Audi TT 52 User Manual
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
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Service
Workshop Manual
Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4valve common rail, generation II)
Engine ID
Edition 05.2010
CFG
B
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
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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
23 - Mixture preparation - injection
28 - Glow plug system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt D3E8029B417
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 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
Contents
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety precautions and rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions for vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Rules for cleanliness and instructions for working on fuel system . . . . . . . . . . . . . . . . . . . . 2
1.4 To avoid any risk of injuries to persons and/or damage to the injection and glow plug system,
always observe the following safety precautions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 System layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Air cleaner - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.5 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1 Intake manifold with attached components - exploded view . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.1 High-pressure pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.3 Performing first fuel filling operation after installing high-pressure pump . . . . . . . . . . . . . . 29
7.4 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.1 Injectors - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.2 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.3 Performing adaption of injector delivery calibration values . . . . . . . . . . . . . . . . . . . . . . . . 33
8.4 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.5 Checking return flow rate of injectors at starter cranking speed . . . . . . . . . . . . . . . . . . . . 36
8.6 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.7 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9 Components of injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.1 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.2 Installing high-pressure pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.3 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.4 Checking fuel pressure (low pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.5 Checking delivery rate of fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.6 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 51
9.7 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.8 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10 Lambda probe and exhaust gas temperature senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.1 Lambda probe and exhaust gas temperature senders - exploded view . . . . . . . . . . . . . . . . 58
10.2 Removing and installing Lambda probe G39 with Lambda probe heater Z19 . . . . . . . . . . 58
10.3 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 59
11 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
11.1 Wiring and component check with test box V.A.G 1598/42 . . . . . . . . . . . . . . . . . . . . . . . . 61
11.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Contents i
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.1 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.2 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 69
1.3 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.4 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
ii Contents
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
23 – Mixture preparation - injection
1 Safety precautions and rules for
cleanliness
⇒ “1.1 Safety precautions”, page 1
⇒ “1.2 Safety precautions for vehicles with start/stop system”,
page 1
⇒ “1.3 Rules for cleanliness and instructions for working on fuel
system”, page 2
⇒ “1.4 To avoid any risk of injuries to persons and/or damage to
the injection and glow plug system, always observe the following
safety precautions:”, page 3
⇒ “1.5 Checking vacuum system”, page 3
1.1 Safety precautions
Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
Accidents can be caused if the driver is distracted by test
equipment while road-testing, or if test equipment is not prop‐
erly secured.
Persons sitting in the front passenger's seat could be injured if
the airbag is triggered in an accident.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Test equipment must always be secured on the rear seat
with a strap and operated from the rear seat by a second
person.
1.2 Safety precautions for vehicles with start/stop system
Risk of injury due to automatic engine start on vehicles with
start/stop system.
♦ On vehicles with activated start/stop system (this is indi‐
♦ Therefore it is important to ensure that the start/stop sys‐
WARNING
cated by a message in the instrument cluster display), the
engine may start automatically on demand.
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).
1. Safety precautions and rules for cleanliness 1
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
1.3 Rules for cleanliness and instructions for working on fuel system
To prevent the high-pressure fuel pump from running while it is
empty and to ensure that the engine starts quickly after parts have
been renewed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank and
the high-pressure fuel pump are removed or renewed, the ba‐
sic setting “Checking fuel system pressurisation pump” must
be performed to bleed the fuel system.
♦ If the supplementary fuel pump, fuel line (between fuel tank
and high-pressure fuel pump) or fuel filter is removed or re‐
newed, the basic setting “Checking fuel system pressurisation
pump” must be performed before the engine is started for the
first time.
♦ If the high-pressure fuel pump is removed or renewed, the ba‐
sic setting “Checking fuel system pressurisation pump” must
be performed before the engine is started for the first time.
Procedure for first fuel filling ⇒ page 29
• Clean tools and workbench etc. before working on the injection
system.
• Thoroughly clean all unions and surrounding areas before dis‐
connecting.
• When removing components, plug all open connections im‐
mediately with suitable clean sealing caps.
• Do not remove sealing caps from components until immedi‐
ately prior to installation. After removal, components should
be kept in new, sealable plastic bags (use the original new part
packaging if possible).
• Before installation, check the injectors and their surroundings
visually; they must be undamaged and free of lint. Make sure
the injector bores in the cylinder head are clean. Wipe out if
necessary using a clean cloth, taking care not to cause dam‐
age. Do not use sharp objects of any kind.
• If the high-pressure fuel lines are to be re-used, you must mark
them before removal. High-pressure fuel lines must always be
re-installed in their original positions (i.e. on the same cylin‐
der).
