Audi TT 39 User Manual

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Service

Workshop Manual

Audi TT 2007 ➤

Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine)

Engine ID

Edition 07.2007

BUB

CBR

A

Service Department. Technical Information

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Service

List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups

Re pa ir G ro up

24 - Mixture preparation - injection

28 - Ignition 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 ➤

Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine) - Edition 07.2007

Contents

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety precautions and rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Rules for cleanliness when working on fuel supply system and injection system . . . . . . . . 2

2 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.3 Air cleaner - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.4 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.5 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.6 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.7 Intake manifold - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.8 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.9 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.10 Checking vacuum unit for intake manifold flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.11 Removing and installing vacuum unit for intake manifold flaps . . . . . . . . . . . . . . . . . . . . . . 22

2.12 Checking fuel pressure regulator and residual pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.13 Fuel rail with injectors - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.14 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.15 Checking injection quantity and spray pattern of injectors; checking for leaks . . . . . . . . . . 29

2.16 Removing and installing Lambda probes (before catalytic converter) . . . . . . . . . . . . . . . . 32

2.17 Removing and installing Lambda probes (after catalytic converter) . . . . . . . . . . . . . . . . . . 33

3 Engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.1 Wiring and component check with test box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

1 General notes and safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.1 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.2 Ignition system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.3 Removing and installing ignition coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Contents i

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Audi TT 2007 ➤ Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine) - Edition 07.2007

ii Contents

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Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine) - Edition 07.2007

24 – Mixture preparation - injection

1 Safety precautions and rules for

cleanliness

1.1 Safety precautions

Observe the following to prevent injuries to persons and damage to the injection and ignition system:

♦ Always switch off the ignition before connecting or discon‐

necting electrical wiring for the injection or ignition system or tester cables.

♦ Always switch off ignition before washing engine.

♦ Faults are stored in engine control unit if electrical connectors

have been unplugged:

– With ignition switched off, connect vehicle diagnostic, testing

and information system -VAS 5051B- .

– Start “Guided Functions” mode.

– Generate readiness code in engine control unit.

Audi TT 2007 ➤

Caution

To prevent damage to the electronic components when dis‐ connecting the battery:

♦ Observe notes on procedure for disconnecting the battery.

♦ Always switch off the ignition before disconnecting the

battery.

– Disconnect battery ⇒ Rep. Gr. 27 .

When working on the fuel system note the following warnings:

WARNING

Risk of injury - fuel system operates under high pressure.

♦ Wrap a cloth around the connection before opening the

fuel system. Then release pressure by carefully loosening the connection.

1. Safety precautions and rules for cleanliness 1

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Audi TT 2007 ➤ Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine) - Edition 07.2007

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.

Injuries can also be caused if the passenger's airbag is trig‐ gered in a collision.

• 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- 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.

1.2 Rules for cleanliness when working on fuel supply system and injection system

Even small amounts of dirt can cause malfunctions. For this rea‐ son, please observe the following rules when working on the fuel supply system and injection system:

♦ Carefully clean connection points and the surrounding area

with engine cleaner or brake cleaner and dry thoroughly before opening.

♦ Seal off open lines and connections with clean plugs or sealing

caps immediately.

♦ Place parts that have been removed on a clean surface and

cover them over. Use only lint-free cloths.

♦ Carefully cover or seal open components if repairs cannot be

carried out immediately.

♦ Only install clean components; replacement parts should only

be unpacked immediately prior to installation. Do not use parts that have 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 Rep. Gr.24 - Mixture preparation - injection

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Audi TT 2007 ➤

Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine) - Edition 07.2007

2 Injection system

2.1 Test data

Engine data 3.2 ltr. / 4V / 184 kW engine

Idling speed

600 ... 700 rpm

Cannot be adjusted; regulated by idling speed stabili‐ sation

Maximum rpm governed by

approx. 6,500 rpm

deactivation of fuel injectors Fuel pressure at idling speed approx. 4.0 bar Residual pressure after 10 minutes at least 3.0 bar Injectors Spray pattern Two-hole nozzle / same for all injectors

Injection quantity

128 … 140 ml

(30 sec.)

1)

•

Current values ⇒ Data sheets for exhaust emission test.

1)

2.2 Overview of fitting locations

1 - 3-pin connector

❑ For knock sensor 1 -

G61-

❑ Fitting location

⇒ page 9

2 - Knock sensor 1 -G61-

❑ Fitting location

⇒ page 9

3 - Activated charcoal filter sol‐ enoid valve 1 -N80-

4 - Lambda probe before cata‐ lytic converter -G39- with Lambda probe heater -Z19-

❑ Fitting location

⇒ page 7

❑ Removing and installing

⇒ page 32

5 - Electrical connectors

❑ For Lambda probe after

catalytic converter G130- with Lambda probe 1 heater after cat‐ alytic converter -Z29-

❑ For Lambda probe 2 af‐

ter catalytic converter G131- with Lambda probe 2 heater after cat‐ alytic converter -Z30-

❑ Fitting location

⇒ page 7

6 - Lambda probe after catalyt‐ ic converter -G130- with Lamb‐ da probe 1 heater after catalyt‐

