Audi TT 38 User Manual

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Service

Workshop Manual

Audi TT 2007 ➤

Fuel supply system, petrol engines

Engine ID

BUB BWA BPY

CDAACEPACESACET

CBRACDLACDLBCDMACCTACCZ

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.

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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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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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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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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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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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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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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♦ 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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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

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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

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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

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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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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

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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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♦ 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

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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 .

– 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

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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

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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

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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

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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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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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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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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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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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Audi TT 2007 ➤

Fuel supply system, petrol engines - Edition 11.2010

3.5 Checking fuel pump delivery rate - vehicles with TFSI engine

Special tools and workshop equipment required

♦ K-Jetronic pressure tester -

V.A.G 1318-

♦ Adapter -V.A.G 1318/11-

♦ Adapter -V.A.G

1318/17-1A-

♦ Connector -V.A.G 1318/23-

♦ Remote control -V.A.G

1348/3A- for V.A.G 1348 with adapter cable -V.A.G 1348/3-3-

♦ Auxiliary measuring set -

V.A.G 1594C-

♦ Fuel-resistant measuring

container

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 27

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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 „+“ (positive terminal in en‐

gine compartment).

– Remove filler cap from fuel filler neck.

Rest-of-world vehicles with toothed belt drive:

– Detach fuel line from retainer and remove heat insulation

sleeve at fuel line connection.

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.

– Pull release ring and disconnect fuel line -arrow-.

28 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

USA vehicles with toothed belt drive:

– Detach fuel line from retainer and remove heat insulation

sleeve -1- at fuel line connection.

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.

– Pull release ring and disconnect fuel line -arrow-.

Vehicles with timing chain:

– Push down protective sleeve -1- and disconnect fuel line.

– First press hose connector -2- downwards -arrow A-, then

press release tabs -arrow B-.

– Pull off hose connector, keeping release tabs depressed.

Audi TT 2007 ➤

All vehicles (continued):

– Screw connector -V.A.G 1318/23- and adapter -V.A.G

1318/17-1A- onto K-Jetronic pressure tester -V.A.G 1318- .

– Fit adapter -V.A.G 1318/17-1A- onto disconnected fuel line.

– Screw adapter -V.A.G 1318/11- onto K-Jetronic pressure test‐

er -V.A.G 1318- .

– Attach test hose -arrow- and hold end of hose in measuring

container.

– Open cut-off valve on pressure tester.

• Lever must point in direction of flow.

– Build up pressure in fuel system by pressing the remote control

and slowly closing the cut-off valve on the pressure tester.

• Specification: 4 bar

– From this point on do not move position of cut-off valve.

– Empty the measuring container.

– Press remote control button for 15 seconds.

3. Fuel delivery unit and fuel gauge sender - all vehicles with front-wheel drive 29

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

– Compare amount of fuel delivered with minimum delivery

shown in diagram (cm3/15 sec.).

Note

Voltage at fuel pump with engine stationary and pump running is approx. 2 volts less than battery voltage.

If minimum delivery rate is not reached, check for the following causes:

♦ Fuel lines have been crushed.

♦ Fuel filter is blocked.

♦ Fuel pump is defective.

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 .

3.6 Removing and installing fuel delivery unit

Special tools and workshop equipment required

♦ Wrench -T10202-

Removing

Observe safety precautions ⇒ page 4 .

Observe rules for cleanliness ⇒ page 4 .

TT Roadster:

Caution

• On the TT Roadster, the fuel tank must first be removed before removing the fuel delivery unit.

– Remove fuel tank: Rest-of-world vehicles with front-wheel

drive ⇒ page 8 , USA vehicles with front-wheel drive

⇒ page 16 .

30 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

TT Coupé:

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

Large amounts of fuel can escape.

♦

The fuel tank must not be more than 3/4 full when remov‐ ing the fuel delivery unit, otherwise a large amount of fuel

will escape.

– Drain fuel tank if necessary: Rest-of-world vehicles with front-

wheel drive ⇒ page 7 , USA vehicles with front-wheel drive

⇒ page 15 .

Audi TT 2007 ➤

– Remove rear seat bench ⇒ Rep. gr. 72 .

– Unclip retaining tabs -arrows- for flange cover.

– Unplug electrical connector -arrow- at flange.

3. Fuel delivery unit and fuel gauge sender - all vehicles with front-wheel drive 31

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

– Mark fuel supply line -1- and fuel return line -2-.

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.

– Detach both pipes from flange (press release tabs).

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 3/4 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- .

– Pull fuel delivery unit with seal out of opening in fuel tank.

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 22

Installation is carried out in the reverse order; note the following:

Note

♦

Renew seal.

♦

Take care not to bend float arm of fuel gauge sender -G- when fitting fuel delivery unit.

– Insert fuel delivery unit into fuel tank.

32 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

– 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 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 .

– Connect battery. Observe notes on procedures required after

connecting battery ⇒ Rep. gr. 27 .

TT Roadster:

– Install fuel tank: Rest-of-world vehicles with front-wheel drive

⇒ page 12 , USA vehicles with front-wheel drive ⇒ page 20 .

All vehicles (continued):

– Put at least 5 litres of fuel into tank after installing fuel delivery

unit.