• The following components and seals/O-rings must always be
renewed when the injectors are removed and installed: “cop‐
per seal” and “O-ring for injector bore”.
• The following components and seals/O-rings must always be
renewed when an injector is renewed: “clamping piece”, “cop‐
per seal” and “O-ring for injector bore”.
• Always fit new copper seals for the injectors. Check all new O-
rings for damage before installing. Lubricate O-rings lightly
with assembly oil or clean engine oil before installing.
• Take care not to damage the injectors when removing the old
copper seals.
• Align the high-pressure fuel lines so they are free of tension.
Tighten all unions lightly to start with before tightening to final
torque.
• Never attempt to bend high-pressure fuel lines to shape.
• When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
2 Rep. Gr.23 - Mixture preparation - injection
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Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
• Do not dismantle individual common rail components.
• If there is a fault, the complete components must be renewed.
• Do not bleed the common rail system by unfastening highpressure components after the engine has been started.
• When the engine is running, do not perform any repairs to the
common rail system; in particular, do not open or detach the
high-pressure pipes.
• All cable ties which are released or cut open when removing
must be refitted in the same position when installing.
• When the fuel system is open: Do not work with compressed
air if this can be avoided. Do not move the vehicle unless ab‐
solutely necessary.
• Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
1.4 To avoid any risk of injuries to persons
and/or damage to the injection and glow
plug system, always observe the follow‐
ing safety precautions:
♦ Persons wearing a pacemaker should not lean over the engine
compartment while the engine is running, as the injectors use
high voltage pulses.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off the ignition before connecting or discon‐
necting injection and glow plug system wiring or tester cables.
♦ Always switch off the ignition before cleaning the engine.
♦ Always switch off the ignition before connecting or discon‐
necting the battery, otherwise the engine control unit may be
damaged.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. The event memory should therefore be inter‐
rogated and (if necessary) erased after completing the tests
and any repair work that may be required.
1.5 Checking vacuum system
Special tools and workshop equipment required
♦ Hand vacuum pump -VAS 6213-
Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
1. Safety precautions and rules for cleanliness 3
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
♦ Traces of animal bites
♦ Kinked or crushed lines
♦ Lines porous or leaking
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
– If a fault is stored in the event memory, check all vacuum lines
leading to the corresponding component, and also check the
remaining vacuum lines leading to other components.
– If it is not possible to build up a vacuum with the hand vacuum
pump -VAS 6213- or if the vacuum pressure drops again im‐
mediately, check the hand vacuum pump and connecting
hoses for leaks.
4 Rep. Gr.23 - Mixture preparation - injection
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
2 Overview of fitting locations
Components “A” to “H” are not shown in the illustration.
1 - Supplementary fuel pump V393-
❑ Exploded view ⇒ Rep.
Gr. 20
2 - Pressure differential sender
-G505-
❑ Exploded view
⇒ page 58
❑ Adaption must be per‐
formed after renewing
this component
3 - Hall sender -G40- (cam‐
shaft position sensor)
❑ Fitting location
⇒ page 10
❑ 10 Nm
4 - Injectors
❑ Exploded view
⇒ page 31
5 - Engine control unit -J623-
❑ Fitting location
⇒ page 7
6 - Lambda probe -G39- with
Lambda probe heater -Z19-
❑ Exploded view
⇒ page 58
❑ 50 Nm
7 - Position sender for charge
pressure positioner -G581-
❑ Fitting location
⇒ page 10
8 - Exhaust gas recirculation
control motor -V338- with exhaust gas recirculation potentiometer -G212-
❑ Integrated into exhaust gas recirculation cooler
❑ Fitting location ⇒ page 9
❑ Removing and installing ⇒ Engine, mechanics; Rep. Gr. 26
9 - Fuel pressure regulating valve -N276-
❑ Exploded view ⇒ page 43
❑ Checking ⇒ page 46
10 - Charge pressure control solenoid valve -N75-
❑ Fitting location ⇒ page 9
11 - Electrical connector
❑ For exhaust gas temperature sender 4 -G648❑ For exhaust gas temperature sender 1 -G235❑ For Lambda probe -G39❑ Fitting location ⇒ page 9
2. Overview of fitting locations 5
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
12 - Coolant temperature sender -G62-
❑ Fitting location ⇒ page 10
13 - Air mass meter -G70-
❑ Exploded view ⇒ page 15
14 - Engine speed sender -G28-
❑ Fitting location ⇒ page 11
