 Adapting fuel pump after renewing fuel delivery unit - vehicles with TFSI engine with toothed
belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.11 Checking fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Contents i
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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, petrol engines - Edition 11.2010
6.12 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.13 Checking fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.14 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.15 Suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.16 Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7 Fuel filter - all vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.1 Fuel filter - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8 Activated charcoal filter system - rest-of-world vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8.1 Activated charcoal filter system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8.2 Removing and installing activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9 Activated charcoal filter system and tank leak diagnostic system - USA vehicles . . . . . . . . 98
9.1 Activated charcoal filter system and tank leak diagnostic system - exploded view . . . . . . 98
9.2 Removing and installing activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
9.3 Routing of pipes/hoses for activated charcoal filter system and tank leak diagnostic system
- TFSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
9.4 Routing of pipes/hoses for activated charcoal filter system and tank leak diagnostic system
- 3.2 ltr. MPI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
9.5 Tank leak diagnostic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9.6 Performing tank leak diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9.7 Removing and installing fuel system diagnostic pump V144 . . . . . . . . . . . . . . . . . . . . . . 105
10 Accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.1 Accelerator pedal module (version 1) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.2 Removing and installing accelerator pedal module - version 1 . . . . . . . . . . . . . . . . . . . . . . 106
10.3 Accelerator pedal module (version 2) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
10.4 Removing and installing accelerator pedal module - version 2 . . . . . . . . . . . . . . . . . . . . . . 109
ii Contents
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Fuel supply system, petrol engines - Edition 11.2010
00 – Technical data
1 Safety precautions
1.1 Working on the fuel system
When working on the fuel system note the following warnings:
WARNING
The fuel system of vehicles with FSI engine operates at very
high pressure. This can cause injury.
♦ The fuel pressure in the high-pressure section of the in‐
jection system must be reduced to a residual pressure
prior to opening the system.
♦ Wrap a clean cloth around the connection and carefully
loosen the connection to allow the residual pressure to
dissipate.
Audi TT 2007 ➤
– Procedure before opening high-pressure section of injection
system ⇒ Rep. gr. 24 .
Perform the following steps before starting to work on the fuel
supply system:
WARNING
Mobile phones can cause an explosion risk.
♦ Ensure that any mobile phones are well clear of the work‐
bay.
Caution
To prevent irreparable damage to the electronic components
when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery.
♦ Disconnect battery ⇒ Rep. gr. 27 .
♦ Briefly open filler cap for fuel tank and close again.
1. Safety precautions 1
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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, petrol engines - Edition 11.2010
1.2 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).
1.3 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.
TT Coupé:
Test equipment must always be secured on the rear seat with
a strap and operated from the rear seat by a second person.
TT Roadster:
♦ Move the passenger's seat back as far as it will go.
♦ Use only vehicle diagnosis and service information sys‐
tem -VAS 5052 A- or diagnosis system -VAS 5053- .
♦ The test equipment -1- must rest flat on the passenger's
thighs (as shown in illustration) and must be operated by
the passenger.
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 the tank if necessary. Procedure on vehicles
with front-wheel drive ⇒ page 7 , on vehicles with fourwheel drive ⇒ page 40 .
2 Rep. gr.00 - Technical data
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Fuel supply system, petrol engines - Edition 11.2010
♦ 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.
When removing and installing the fuel tank, note the following:
♦ Fuel tank must be empty to reduce weight. Drain the tank if
necessary. Procedure for vehicles in rest-of-world (front-wheel
drive) ⇒ page 7 , vehicles in rest-of-world (four-wheel drive)
⇒ page 40 , USA vehicles (front-wheel drive) ⇒ page 15 ,
USA vehicles (four-wheel drive) ⇒ page 49 .
Audi TT 2007 ➤
1. Safety precautions 3
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Fuel supply system, petrol engines - Edition 11.2010
2 General repair instructions
2.1 Rules for cleanliness
Even small amounts of dirt can cause malfunctions. When work‐
ing on the fuel supply system and injection system, pay careful
attention to the following basic rules:
♦ 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. Do not use fluffy 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 been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).
♦ When the system is open: Do not work with compressed air.
Do not move the vehicle unless absolutely necessary.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
2.2 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.
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.
2.3 Test conditions
• Battery voltage at least 12.5 V.