– On vehicles with TFSI engine with toothed belt drive, the fuel

pump must be adapted after renewing the fuel delivery unit

⇒ page 33 .

Audi TT 2007 ➤

3.7 Adapting fuel pump after renewing fuel

delivery unit - vehicles with TFSI engine with toothed belt drive

Note

♦

On vehicles with TFSI engine with toothed belt drive, the fuel delivery unit must be adapted to the engine control unit after renewing the fuel delivery unit.

♦

This operation is not required on vehicles with TFSI engine with timing chain.

Special tools and workshop equipment required

3. Fuel delivery unit and fuel gauge sender - all vehicles with front-wheel drive 33

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

♦ Vehicle diagnostic, testing and information system -VAS

5051B-

Procedure

• No faults stored in event memory.

– Connect vehicle diagnostic, testing and information system -

VAS 5051B- to diagnostic connection -arrow- and start engine.

– Select following menu options:

♦ „Vehicle self-diagnosis“

♦ „01 - Engine electronics“

♦ „Basic setting, display group 103“

♦ „Activate“

– Check display in zone „4“.

Indicated on display: „ADP runs“. When the fuel pump has been successfully adapted, the display will show „ADP OK“.

Note

If display shows „ADP n.OK“: interrogate event memory.

– End „vehicle self-diagnosis“.

– Switch off ignition and unplug diagnostic connector.

3.8 Checking fuel gauge sender -G-

Special tools and workshop equipment required

♦ Hand-held multimeter -V.A.G 1526D-

34 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

♦ Auxiliary measuring set -V.A.G 1594C-

Procedure

TT Coupé:

– Remove rear seat bench ⇒ Rep. gr. 72 .

TT Roadster:

– Remove back panel side trim (right-side) ⇒ Rep. gr. 70 .

All vehicles (continued):

– Unclip retaining tabs -arrows- for flange cover.

Audi TT 2007 ➤

– Unplug electrical connector -arrow- at flange.

3. Fuel delivery unit and fuel gauge sender - all vehicles with front-wheel drive 35

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

– 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 30 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. 50 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 .

3.9 Removing and installing fuel gauge sender -G-

Removing

Observe safety precautions ⇒ page 4 .

Observe rules for cleanliness ⇒ page 4 .

TT Roadster:

Caution

• On the TT Roadster, the fuel tank must be removed before removing the fuel gauge sender -G- .

– Remove fuel tank: Rest-of-world vehicles ⇒ page 8 , USA ve‐

hicles ⇒ page 16 .

All vehicles (continued):

– Remove fuel delivery unit ⇒ page 30 .

36 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

Version 1:

Caution

Risk of damage.

♦ First release retainer tabs on connector contact before

detaching electrical connectors on fuel gauge sender -G- .

– Release and detach electrical connectors -1 … 3-.

– Lift retaining tabs -4- and -5- with a screwdriver and pull fuel

gauge sender -G- off downwards -arrow-.

Version 2:

– Use screwdriver to release retaining tabs -arrows- and lift out

fuel gauge sender -G- .

Audi TT 2007 ➤

Caution

Risk of damage.

♦ First release retainer tabs on connector contact before

detaching electrical connectors on fuel gauge sender -G- .

– Release and detach electrical connectors -1 … 3-.

Installing

Installation is carried out in the reverse order; note the following:

3. Fuel delivery unit and fuel gauge sender - all vehicles with front-wheel drive 37

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

Version 1:

– Insert fuel gauge sender -G- into guides on fuel delivery unit

and press upwards until it clicks into place.

– Plug in electrical connectors -1 ... 3- and check that they have

engaged properly.

Version 2:

– Plug in electrical connectors -1 ... 3- and check that they have

engaged properly.

– Insert fuel gauge sender -G- into guides on fuel delivery unit

and press upwards until it clicks into place.

All versions (continued):

– Install fuel delivery unit ⇒ page 32 ; observe instructions for

connecting battery.

38 Rep. gr.20 - Fuel supply system

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Audi TT 2007 ➤

Fuel supply system, petrol engines - Edition 11.2010

4 Fuel tank with attached components

- rest-of-world vehicles with fourwheel drive

4.1 Fuel tank with attached components - exploded view

1 - Nut

❑ 23 Nm

2 - Heat shield for fuel tank

❑ With support bracket

3 - Fuel line

❑ To engine ❑ Press release tab on

pipe connector to dis‐ connect

4 - Breather line

❑ From gravity valve to ac‐

tivated charcoal filter

❑ 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 40

❑ 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. Specifi‐ cation: approx. 0 Ω

9 - Bolt

❑ 11 Nm

10 - Pop rivet

11 - Fuel tank

❑ Removing and installing ⇒ page 42

12 - Securing strap

❑ Installation position: Fixing point (hole) points in direction of travel

4. Fuel tank with attached components - rest-of-world vehicles with four-wheel drive 39

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

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.

4.2 Draining fuel tank

Special tools and workshop equipment required

♦ Wrench -T10202-

♦ Fuel extractor -VAS 5190-

Procedure

Observe safety precautions ⇒ page 4 .

Observe rules for cleanliness ⇒ page 4 .