❑ 4.5 Nm
15 - Exhaust gas recirculation cooler change-over valve -N345-
❑ Fitting location ⇒ page 11
16 - Pump for exhaust gas recirculation cooler -V400-
❑ Fitting location ⇒ page 9
17 - Throttle valve module -J338- with throttle valve potentiometer -G69-
❑ Exploded view ⇒ page 21
18 - Glow plugs
❑ Glow plug 1 -Q10❑ Glow plug 2 -Q11❑ Glow plug 3 -Q12❑ Glow plug 4 -Q13❑ Removing and installing ⇒ page 67
❑ 17 Nm
19 - Fuel temperature sender -G81-
❑ In fuel supply line
❑ Fitting location ⇒ page 9
20 - Charge pressure sender -G31- with intake air temperature sender -G42-
❑ Fitting location ⇒ page 8
21 - High-pressure pump with fuel metering valve -N290-
❑ Exploded view ⇒ page 25
❑ Do not open fuel metering valve -N290❑ After renewing, first fuel filling operation MUST be performed (it is important not to allow pump to run
while it is still empty) ⇒ page 29
22 - Fuel pressure sender -G247-
❑ Exploded view ⇒ page 31
23 - Radiator outlet coolant temperature sender -G83-
❑ Fitting location ⇒ page 10
24 - Fuel filter
❑ Exploded view ⇒ Rep. Gr. 20
❑ Renewing ⇒ Rep. Gr. 20
A - Low heat output relay -J359- and high heat output relay -J360-
❑ Fitting location ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
B - Brake light switch -F- and brake pedal switch -F47-
❑ Fitting location ⇒ page 7
C - Clutch position sender -G476-
❑ Fitting location ⇒ page 8
❑ Only fitted on vehicles with manual gearbox
D - Accelerator position sender -G79- and accelerator position sender 2 -G185-
❑ Fitting location ⇒ page 7
6 Rep. Gr.23 - Mixture preparation - injection
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Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
E - Exhaust gas temperature sender 1 -G235-
❑ Exploded view ⇒ page 58
F - Exhaust gas temperature sender 3 -G495-
❑ Exploded view ⇒ page 58
G - Exhaust gas temperature sender 4 -G648-
❑ Exploded view ⇒ page 58
H - Particulate filter
❑ Combined with catalytic converter
❑ Adaption must be performed after renewing this component
❑ Removing and installing ⇒ Rep. Gr. 26
Fitting location of engine control unit -J623-
♦ In electronics box (plenum chamber)
Removing and installing ⇒ page 62
Fitting location: accelerator position sender -G79- and accelerator
position sender 2 -G185-
♦ Combined with accelerator pedal module
Note
The illustration shows the set-up for left-hand drive vehicles.
Removing and installing accelerator pedal module ⇒ Rep. Gr.
20
Fitting location of brake light switch -F- and brake pedal switch F47-
1 - Brake light switch -F- and brake pedal switch -F47-
♦ On brake master cylinder
Removing and installing ⇒ Rep. Gr. 47
2. Overview of fitting locations 7
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
Fitting location of clutch position sender -G476-
♦ On clutch master cylinder-arrow-.
Removing and installing ⇒ Rep. Gr. 30
Integrated functions: clutch pedal switch for engine start -F194and clutch pedal switch -F36- (manual gearbox only)
Fitting location of fuel pump control unit -J538-
1 - Connector for fuel pump control unit -J538-
2 - Fuel pump control unit -J538-
3 - Fuel system pressurisation pump -G6-
Removing and installing ⇒ Rep. Gr. 20
Fitting location of charge pressure sender -G31- with intake air
temperature sender -G42-
1 - Charge pressure sender -G31- with intake air temperature
sender -G42-
♦ At air pipe (right-side)
Removing and installing ⇒ Rep. Gr. 21
8 Rep. Gr.23 - Mixture preparation - injection
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
Components at rear of engine
2 - Exhaust gas recirculation control motor -V338- with exhaust
gas recirculation potentiometer -G212-
4 - Vacuum unit for exhaust gas recirculation cooling system
Electrical connectors
1 - For exhaust gas temperature sender 1 -G235-
2 - For exhaust gas temperature sender 4 -G648-
3 - For Lambda probe -G39-
4 - For exhaust gas temperature sender 3 -G495-
Fitting location of pump for exhaust gas recirculation cooler V400-
2 - Pump for exhaust gas recirculation cooler -V400-
♦ At front of engine
Removing and installing ⇒ Rep. Gr. 19
Fitting location of fuel temperature sender -G81-
4 - Fuel temperature sender -G81-
♦ In fuel supply line at high-pressure pump
2. Overview of fitting locations 9
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
Fitting location of Hall sender -G40-
♦ Next to camshaft sprocket -arrow-
Removing and installing ⇒ page 69
Fitting location of coolant temperature sender -G62-
4 - Coolant temperature sender -G62-
♦ On right side of engine under exhauster pump
Removing and installing ⇒ Rep. Gr. 19
Fitting location of radiator outlet coolant temperature sender G83-
2 - Radiator outlet coolant temperature sender -G83-
♦ In coolant pipe (right-side) above alternator
Removing and installing ⇒ Rep. Gr. 19
Fitting location of position sender for charge pressure positioner
-G581-
♦ At rear of engine at turbocharger -arrow-.