2. Injection system 3

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Audi TT 2007 ➤ Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine) - Edition 07.2007

ic converter -Z29-

❑ Fitting location ⇒ page 7 ❑ Removing and installing ⇒ page 33

7 - Engine control unit -J623-

❑ Removing and installing ⇒ page 35

8 - Lambda probe 2 after catalytic converter -G131- with Lambda probe 2 heater after catalytic converter -Z30-

❑ Fitting location ⇒ page 7 ❑ Removing and installing ⇒ page 33

9 - Lambda probe 2 before catalytic converter -G108- with Lambda probe 2 heater -Z28-

❑ Fitting location ⇒ page 7 ❑ Removing and installing ⇒ page 32

10 - Heating element for crankcase breather -N79-

11 - Ignition coils with output stages

❑ Cylinder 1 ignition coil 1 with output stage -N70❑ Cylinder 2 ignition coil 2 with output stage -N127❑ Cylinder 3 ignition coil 3 with output stage -N291❑ Cylinder 4 ignition coil 4 with output stage -N292❑ Cylinder 5 ignition coil 5 with output stage -N323❑ Cylinder 6 ignition coil 6 with output stage -N324❑ Removing and installing ⇒ page 43

12 - Throttle valve module -J338-

❑ Including throttle valve drive for electric throttle -G186- , throttle valve drive angle sender 1 for electric

throttle -G187- and throttle valve drive angle sender 2 for electric throttle -G188-

13 - Electrical connectors

❑ For Lambda probe, before catalytic converter -G39- with Lambda probe heater -Z19❑ For Lambda probe 2, before catalytic converter -G108- with Lambda probe 2 heater -Z28❑ Fitting location ⇒ page 6

14 - Air mass meter -G70-

❑ Removing and installing ⇒ page 14

15 - Clutch position sender -G476-

❑ For vehicles with manual gearbox ❑ Fitting location ⇒ page 6 .

16 - Accelerator position sender -G79- and accelerator position sender 2 -G185-

Fitting location ⇒ page 6

17 - Instrument cluster

❑ With exhaust emissions warning lamp -K83-

18 - Electronics box in engine compartment

❑ With fuel pump relay -J17❑ With Motronic current supply relay -J271❑ With secondary air pump relay -J299❑ Fitting locations ⇒ page 8

19 - Sender 1 for secondary air pressure -G609-

❑ Only for engine code CBRA ❑ Fitting location ⇒ page 10

20 - Hall sender 2 -G163-

❑ Fitting location ⇒ page 9

4 Rep. Gr.24 - Mixture preparation - injection

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Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine) - Edition 07.2007

21 - Exhaust camshaft control valve 1 -N318-

❑ Brown connector ❑ Fitting location ⇒ page 9

22 - Inlet camshaft control valve 1 -N205-

❑ Black connector ❑ Fitting location ⇒ page 9

23 - Hall sender -G40-

❑ Fitting location ⇒ page 9

24 - Coolant temperature sender -G62-

❑ Fitting location ⇒ page 8

25 - Vacuum unit for intake manifold flaps

❑ Checking ⇒ page 20 ❑ Removing and installing ⇒ page 22

26 - Engine speed sender -G28-

❑ Fitting location ⇒ page 8

27 - Variable intake manifold change-over valve -N156-

❑ Fitting location ⇒ page 8

28 - Secondary air pump motor -V101-

❑ Removing and installing ⇒ Rep. Gr. 26

29 - Checking secondary air inlet valve -N112- and secondary air inlet valve 2 -N320-

❑ Only for engine code CBRA ❑ Fitting location ⇒ page 9

30 - Knock sensor 2 -G66-

❑ Fitting location ⇒ page 9

31 - 3-pin connector

❑ For engine speed sender -G28❑ Fitting location ⇒ page 8

32 - Injectors

❑ Cylinder 1 injector for cylinder 1 -N30❑ Cylinder 2 injector for cylinder 2 -N31❑ Cylinder 3 injector for cylinder 3 -N32❑ Cylinder 4 injector for cylinder 4 -N33❑ Cylinder 5 injector for cylinder 5 -N83❑ Cylinder 6 injector for cylinder 6 -N84❑ Checking injection quantity and spray pattern; checking for leaks ⇒ page 29 ❑ Removing and installing ⇒ page 27

Audi TT 2007 ➤

2. Injection system 5

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Audi TT 2007 ➤ Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine) - Edition 07.2007

Fitting location of accelerator position sender -G79- with acceler‐ ator position sender 2 -G185-

♦ To unplug the electrical connector -2- press the release tab

and pull off the cable guide -1-.

♦ Removing and installing ⇒ Rep. Gr. 20

Note

Diagram shows set-up on left-hand drive vehicles.

Fitting location of clutch position sender -G476-

♦ On clutch master cylinder-arrow-.

♦ Removing and installing ⇒ Rep. Gr. 30

Fitting location of connectors for Lambda probes before catalytic converter

1 - Lambda probe 2 before catalytic converter -G108- with

Lambda probe 2 heater -Z28-

2 - Lambda probe before catalytic converter -G39- with Lamb‐

da probe heater -Z19-

Note

Disregard -item 3-.