• Fuel pump fuse OK ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
• Fuel pump control unit -J538- OK; checking via „Guided Fault
Finding“ ⇒ Vehicle diagnostic, testing and information system
VAS 5051.
• Fuel pump relay -J17- OK ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.
•
Fuel tank at least 1/4 full.
4 Rep. gr.00 - Technical data
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• Fuel filter OK.
• Fuel lines OK (not obstructed or crushed).
• Ignition off.
Audi TT 2007 ➤
Fuel supply system, petrol engines - Edition 11.2010
2. General repair instructions 5
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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, petrol engines - Edition 11.2010
20 – Fuel supply system
1 Fuel tank with attached components
- rest-of-world vehicles with frontwheel drive
1.1 Fuel tank with attached components - exploded view
1 - Nut
❑ 20 Nm
2 - Securing strap
❑ Installation position: Fix‐
ing point (hole) points in
direction of travel
3 - Heat shield for fuel tank
4 - Nut
❑ 20 Nm
5 - Fuel line
❑ To engine
❑ Press release tab on
pipe connector to dis‐
connect
6 - Breather line
❑ From fuel filler neck to
activated charcoal filter
❑ Clip onto fuel tank
7 - Electrical connector
❑ For fuel system pressur‐
isation pump -G6- and
fuel gauge sender -G-
8 - Protective plate
❑ For fuel filler neck
9 - Bolt
❑ 11 Nm
10 - Filler cap
❑ Secured to tank flap unit
11 - Earth connection
❑ To eliminate electrostatic charge
❑ Installation position ⇒ page 7
❑ Ensure that connector is seated properly
❑ After installation, use an ohmmeter to check the electrical connection between the protective plate
-item 7- on the fuel filler neck and a bare metal part on the body. Specification: approx. 0 Ω
12 - Bolt
❑ 11 Nm
13 - Pop rivet
14 - Fuel tank
❑ Removing and installing ⇒ page 8
6 Rep. gr.20 - Fuel supply system
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Fuel supply system, petrol engines - Edition 11.2010
15 - Nut
❑ 20 Nm
16 - Locking washer
❑ Removing: turn anti-clockwise
❑ 3 Nm
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.
Audi TT 2007 ➤
1.2 Draining fuel tank
Special tools and workshop equipment required
♦ Fuel extractor -VAS 5190-
Procedure
Observe safety precautions ⇒ page 4 .
Observe rules for cleanliness ⇒ page 4 .
– Release the tank flap.
Caution
To prevent irreparable damage to the electronic components
when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
1. Fuel tank with attached components - rest-of-world vehicles with front-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, petrol engines - Edition 11.2010
– Disconnect battery ⇒ Rep. gr. 27 .
WARNING
Risk of explosion caused by electrostatic discharge.
♦ Secure earth wire of fuel extractor -VAS 5190- to a bare
metal part on the body.
– 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.
Note
♦
The procedure when using a fuel extractor without a shaft end
is fundamentally 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 via fuel filler neck.
– Carefully remove extraction hose.
– Connect battery after completing work. Observe notes on pro‐
cedures required after connecting battery ⇒ Rep. gr. 27 .
1.3 Removing and installing fuel tank with attached components
Special tools and workshop equipment required
8 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.
♦ Engine and gearbox jack -V.A.G 1383 A-
♦ Hook -3004-
Audi TT 2007 ➤
Fuel supply system, petrol engines - Edition 11.2010
Removing
Observe safety precautions ⇒ page 4 .
Observe rules for cleanliness ⇒ page 4 .
– Release the tank flap.
Caution
To prevent irreparable damage to the electronic components
when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
– Disconnect battery ⇒ Rep. gr. 27 .
WARNING
Risk of accident caused by weight of fuel tank
♦ Fuel tank must be empty when it is removed.
– Drain fuel tank ⇒ page 7 .
1. Fuel tank with attached components - rest-of-world vehicles with front-wheel drive 9
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Audi TT 2007 ➤
Fuel supply system, petrol engines - Edition 11.2010
– 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.
– Pull out spreader pins -1- and -2-.
– Disengage stone deflector -3- on trailing arm (right-side)
-arrows- and remove.
TT Roadster:
– Remove bolts -1 ... 4- and detach diagonal struts.