10 Rep. Gr.23 - Mixture preparation - injection
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 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
Fitting location of exhaust gas recirculation cooler change-over
valve -N345-
♦ On intake manifold -left arrow-.
Fitting location of engine speed sender -G28-
1 - Engine speed sender -G28-
2 - Sender wheel
♦ On flywheel side of engine.
Removing and installing ⇒ page 70
2. Overview of fitting locations 11
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
3 System layout
WARNING
♦ Always read rules for cleanliness and instructions for
working on fuel system ⇒ page 2 .
♦ Follow these instructions and rules for cleanliness before
starting work and while working on the fuel system.
Caution
The high-pressure fuel pump has very close tolerances and
must not be allowed to run without fuel. To prevent this and to
enable the engine to start quickly after parts have been re‐
newed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank
and the high-pressure pump are removed or renewed, the
first fuel filling operation must be performed.
♦ If a fuel pump, fuel line (between fuel tank and high-pres‐
sure pump) or fuel filter is removed or renewed, the fuel
system must be bled before the engine is started for the
first time.
♦ If the high-pressure pump is removed or renewed, the fuel
system must be bled before the engine is started for the
first time.
Procedure for first fuel filling ⇒ page 29
Note
The high-pressure pump will be damaged if the first fuel filling
procedure is not performed.
12 Rep. Gr.23 - Mixture preparation - injection
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 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
1 - Fuel metering valve -N290-
❑ Do not unscrew
2 - High-pressure pump
❑ Exploded view
⇒ page 25
❑ After renewing, first fuel
filling operation MUST
be performed (it is im‐
portant not to allow
pump to run while it is
still empty) ⇒ page 29
❑ After renewing high-
pressure pump or fuel
pressure regulating
valve -N276- , learnt val‐
ues must be re-adapted;
see “Guided Functions”
in vehicle diagnostic
tester
3 - Fuel pressure sender G247-
❑ Exploded view
⇒ page 31
4 - Fuel rail
5 - Fuel pressure regulating
valve -N276-
❑ Exploded view
⇒ page 31
❑ After renewing high-
pressure pump or fuel
pressure regulating
valve -N276- , learnt val‐
ues must be re-adapted;
see “Guided Functions”
in vehicle diagnostic
tester
6 - Injector
❑ Exploded view ⇒ page 31
7 - Fuel return line
8 - Not fitted
9 - Fuel tank
❑ With fuel system pressurisation pump -G6-
10 - Fuel filter
❑ Exploded view ⇒ Rep. Gr. 20
11 - Supplementary fuel pump -V393-
❑ Exploded view ⇒ Rep. Gr. 20
3. System layout 13
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
4 Bleeding fuel system
Caution
If components of the fuel system between the fuel tank and the
high-pressure fuel pump are removed or renewed, the basic
setting “Checking fuel system pressurisation pump” must be
performed to bleed the fuel system.
If the supplementary fuel pump, fuel line (between fuel tank
and high-pressure fuel pump) or fuel filter is removed or re‐
newed, the basic setting “Checking fuel system pressurisation
pump” must be performed before the engine is started for the
first time.
Proceed as follows to fill fuel system with fuel:
– Connect a vehicle diagnostic tester.
– Switch on ignition.
– Select “Engine electronics” in vehicle self-diagnosis.
– Then select “Basic setting”.
– Select “Checking fuel system pressurisation pump” from the
list.
– Press “Start” button.
– The fuel pumps start running.
– The fuel pumps must run for approx. 1 minute to ensure that
the fuel system is filled sufficiently with fuel.
Note
To repeat basic setting, switch ignition off and on once. Then start
basic setting again.
– Start engine after filling fuel system.
– Run engine at moderate speed for several minutes and then
switch off.
– Check fuel system for leaks.
– Erase entry in event memory using diagnostic tester.
– After completing the repair, road-test the vehicle over a dis‐
tance of at least 20 km. Accelerate with full throttle at least
once. Then inspect the high-pressure section of the fuel sys‐
tem again for leaks.
Note
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the engine and erase the event memory. Then
continue the road test.