– Release the tank flap.

40 Rep. gr.20 - Fuel supply system

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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.

Audi TT 2007 ➤

– 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 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 .

4. Fuel tank with attached components - rest-of-world vehicles with four-wheel drive 41

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

All vehicles (continued):

– 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.

– 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 85 ; observe

notes on procedure for connecting battery.

4.3 Removing and installing fuel tank with attached components

Special tools and workshop equipment required

42 Rep. gr.20 - Fuel supply system

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♦ 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 40 .

4. Fuel tank with attached components - rest-of-world vehicles with four-wheel drive 43

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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.

– Remove diagonal struts ⇒ Rep. gr. 42 .

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

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/0BR/0BY;

Rep. gr. 39 .

44 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

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 tab.

WARNING

Risk of accident caused by weight of fuel tank

♦ Fuel tank must be empty when it is removed.

Audi TT 2007 ➤

– First remove bolts -2, 5, 6-.

– Disengage wiring harness -arrows- and move clear.

– Position engine and gearbox jack -V.A.G 1383 A- below vehi‐

cle to support tank.

– Remove bolts -1, 3, 4, and 7-.

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 connectors on flanges with your hand.

Note

The following two illustrations show the electrical connectors on the flanges in their installation position.

– Unplug electrical connector -1- on flange (left-side).

– Disengage electrical connector -2- for Haldex coupling.

4. Fuel tank with attached components - rest-of-world vehicles with four-wheel drive 45

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

– Unplug electrical connector -arrow- at flange (right-side).

– 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 39

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-.

46 Rep. gr.20 - Fuel supply system

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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 right wheel housing liner ⇒ Rep. gr. 66 .

– Install propshaft ⇒ Rear final drive 02D/0AV/0BR/0BY; Rep.

gr. 39 .

– Install rear section of exhaust system ⇒ Rep. gr. 26 .

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 ➤

4. Fuel tank with attached components - rest-of-world vehicles with four-wheel drive 47

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

5 Fuel tank with attached components

- USA vehicles with four-wheel drive

5.1 Fuel tank with attached components - exploded view

1 - Nut

❑ 23 Nm

2 - Heat shield for fuel tank

❑ With support bracket

3 - Nut

❑ 23 Nm

4 - Fuel line

❑ To engine ❑ Press release tab on

pipe connector to dis‐ connect

5 - Breather line

❑ From activated charcoal

filter to activated char‐ coal filter solenoid valve 1 -N80-

❑ Clip onto fuel tank

6 - Electrical connector

❑ For fuel system pressur‐

isation pump -G6- and fuel gauge sender -G-

7 - Protective plate

❑ For fuel filler neck

8 - Bolt

❑ 11 Nm

9 - Filler cap

❑ Secured to tank flap unit

10 - Earth connection

❑ To eliminate electrostat‐

ic charge ❑ Installation position ⇒ page 49 ❑ Make sure that connector is securely fitted ❑ 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

11 - Breather line

❑ From gravity valve to activated charcoal filter ❑ Clip onto bracket in wheel housing ❑ Press release tab on pipe connector to disconnect

12 - Pop rivet

13 - Fuel tank

❑ Removing and installing ⇒ page 51

48 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

14 - 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.

Audi TT 2007 ➤

5.2 Draining fuel tank

Special tools and workshop equipment required

♦ Wrench -T10202-

♦ Fuel extractor -VAS 5190-

Procedure

Observe safety precautions ⇒ page 4 .

Observe rules for cleanliness ⇒ page 4 .

– Release the tank flap.

5. Fuel tank with attached components - USA vehicles with four-wheel drive 49

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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 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 .

50 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

All vehicles (continued):

– 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.

Audi TT 2007 ➤

– 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 85 ; observe

notes on procedure for connecting battery.

5.3 Removing and installing fuel tank with attached components

Special tools and workshop equipment required

5. Fuel tank with attached components - USA vehicles with four-wheel drive 51

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

♦ Engine and gearbox jack -V.A.G 1383 A-

♦ Hook -3004-

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 49 .

52 Rep. gr.20 - Fuel supply system

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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.

Audi TT 2007 ➤

– Remove diagonal struts ⇒ Rep. gr. 42 .

– 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.

– Disconnect exhaust system at clamp -1-.

5. Fuel tank with attached components - USA vehicles with four-wheel drive 53

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

– 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.

– Remove propshaft ⇒ Rear final drive 02D/0AV/0BR/0BY;

Rep. gr. 39 .

– 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 tab and disconnect fuel line -1- at front right of

fuel tank.

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-.

– Disengage wiring harness -arrows- and move clear.

– Position engine and gearbox jack -V.A.G 1383 A- below vehi‐

cle to support tank.

– Remove bolts -1, 3, 4, and 7-.

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 connectors on flanges with your hand.

54 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

Note

The following two illustrations show the electrical connectors on the flanges in their installation position.

– Unplug electrical connector -1- on flange (left-side).

– Disengage electrical connector -2- for Haldex coupling.

– Unplug electrical connector -arrow- at flange (right-side).

– 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 48

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.

Audi TT 2007 ➤

– Secure fuel tank by first tightening bolts at points -1, 3, 4, 7-,

then at points -2, 5, 6-.