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
with respect to the correctness of information in this document. Copyright by AUDI AG.
Fuel supply system, petrol engines - Edition 11.2010
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.
– Disconnect exhaust system at clamp -1-.
– 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.
WARNING
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.
– Disconnect fuel line -2- and breather line -1- from front right of
fuel tank by pressing release tabs.
WARNING
Risk of accident caused by weight of fuel tank
♦ Fuel tank must be empty when it is removed.
– First unscrew bolts -1- and -3-.
– Position engine and gearbox jack -V.A.G 1383 A- below vehi‐
cle to support tank.
– Remove bolts -2- and -4-.
1. Fuel tank with attached components - rest-of-world vehicles with front-wheel drive 11
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Fuel supply system, petrol engines - Edition 11.2010
Caution
Risk of overstretching electrical wiring.
♦ Subsequently, when lowering fuel tank, make sure that
electrical wiring is not under tension.
– Lower fuel tank using engine and gearbox jack -V.A.G 1383
A- only until you can reach electrical connector on flange with
your hand.
Note
Illustration shows electrical connector on flange in installation po‐
sition.
– Unplug electrical connector -arrow- at flange.
– Remove fuel tank downwards (turning it sideways as re‐
quired).
Installing
• Tightening torques ⇒ page 6
Installation is carried out in the reverse order; note the following:
– Position fuel tank with securing strap on underbody, using en‐
gine and gearbox jack -V.A.G 1383 A- .
– 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 -2- and -4-,
then at points -1- and -3-.
12 Rep. gr.20 - Fuel supply system
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.
Fuel supply system, petrol engines - Edition 11.2010
– 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 section of exhaust system ⇒ Rep. gr. 26 .
– Install rear right wheel housing liner ⇒ Rep. gr. 66. .
TT Roadster:
– Install diagonal struts ⇒ Rep. gr. 42 .
All vehicles (continued):
– Connect battery. Observe notes on procedures required after
connecting battery ⇒ Rep. gr. 27 .
Audi TT 2007 ➤
1. Fuel tank with attached components - rest-of-world vehicles with front-wheel drive 13
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Fuel supply system, petrol engines - Edition 11.2010
2 Fuel tank with attached components
- USA vehicles with front-wheel drive
2.1 Fuel tank with attached components - exploded view
1 - Nut
❑ 20 Nm
2 - Securing strap
❑ Installation position: Fix‐
ing point (hole) points in
direction of travel
3 - Heat shield for fuel tank
4 - Nut
❑ 20 Nm
5 - Fuel line
❑ To engine
❑ Press release tab on
pipe connector to dis‐
connect
6 - Breather line
❑ From activated charcoal
filter to activated char‐
coal filter solenoid
valve 1 -N80-
❑ Clip onto fuel tank
7 - Electrical connector
❑ For fuel system pressur‐
isation pump -G6- and
fuel gauge sender -G-
8 - Protective plate
❑ For fuel filler neck
9 - Bolt
❑ 11 Nm
10 - Filler cap
❑ Secured to tank flap unit
11 - Bolt
❑ 11 Nm
12 - Earth connection
❑ To eliminate electrostatic charge
❑ Installation position ⇒ page 15
❑ Ensure that connector is seated properly
❑ After installation, use an ohmmeter to check the electrical connection between the protective plate
-item 7- on the fuel filler neck and a bare metal part on the body. Specification: approx. 0 Ω
13 - Breather line
❑ From gravity valve to activated charcoal filter
❑ Clip onto bracket in wheel housing
❑ Press release tab on pipe connector to disconnect
14 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, petrol engines - Edition 11.2010
14 - Pop rivet
15 - Fuel tank
❑ Removing and installing ⇒ page 16
16 - Nut
❑ 20 Nm
17 - Locking washer
❑ Removing: turn anti-clockwise
❑ 3 Nm
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
Audi TT 2007 ➤
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.
2.2 Draining fuel tank
Special tools and workshop equipment required
♦ Fuel extractor -VAS 5190-
Procedure
Observe safety precautions ⇒ page 4 .
Observe rules for cleanliness ⇒ page 4 .
– Release the tank flap.
2. Fuel tank with attached components - USA vehicles with front-wheel drive 15
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Fuel supply system, petrol engines - Edition 11.2010
Caution
To prevent irreparable damage to the electronic components
when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
– Disconnect battery ⇒ Rep. gr. 27 .