6 Rep. Gr.24 - Mixture preparation - injection

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Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine) - Edition 07.2007

Fitting location and tightening torque of Lambda probes before catalytic converter

♦ In front exhaust pipe

1 - Lambda probe 2 before catalytic converter -G108- with

Lambda probe 2 heater -Z28-

2 - Lambda probe before catalytic converter -G39- with Lamb‐

da probe heater -Z19-

– Tighten Lambda probes to 55 Nm.

Fitting location of connectors for Lambda probes after catalytic converter

♦ On underside of vehicle (right-side)

– Remove nuts -1- and -2- on retainer for electrical connectors.

Note

Audi TT 2007 ➤

Disregard -item 3-.

– Detach cover.

1 - Lambda probe after catalytic converter -G130- with Lambda

probe 1 heater after catalytic converter -Z29-

2 - Lambda probe 2 after catalytic converter -G131- with Lamb‐

da probe 2 heater after catalytic converter -Z30-

Fitting location and tightening torque of Lambda probes after cat‐ alytic converter

♦ In catalytic converters.

1 - Lambda probe 2 after catalytic converter -G131- with Lamb‐

da probe 2 heater after catalytic converter -Z30-

2 - Lambda probe after catalytic converter -G130- with Lambda

probe 1 heater after catalytic converter -Z29-

– Tighten Lambda probes to 55 Nm.

2. Injection system 7

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Audi TT 2007 ➤ Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine) - Edition 07.2007

Fitting locations in electronics box in engine compartment

2.1 - Electric fuel pump 2 relay -J49-

2.2 - Continued coolant circulation relay -J151-

3 - Secondary air pump relay -J299-

4 - Motronic current supply relay -J271-

5 - Fuel pump relay -J17-

Fitting location: engine speed sender -G28- with 3-pin connector

♦ At front of engine.

1 - 3-pin connector

2 - Engine speed sender -G28-

Fitting location of intake manifold change-over valve -N156-

♦ On vacuum reservoir (at front of engine) -arrow-.

Fitting location of coolant temperature sender -G62-

♦ At front left of cylinder head -arrow-.

♦ Removing and installing ⇒ Rep. Gr. 19

8 Rep. Gr.24 - Mixture preparation - injection

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Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine) - Edition 07.2007

Fitting location of knock sensor 1 -G61-

♦ At rear right on cylinder block.

1 - Knock sensor 1 -G61-

2 - 3-pin connector

Fitting location of knock sensor 2 -G66-

♦ At front of cylinder block -arrow-.

Audi TT 2007 ➤

Fitting location of Hall sender and camshaft control valves

♦ On left side of cylinder head.

1 - Hall sender -G40-

2 - Hall sender 2 -G163-

3 - Inlet camshaft control valve 1 -N205-

4 - Exhaust camshaft control valve 1 -N318-

Fitting location of secondary air inlet valves (engine code CBRA)

♦ At vacuum reservoir (at front of engine)

1 - Secondary air inlet valve -N112-

2 - Secondary air inlet valve 2 -N320-

♦ Removing and installing ⇒ Rep. Gr. 26

2. Injection system 9

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Audi TT 2007 ➤ Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine) - Edition 07.2007

Fitting location of sender 1 for secondary air pressure -G609(engine code CBRA)

♦ Near throttle valve module -J338-

1 - Sender 1 for secondary air pressure -G609-

♦ Removing and installing ⇒ Rep. Gr. 26

Note

Disregard -arrows-.

2.3 Air cleaner - exploded view

1 - Gasket

❑ Clipped into air cleaner

housing (bottom sec‐ tion)

2 - Front air duct

❑ Clean out dirt, leaves

and salt deposits

3 - Bolt

❑ 2 Nm

4 - Lower part of air duct

❑ Clean out dirt, leaves

and salt deposits

5 - Air duct cover

6 - Bolt

❑ 5 Nm

7 - Bolt

❑ 3 Nm

8 - Air hose

9 - Air mass meter -G70-

❑ Removing and installing

⇒ page 14

10 - Seal

❑ Renew if damaged

11 - Air cleaner housing (top section)

❑ Removing and installing

⇒ “2.4 Removing and in‐ stalling air filter ele‐ ment”, page 12

12 - Air filter element

❑ Removing and installing ⇒ page 12 ❑ Always use genuine part for air filter element ❑ Observe change intervals ⇒ Maintenance ; Booklet 810

13 - Air cleaner housing (bottom section)

❑ Removing and installing ⇒ page 13 ❑ Clean out dirt, leaves and salt deposits

10 Rep. Gr.24 - Mixture preparation - injection

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Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine) - Edition 07.2007

14 - Bolt

❑ 10 Nm

15 - Rubber grommet

❑ Captive

16 - Bolt

❑ 10 Nm

17 - Bracket for air cleaner housing

18 - Retaining peg

❑ 10 Nm

19 - Rubber grommet

Audi TT 2007 ➤

2. Injection system 11