5. Fuel tank with attached components - USA vehicles with four-wheel drive 55

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Audi TT 2007 ➤ 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 right wheel housing liner ⇒ Rep. gr. 66 .

– Install propshaft ⇒ Rear final drive 02D/0AV/0BR/0BY; Rep.

gr. 39 .

– Install rear section of exhaust system ⇒ Rep. gr. 26 .

TT Roadster:

– Install diagonal struts ⇒ Rep. gr. 42 .

All vehicles (continued):

– Connect battery. Observe notes on procedures required after

connecting battery ⇒ Rep. gr. 27 .

56 Rep. gr.20 - Fuel supply system

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Audi TT 2007 ➤

Fuel supply system, petrol engines - Edition 11.2010

6 Fuel delivery unit and fuel gauge

senders - all vehicles with four-wheel drive

6.1 Fuel delivery unit and fuel gauge senders - exploded view

1 - Fuel gauge sender -G-

❑ Checking resistance

values ⇒ page 78

❑ Removing and installing

⇒ page 80

2 - Fuel delivery unit with flange

❑ Checking fuel pump

(electrical test)

⇒ page 58

❑ Checking residual pres‐

sure ⇒ Rep. gr. 24

❑ Removing and installing

⇒ page 73

❑ Put at least 5 litres of

fuel into tank after instal‐ ling

3 - Seal

❑ Renew ❑ Install dry

4 - 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

5 - Fuel return line

❑ From fuel filter ❑ Do not kink ❑ 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 - Fuel supply pipe

❑ From suction-jet pump to fuel delivery unit ❑ Clipped onto fuel delivery unit

9 - Electrical connector

❑ For fuel gauge sender 2 -G169-

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 57

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

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-. ❑ Installation position ⇒ page 86 ❑ Checking resistance values ⇒ page 81 ❑ Removing and installing ⇒ page 83

13 - Suction-jet pump

❑ With pipes ❑ Only available together with -item 12-. ❑ Removing and installing ⇒ page 87

14 - Supply pipe for suction-jet pump

❑ From fuel pump to suction-jet pump ❑ Press release tab on pipe connector to disconnect

6.2 Checking fuel pump (electrical test)

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-

58 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

♦ Auxiliary measuring set -V.A.G 1594C-

Procedure

Observe test conditions ⇒ page 4 .

– Press the two clips in direction of the -arrows- and remove

cover from electronics box in engine compartment.

Audi TT 2007 ➤

– Detach fuse at position 1 -arrow- from „fuse holder

ST2“ (brown) -item 2-.

– Connect remote control -V.A.G 1348/3A- for V.A.G 1348 with

adapter cable -V.A.G 1348/3-2- to fuse contact for fuel pump and to the positive „+“ battery terminal.

– Press remote control button -V.A.G 1348/3 A- .

• Pump should start running audibly.

Note

The fuel pump runs very quietly. Where possible, avoid noisy sur‐ roundings for this test.

If no noise can be heard from pump:

TT Coupé:

– Remove rear seat bench ⇒ Rep. gr. 72 .

TT Roadster:

– Remove back panel side trim (right-side) ⇒ Rep. gr. 70 .

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 59

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

All vehicles (continued):

– Unclip the retaining tabs -arrows- for the flange cover (right-

side).

– Unplug electrical connector -arrow- at flange.

– Connect multimeter between contacts -1- and -5- of connector

to measure voltage.

– Press remote control button.

• Specification: approx. battery voltage

If specification is not obtained:

– Eliminate open circuit in wiring (refer to current flow diagram).

If reading matches specification although no noise can be heard from pump:

– Remove fuel delivery unit ⇒ page 73 .

– 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:

– Install fuel delivery unit ⇒ page 76 .

60 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

6.3 Checking fuel pump control unit -J538- vehicles with TFSI engine

♦ 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.

6.4 Removing and installing fuel pump con‐ trol unit -J538- - vehicles with 1.8 ltr./

2.0 ltr. TFSI engine

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-.

Audi TT 2007 ➤

– 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 .

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 61

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

6.5 Removing and installing fuel pump con‐ trol unit -J538- - vehicles with 2.5 ltr. TFSI engine

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):

– Take electrical connector -3- out of flange cover and unplug

(press release tab).

– Pull grommet -1- off flange cover -2-.

– Unclip retaining tabs -arrows- for flange cover.

– Detach flange cover.

– Unplug electrical connector -arrow- at flange.

62 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

– Disengage handbrake cable -1- from bracket.

– Remove bolts -4-.

Caution

Risk of overstretching electrical wiring.

♦ Lower fuel tank using engine and gearbox jack -V.A.G

1383 A- by max. 20 mm so that fuel pump control unit can be detached together with electrical wiring harness and connector.

Audi TT 2007 ➤

– Remove bolts -3, 4, 5-.

– Lower fuel tank with engine and gearbox jack -V.A.G 1383 A-

by max. 20 mm.

– Detach bracket -3- with control unit -2-, and at the same time

guide out electrical connector and wiring harness for fuel pump control unit.

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 .