WARNING
Risk of explosion caused by electrostatic discharge.
♦ Secure earth wire of fuel extractor -VAS 5190- to a bare
metal part on the body.
– 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.
Note
♦
The procedure when using a fuel extractor without a shaft end
is fundamentally 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 via fuel filler neck.
– Carefully remove extraction hose.
– Connect battery after completing work. Observe notes on pro‐
cedures required after connecting battery ⇒ Rep. gr. 27 .
2.3 Removing and installing fuel tank with attached components
Special tools and workshop equipment required
16 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.
♦ Engine and gearbox jack -V.A.G 1383 A-
♦ Hook -3004-
Audi TT 2007 ➤
Fuel supply system, petrol engines - Edition 11.2010
Removing
Observe safety precautions ⇒ page 4 .
Observe rules for cleanliness ⇒ page 4 .
– Release the tank flap.
Caution
To prevent irreparable damage to the electronic components
when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
– Disconnect battery ⇒ Rep. gr. 27 .
WARNING
Risk of accident caused by weight of fuel tank
♦ Fuel tank must be empty when it is removed.
– Drain fuel tank ⇒ page 15 .
2. Fuel tank with attached components - USA vehicles with front-wheel drive 17
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, petrol engines - Edition 11.2010
– 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 .
– Remove bolts -3- and -4- for fuel filler neck.
– Remove breather line -2- going to activated charcoal filter
(press release tab).
– Detach electrical wire -1- for ABS speed sensor from bracket
on fuel filler neck.
– Move overflow hose -5- on fuel filler neck clear.
– Pull out spreader pins -1- and -2-.
– Disengage stone deflector -3- on trailing arm (right-side)
-arrows- and remove.
TT Roadster:
– Remove bolts -1 ... 4- and detach diagonal struts.
18 Rep. gr.20 - Fuel supply system
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.
Fuel supply system, petrol engines - Edition 11.2010
All vehicles (continued):
– Press release tab and disconnect breather line -arrow- leading
to activated charcoal filter.
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.
Audi TT 2007 ➤
– Disconnect exhaust system at clamp -1-.
– 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
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.
– Press release tab and disconnect breather line -2- at front right
of fuel tank.
WARNING
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.
– Press release tabs and disconnect fuel line -1- at front right of
fuel tank.
2. Fuel tank with attached components - USA vehicles with front-wheel drive 19
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, petrol engines - Edition 11.2010
WARNING
Risk of accident caused by weight of fuel tank
♦ Fuel tank must be empty when it is removed.
– First unscrew bolts -1- and -3-.
– Position engine and gearbox jack -V.A.G 1383 A- below vehi‐
cle to support tank.
– Remove bolts -2- and -4-.
Caution
Risk of overstretching electrical wiring.
♦ Subsequently, when lowering fuel tank, make sure that
electrical wiring is not under tension.
– Lower fuel tank using engine and gearbox jack -V.A.G 1383
A- only until you can reach electrical connector on flange with
your hand.
Note
Illustration shows electrical connector on flange in installation po‐
sition.
– Unplug electrical connector -arrow- at flange.
– Remove fuel tank downwards (turning it sideways as re‐
quired).
Installing
• Tightening torques ⇒ page 14
Installation is carried out in the reverse order; note the following:
– Position fuel tank with securing strap on underbody, using en‐
gine and gearbox jack -V.A.G 1383 A- .
– 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 -2- and -4-,
then at points -1- and -3-.
20 Rep. gr.20 - Fuel supply system
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.
Fuel supply system, petrol engines - Edition 11.2010
– 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 breather line (leading to activated charcoal filter) at filler
neck.
– Install rear section of exhaust system ⇒ Rep. gr. 26 .
– Install rear right wheel housing liner ⇒ Rep. gr. 66. .
TT Roadster:
– Install diagonal struts ⇒ Rep. gr. 42 .
All vehicles (continued):
– Connect battery. Observe notes on procedures required after
connecting battery ⇒ Rep. gr. 27 .