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 63

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

6.6 Checking fuel pump delivery rate - vehicles with 1.8 ltr./2.0 ltr. TFSI engine

Special tools and workshop equipment required

♦ K-Jetronic pressure tester -

V.A.G 1318-

♦ Adapter -V.A.G 1318/11-

♦ Adapter -V.A.G

1318/17-1A-

♦ Connector -V.A.G 1318/23-

♦ Remote control -V.A.G

1348/3A- for V.A.G 1348 with adapter cable -V.A.G 1348/3-3-

♦ Auxiliary measuring set -

V.A.G 1594C-

♦ Fuel-resistant measuring

container

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 .

64 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

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 1348/3A- 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 „+“ (positive terminal in en‐

gine compartment).

– Remove filler cap from fuel filler neck.

Rest-of-world vehicles with toothed belt drive:

– Detach fuel line from retainer and remove heat insulation

sleeve at fuel line connection.

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.

– Pull release ring and disconnect fuel line -arrow-.

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 65

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

USA vehicles with toothed belt drive:

– Detach fuel line from retainer and remove heat insulation

sleeve -1- at fuel line connection.

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.

– Pull release ring and disconnect fuel line -arrow-.

Vehicles with timing chain:

– Push down protective sleeve -1- and disconnect fuel line.

– First press hose connector -2- downwards -arrow A-, then

press release tabs -arrow B-.

– Pull off hose connector, keeping release tabs depressed.

All vehicles (continued):

– Screw connector -V.A.G 1318/23- and adapter -V.A.G

1318/17-1A- onto K-Jetronic pressure tester -V.A.G 1318- .

– Fit adapter -V.A.G 1318/17-1A- onto disconnected fuel line.

– Screw adapter -V.A.G 1318/11- onto K-Jetronic pressure test‐

er -V.A.G 1318- .

– Attach test hose -arrow- and hold end of hose in measuring

container.

– Open cut-off valve on pressure tester.

• Lever must point in direction of flow.

– Build up pressure in fuel system by pressing the remote control

and slowly closing the cut-off valve on the pressure tester.

• Specification: 4 bar

– From this point on do not move position of cut-off valve.

– Empty the measuring container.

– Press remote control button for 15 seconds.

66 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

– Compare amount of fuel delivered with minimum delivery

shown in diagram (cm3/15 sec.).

Note

Voltage at fuel pump with engine stationary and pump running is approx. 2 volts less than battery voltage.

If minimum delivery rate is not reached, check for the following causes:

♦ Fuel lines have been crushed.

♦ Fuel filter is blocked.

♦ Fuel pump is defective.

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 .

Audi TT 2007 ➤

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 67

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

6.7 Checking fuel pump delivery rate - vehicles with 2.5 ltr. TFSI engine

Special tools and workshop equipment required

♦ K-Jetronic pressure tester -

V.A.G 1318-

♦ Adapter -V.A.G 1318/11-

♦ Adapter -V.A.G

1318/17-1A-

♦ Connector -V.A.G 1318/23-

♦ Remote control -V.A.G

1348/3A- for V.A.G 1348 with adapter cable -V.A.G 1348/3-3-

♦ Auxiliary measuring set -

V.A.G 1594C-

♦ Fuel-resistant measuring

container

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 .

68 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

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 1348/3A- 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 „+“ (positive terminal in en‐

gine compartment).

– Remove filler cap from fuel filler neck.

– Detach fuel line from retainer and remove heat insulation

sleeve -1- at fuel line connection.

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 -3- by pulling release ring -2-.

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 69

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

– Screw connector -V.A.G 1318/23- and adapter -V.A.G

1318/17-1A- onto K-Jetronic pressure tester -V.A.G 1318- .

– Fit adapter -V.A.G 1318/17-1A- onto disconnected fuel line.

– Screw adapter -V.A.G 1318/11- onto K-Jetronic pressure test‐

er -V.A.G 1318- .

– Attach test hose -arrow- and hold end of hose in measuring

container.

– Open cut-off valve on pressure tester.

• Lever must point in direction of flow.

– Build up pressure in fuel system by pressing the remote control

and slowly closing the cut-off valve on the pressure tester.

• Specification: 4 bar

– From this point on do not move position of cut-off valve.

– Empty the measuring container.

– Press remote control button for 15 seconds.

– Compare amount of fuel delivered with minimum delivery

shown in diagram (cm3/15 sec.).

Note

Voltage at fuel pump with engine stationary and pump running is approx. 2 volts less than battery voltage.

If minimum delivery rate is not reached, check for the following causes:

♦ Fuel lines have been crushed.

♦ Fuel filter is blocked.

♦ Fuel pump is defective.

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 .

6.8 Checking fuel pump delivery rate - vehi‐ cles with 3.2 ltr. MPI engine

Special tools and workshop equipment required

70 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

♦ Adapter -V.A.G 1318/17-1- from adapter set -V.A.G 1318/17-

♦ Remote control -V.A.G 1348/3A- for V.A.G 1348 with adapter

cable -V.A.G 1348/3-3-

Audi TT 2007 ➤

♦ Fuel-resistant measuring container

Procedure

Observe test conditions ⇒ page 4 .

– Remove filler cap from fuel filler neck.

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).

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 71

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

– 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 „+“.

Risk of injury - fuel system operates under high pressure.

WARNING

♦ To reduce the pressure in the fuel system, wrap a clean

cloth around the connection and carefully loosen the con‐ nection.

– Press release tab and disconnect fuel return line -arrow-.

– Fit adapter -V.A.G 1318/17-1- onto disconnected fuel return

line and hold adapter hose in measuring container.

– Press remote control button for 15 seconds.

72 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

– Compare amount of fuel delivered with minimum delivery

shown in diagram (cm3/15 sec.).

Note

Voltage at fuel pump with engine stationary and pump running is approx. 2 volts less than battery voltage.

If minimum delivery rate is not reached, check for the following causes:

♦ Fuel lines have been crushed.

♦ Fuel filter is blocked.

♦ Fuel pump is defective.

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 .

Audi TT 2007 ➤

6.9 Removing and installing fuel delivery unit

Special tools and workshop equipment required

♦ Wrench -T10202-

Removing

Observe safety precautions ⇒ page 4 .

Observe rules for cleanliness ⇒ page 4 .

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 .

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 73

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

TT Roadster:

Caution

• On the TT Roadster, the fuel tank must first be removed before removing the fuel delivery unit.

– Remove fuel tank: Rest-of-world vehicles ⇒ page 42 , USA

vehicles ⇒ page 51 .

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: Rest-of-world vehicles

⇒ page 40 , USA vehicles ⇒ page 49 .

– Remove rear seat bench ⇒ Rep. gr. 72 .

– Unclip the retaining tabs -arrows- for the flange cover (right-

side).

– Unplug electrical connector -arrow- at flange.

74 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

– Mark fuel supply line -1- and fuel return line -2-.

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.

– Detach both pipes from flange (press release tabs).

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

Audi TT 2007 ➤

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.

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 75

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

– In opening in fuel tank, press release tab to disconnect supply

pipe -2- to suction-jet pump.

– Disconnect fuel supply pipe -1- (press release catch -arrow-).

– 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 57

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.

– Insert fuel delivery unit into fuel tank, with flange set aside.

– Fit fuel supply pipe -1-, so that it engages (you should hear it

click into place).

– Fit supply pipe -2- leading to suction-jet pump so that it en‐

gages audibly.

76 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

– Install new seal for flange (seal must be installed dry).

– Slot guide sleeve on flange into guide sleeve on fuel delivery

unit; make sure spring is not damaged.

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.

Audi TT 2007 ➤

– Tighten locking ring.

TT Coupé:

– Install rear seat bench ⇒ Rep. gr. 72 .

– Connect battery. Observe notes on procedures required after

connecting battery ⇒ Rep. gr. 27 .

TT Roadster:

– Install fuel tank: Rest-of-world vehicles with four-wheel drive

⇒ page 46 , USA vehicles with four-wheel drive ⇒ page 55 .

All vehicles (continued):

– Put at least 5 litres of fuel into tank after installing fuel delivery

unit.

– On vehicles with TFSI engine with toothed belt drive, the fuel

pump must be adapted after renewing the fuel delivery unit

⇒ page 77 .

6.10 Adapting fuel pump after renewing fuel

delivery unit - vehicles with TFSI engine with toothed belt drive

Note

♦

On vehicles with TFSI engine with toothed belt drive, the fuel delivery unit must be adapted to the engine control unit after renewing the fuel delivery unit.

♦

This operation is not required on vehicles with TFSI engine with timing chain.

Special tools and workshop equipment required

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 77

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

♦ Vehicle diagnostic, testing and information system -VAS

5051B-

Procedure

• No faults stored in event memory.

– Connect vehicle diagnostic, testing and information system -

VAS 5051B- to diagnostic connection -arrow- and start engine.

– Select following menu options:

♦ „Vehicle self-diagnosis“

♦ „01 - Engine electronics“

♦ „Basic setting, display group 103“

♦ „Activate“

– Check display in zone „4“.

Indicated on display: „ADP runs“. When the fuel pump has been successfully adapted, the display will show „ADP OK“.

Note

If display shows „ADP n.OK“: interrogate event memory.

– End „vehicle self-diagnosis“.

– Switch off ignition and unplug diagnostic connector.

6.11 Checking fuel gauge sender -G-

Special tools and workshop equipment required

♦ Hand-held multimeter -V.A.G 1526D-

78 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

♦ Auxiliary measuring set -V.A.G 1594C-

Procedure

TT Coupé:

– Remove rear seat bench ⇒ Rep. gr. 72 .

TT Roadster:

– Remove back panel side trim (right-side) ⇒ Rep. gr. 70 .

All vehicles (continued):

– Unclip the retaining tabs -arrows- for the flange cover (right-

side).

Audi TT 2007 ➤

– Unplug electrical connector -arrow- at flange.

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 79

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

– 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 73 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 .

6.12 Removing and installing fuel gauge sender -G-

Removing

Observe safety precautions ⇒ page 4 .

Observe rules for cleanliness ⇒ page 4 .

TT Roadster:

Caution

• On the TT Roadster, the fuel tank must first be removed before removing the fuel delivery unit.

– Remove fuel tank: Rest-of-world vehicles ⇒ page 42 , USA

vehicles ⇒ page 51 .