Audi TT 2007 ➤
2. Fuel tank with attached components - USA vehicles with front-wheel drive 21
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, petrol engines - Edition 11.2010
3 Fuel delivery unit and fuel gauge
sender - all vehicles with front-wheel
drive
3.1 Fuel delivery unit and fuel gauge sender - exploded view
1 - Fuel delivery unit
❑ Different versions avail‐
able ⇒ Electronic parts
catalogue
❑ Checking fuel pump
(electrical test) - vehi‐
cles with TFSI engine
⇒ page 23
❑ Checking residual pres‐
sure ⇒ Rep. gr. 24
❑ Removing and installing
⇒ page 30
❑ Put at least 5 litres of
fuel into tank after instal‐
ling
2 - Seal
❑ Renew
❑ Install dry
3 - Fuel supply line
❑ To fuel filter
❑ Do not kink
❑ Attached to connection
marked „V“ on flange
❑ To disconnect from
flange, press release
tab on connection
4 - Fuel return line
❑ Do not kink
❑ Attached to connection
marked „R“ on flange
❑ To disconnect from
flange, press release
tab on connection
5 - Electrical connector
❑ For fuel system pressurisation pump -G6- and fuel gauge sender -G-
6 - Locking ring
❑ Remove and install using wrench -T10202❑ 110 Nm
7 - Fuel gauge sender -G-
❑ Different versions available ⇒ Electronic parts catalogue
❑ Checking resistance values ⇒ page 34
❑ Removing and installing ⇒ page 36
22 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, petrol engines - Edition 11.2010
3.2 Checking fuel pump (electrical test) - ve‐
hicles with TFSI engine
Special tools and workshop equipment required
♦ Remote control -V.A.G 1348/3A- for V.A.G 1348 with adapter
cable -V.A.G 1348/3-2-
♦ Hand-held multimeter -V.A.G 1526D-
Audi TT 2007 ➤
♦ Auxiliary measuring set -V.A.G 1594C-
Procedure
Observe test conditions ⇒ page 4 .
TT Coupé:
– Remove rear seat bench ⇒ Rep. gr. 72 .
TT Roadster:
– Remove back panel side trim (right-side) ⇒ Rep. gr. 70 .
3. Fuel delivery unit and fuel gauge sender - all vehicles with front-wheel drive 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.
Audi TT 2007 ➤
Fuel supply system, petrol engines - Edition 11.2010
All vehicles (continued):
– Unclip retaining tabs -arrows- for flange cover.
– Unplug electrical connector -arrow- at flange.
– Connect remote control -V.A.G 1348/3A- for V.A.G 1348 to
contact -1- using adapter cable -V.A.G 1348/3-3- and test lead
from auxiliary measuring set -V.A.G 1594C- .
– Tape off 2nd connector contact of 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 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.
24 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, petrol engines - Edition 11.2010
If no noise can be heard from pump:
– Remove fuel delivery unit ⇒ page 30 .
– Check that the electrical wires between flange and fuel pump
are connected and test for continuity.
If no faults are found in the wiring:
– Fuel pump is defective. Renew fuel delivery unit.
Installation is carried out in the reverse order; note the following:
TT Roadster:
– Install back panel side trim (right-side) ⇒ Rep. gr. 70 .
TT Coupé:
– Install rear seat bench ⇒ Rep. gr. 72 .
3.3 Checking fuel pump control unit -J538- vehicles with TFSI engine
Audi TT 2007 ➤
♦ On vehicles with TFSI engine, voltage for the fuel pump is
supplied via fuel pump control unit -J538- .
♦ Check fuel pump control unit -J538- in „Guided Fault Finding“
⇒ Vehicle diagnostic, testing and information system
VAS 5051.
3.4 Removing and installing fuel pump con‐
trol unit -J538- - vehicles with TFSI en‐
gine
Removing
TT Coupé:
– Remove rear seat bench ⇒ Rep. gr. 72 .
TT Roadster:
– Remove back panel side trim (right-side) ⇒ Rep. gr. 70 .
All vehicles (continued):
– Remove fuel pump control unit -J538- from cover for flange
and unplug electrical connector -arrow-.
3. Fuel delivery unit and fuel gauge sender - all vehicles with front-wheel drive 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.
Audi TT 2007 ➤
Fuel supply system, petrol engines - Edition 11.2010
– Unclip the retaining tabs -arrows- for the flange cover (right-
side).
– Unplug electrical connector -arrow- at flange.
Installing
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 .
26 Rep. gr.20 - Fuel supply system
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