80 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

All vehicles (continued):

– Remove fuel delivery unit ⇒ page 73 .

Caution

Risk of damage.

♦ First release retainer tabs on connector contact before

detaching electrical connectors on fuel gauge sender -G- .

– Release and detach electrical connectors -1 … 3-.

– Lift retaining tabs -4- and -5- with a screwdriver and pull fuel

gauge sender -G- off downwards -arrow-.

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 76 ; observe instructions for

connecting battery.

Audi TT 2007 ➤

6.13 Checking fuel gauge sender 2 -G169-

Special tools and workshop equipment required

♦ Hand-held multimeter -V.A.G 1526D-

♦ Auxiliary measuring set -V.A.G 1594C-

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 81

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

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-.

82 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

– 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 83 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 ➤

6.14 Removing and installing fuel gauge sender 2 -G169-

Special tools and workshop equipment required

♦ Wrench -T10202-

Removing

Observe safety precautions ⇒ page 4 .

Observe rules for cleanliness ⇒ page 4 .

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 83

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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 .

TT Roadster:

Caution

• On the TT Roadster, the fuel tank must first be removed before removing the fuel gauge sender 2 -G169- .

– Remove fuel tank: Rest-of-world vehicles ⇒ page 42 , USA

vehicles ⇒ page 51 .

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: Rest-of-world vehicles

⇒ page 40 , USA vehicles ⇒ page 49 .

– 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.

84 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

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 57

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.

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 85

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

– 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 .

– Observe notes on procedures required after connecting bat‐

tery ⇒ Rep. gr. 27 .

TT Roadster:

– Install fuel tank: Rest-of-world vehicles with four-wheel drive

⇒ page 46 , USA vehicles with four-wheel drive ⇒ page 55 .

86 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

6.15 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, 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 pump ⇒ page 58 .

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 87 .

6.16 Removing and installing suction-jet pump

Special tools and workshop equipment required

♦ Wrench -T10202-

Removing

Observe safety precautions ⇒ page 4 .

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 87

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

Observe rules for cleanliness ⇒ page 4 .

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 .

TT Roadster:

Caution

• On the TT Roadster, the fuel tank must first be removed before removing the suction-jet pump.

– Remove fuel tank: Rest-of-world vehicles ⇒ page 42 , USA

vehicles ⇒ page 51 .

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: Rest-of-world vehicles

⇒ page 40 , USA vehicles ⇒ page 49 .

– Remove rear seat bench ⇒ Rep. gr. 72 .

– Unclip the retaining tabs -arrows- for the flange cover (right-

side).

– Unplug electrical connector -arrow- at flange.

88 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

– Mark fuel supply line -1- and fuel return line -2-.

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.

– Detach both pipes from flange (press release tabs).

– Unclip the retaining tabs -arrows- for the flange cover (left-

side).

Audi TT 2007 ➤

– Unplug electrical connector -1- at flange.

– Disengage electrical connector -2- and move it clear to the

side.

TT Roadster:

– With fuel tank removed, mark fuel supply line and fuel return

line on flange (right-side).

– 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- .

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 89

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

– Take flange 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 -2- to suction-jet pump.

– Disconnect fuel supply pipe -1- (press release catch -arrow-).

– Unscrew locking ring (left-side) 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

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 57

Installation is carried out in the reverse order; note the following:

Note

♦

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.

90 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

– Reach into fuel tank opening on right side of vehicle and pull

suction-jet pump with pipes into the installation position.

– Fit supply pipe -1-, so that it engages (you should hear it click

into place).

– Fit supply pipe -2- leading to suction-jet pump so that it en‐

gages audibly.

– Install new seal for flange (seal must be installed dry).

– Slot guide sleeve on flange into guide sleeve on fuel delivery

unit; make sure spring is not damaged.

Caution

Leakage risk

Audi TT 2007 ➤

♦ 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.

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 91

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

– 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.

– 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 .

– Observe notes on procedures required after connecting bat‐

tery ⇒ Rep. gr. 27 .

TT Roadster:

– Install fuel tank: Rest-of-world vehicles with four-wheel drive

⇒ page 46 , USA vehicles with four-wheel drive ⇒ page 55 .

All vehicles (continued):

– Put at least 5 litres of fuel into tank after installing suction-jet

pump

92 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

7 Fuel filter - all vehicles

In the fuel system of the Audi TT, which has no direct fuel return line, the fuel pressure regulator is located in the fuel filter. In this system, only the supply pipe is routed to the front, to the engine compartment. The fuel pressure regulator opens when the pres‐ sure in the fuel supply pipe rises above a specified value. Excess fuel flows from the filter directly back to the tank via a return line.

7.1 Fuel filter - exploded view

1 - Fuel filter with fuel pressure regulator

❑ For TFSI engine with

fuel pressure regulator:

6.4 bar

❑ For MPI engine with fuel

pressure regulator: 4 bar

❑ Flow direction is marked

by arrows

❑ Do not interchange con‐

nections

❑ Installation position: Pin

on filter housing must engage in opening on fil‐ ter bracket guide

⇒ page 95

❑ Removing and installing

2 - Fuel supply line

❑ From fuel tank ❑ Press release tab on

3 - Fuel return line

❑ To fuel tank ❑ Press release tab on

4 - Fuel line

❑ To engine ❑ Press release tab on

5 - Bolt

❑ 1.5 Nm

6 - Bracket for fuel filter

❑ Attached to fuel tank

⇒ page 93

pipe connector to dis‐ connect

Audi TT 2007 ➤

7.2 Removing and installing fuel filter

Special tools and workshop equipment required

♦ Drip tray

7. Fuel filter - all vehicles 93

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

Removing

Observe safety precautions ⇒ page 4 .

Observe rules for cleanliness ⇒ page 4 .

TT Coupé:

– Remove rear seat bench ⇒ Rep. gr. 72 .

TT Roadster:

– Remove back panel side trim (right-side) ⇒ Rep. gr. 70 .

Vehicles with 1.8 ltr./2.0 ltr. TFSI engine:

WARNING

Fuel can escape.

♦ Fuel pump control unit -J538- must be disconnected from

the power supply to prevent the fuel pump from starting up when the driver's door is opened.

– Remove fuel pump control unit -J538- from cover for flange

and unplug electrical connector -arrow-.

Vehicles with MPI engine:

WARNING

Fuel can escape.

♦ The fuel pump must be disconnected from the power sup‐

ply to prevent it from starting up when the driver's door is opened.

– Unclip the retaining tabs -arrows- for the flange cover (right-

side).

– Unplug electrical connector -arrow- at flange.

Note

Unplugging the connector for the fuel pump will prevent the fuel pump from being activated when the driver's door is opened.

94 Rep. gr.20 - Fuel supply system

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Fuel supply system, petrol engines - Edition 11.2010

All vehicles (continued):

– Place drip tray below fuel filter.

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 lines -1, 2, 3- by pressing the release tab.

– Remove bolt -4-.

– Remove fuel filter.

Installing

• Tightening torque ⇒ page 93

Installation is carried out in the reverse order; note the following:

Installation position:

• Flow direction is marked with arrows on filter housing.

• Pin -2- on filter housing must engage in opening on filter brack‐ et guide -1-.

Audi TT 2007 ➤

7. Fuel filter - all vehicles 95

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Audi TT 2007 ➤ Fuel supply system, petrol engines - Edition 11.2010

8 Activated charcoal filter system - rest-

of-world vehicles

8.1 Activated charcoal filter system - exploded view

Note

Illustration shows version for vehicles with 3.2 ltr. MPI engine as an example.

1 - Activated charcoal filter

❑ Removing and installing

⇒ page 96

2 - Spring-type clip

3 - Breather line

❑ To activated charcoal fil‐

ter solenoid valve 1 N80-

4 - Breather line

❑ To fuel tank

5 - Bolt

❑ 8 Nm

6 - Nut

❑ 8 Nm

7 - Bracket for activated char‐ coal filter

8 - Bolt

❑ 8 Nm

8.2 Removing and installing activated char‐ coal filter

Special tools and workshop equipment required

96 Rep. gr.20 - Fuel supply system

Audi TT 38 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

00 – Technical data

1 Safety precautions

1.1 Working on the fuel system

1.4 Removing and installing components from a full or partly full fuel tank

2 General repair instructions

2.1 Rules for cleanliness

2.2 Contact corrosion!

2.3 Test conditions

20 – Fuel supply system

1.1 Fuel tank with attached components - exploded view

1.2 Draining fuel tank

1.3 Removing and installing fuel tank with attached components

2.1 Fuel tank with attached components - exploded view

2.2 Draining fuel tank

2.3 Removing and installing fuel tank with attached components

3.1 Fuel delivery unit and fuel gauge sender - exploded view

3.5 Checking fuel pump delivery rate - vehicles with TFSI engine

3.6 Removing and installing fuel delivery unit

3.8 Checking fuel gauge sender -G-

3.9 Removing and installing fuel gauge sender -G-

4.1 Fuel tank with attached components - exploded view

4. Fuel tank with attached components - rest-of-world vehicles with four-wheel drive 39

4.2 Draining fuel tank

4.3 Removing and installing fuel tank with attached components

5.1 Fuel tank with attached components - exploded view

5.2 Draining fuel tank

5.3 Removing and installing fuel tank with attached components

6.1 Fuel delivery unit and fuel gauge senders - exploded view

6. Fuel delivery unit and fuel gauge senders - all vehicles with four-wheel drive 57

6.2 Checking fuel pump (electrical test)

6.6 Checking fuel pump delivery rate - vehicles with 1.8 ltr./2.0 ltr. TFSI engine

6.7 Checking fuel pump delivery rate - vehicles with 2.5 ltr. TFSI engine

6.9 Removing and installing fuel delivery unit

6.11 Checking fuel gauge sender -G-

6.12 Removing and installing fuel gauge sender -G-

6.13 Checking fuel gauge sender 2 -G169-

6.14 Removing and installing fuel gauge sender 2 -G169-

6.15 Suction-jet pump

6.16 Removing and installing suction-jet pump

7 Fuel filter - all vehicles

7.1 Fuel filter - exploded view

7.2 Removing and installing fuel filter

8.1 Activated charcoal filter system - exploded view