– Interrogate event memory.
14 Rep. Gr.23 - Mixture preparation - injection
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 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
5 Air cleaner
⇒ “5.1 Air cleaner - exploded view”, page 15
⇒ “5.2 Removing and installing engine cover panel”, page 16
⇒ “5.3 Removing and installing air filter element”, page 17
⇒ “5.4 Removing and installing air cleaner housing”, page 18
⇒ “5.5 Removing and installing air mass meter G70 ”, page 20
5.1 Air cleaner - exploded view
1 - Hose connection
2 - Air hose
❑ To turbocharger
❑ Check for dirt and accu‐
mulated leaves, etc.
3 - Bolt
❑ 2x
❑ 1.5 Nm
4 - Air mass meter -G70-
❑ Removing and installing
⇒ page 20
5 - O-ring
❑ Renew
❑ Use silicone-free lubri‐
cant when installing
6 - Bolts
❑ For air cleaner (top sec‐
tion)
❑ 1.5 Nm
7 - Bolt
❑ For air cleaner (bottom
section)
❑ 8 Nm
8 - Sleeve
9 - Washer
10 - Air cleaner (top section)
❑ Clean out dirt, leaves
and salt deposits
11 - Air filter element
❑ Always use genuine part for air filter element
❑ Removing and installing ⇒ page 17
❑ Observe change intervals ⇒ Maintenance ; Booklet 810
12 - Air cleaner (bottom section)
❑ Clean out dirt, leaves and salt deposits
❑ On vehicles for cold climates, air cleaner (bottom section) with hot-air-intake hose is installed
❑ Country-specific version with snow screen
13 - Connection for water drain hose
❑ Clean
5. Air cleaner 15
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
14 - Water drain hose
❑ Clean
15 - Flutter valve
❑ Clean and re-install
16 - Intake air duct
❑ To lock carrier
❑ Clean out dirt, leaves and salt deposits
17 - Spring-type clip
18 - Connecting hose
❑ To turbocharger
5.2 Removing and installing engine cover panel
Removing
– Carefully pull engine cover panel off retaining pins one after
the other -arrows-. Do not jerk the cover panel away, and do
not try to pull on one side only.
Installing
– To avoid damage, do not strike the engine cover panel with
your fist or with any kind of tool.
– Position engine cover panel on engine (note locations of oil
filler neck and oil dipstick).
– Press engine cover panel with both hands into the rubber
grommets at the rear and then into the grommets at the front.
16 Rep. Gr.23 - Mixture preparation - injection
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 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
5.3 Removing and installing air filter ele‐
ment
Removing
– Remove bolts -arrows-.
Note
Disregard -items 1, 2, 3-.
– Lift up air cleaner (top section) and take out air filter element.
Installing
• Tightening torque
⇒ “5.1 Air cleaner - exploded view”, page 15
To ensure that the air mass meter functions properly, it is impor‐
tant to observe the following notes and instructions.
Note
♦
If the air filter element is very dirty or wet, dirt or water could
reach the air mass meter and affect the air mass value. This
would lead to loss of power, since a smaller injection quantity
is calculated.
♦
Always use genuine part for air filter element.
♦
The air cleaner housing MUST be clean.
♦
To prevent malfunctions, cover critical parts of the engine air
intake (air mass meter, air pipes, etc.) with a clean cloth when
blowing out the air cleaner housing with compressed air.
♦
Observe environmental requirements for disposal.
– Remove snow screen -1- and clean it.
Note
The snow screen is not fitted on all vehicles.
5. Air cleaner 17
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
– Clean water drain -arrow- and air cleaner (bottom section).
– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections) using a vacuum cleaner.
– Check for salt residue, dirt and leaves in air mass meter and
air intake hose (engine intake side).
– Check for dirt and leaves in air duct going from lock carrier to
air cleaner housing.
– When installing air filter element, check that it is properly cen‐
tred in retainer in air cleaner (bottom section).
– Fit the top section of the air cleaner carefully on the bottom
section, without using force. Make sure the top section of the
air cleaner is fitted straight on the air filter element (note posi‐
tion of sealing lip on air filter element).
– Ensure secure fit of intake hose at air mass meter.
The remaining installation steps are carried out in the reverse se‐
quence.
5.4 Removing and installing air cleaner housing
Removing
– Pull cover off air duct (release clips on sides) -arrows-.
– Release clips on left and right -arrow A- and unclip air duct at
bottom -2-.
– Swivel air duct (bottom) slightly to the rear and detach air duct
(bottom) from retainers -3-.
– Detach air pipe -1- from air duct (bottom) -arrow B-.
18 Rep. Gr.23 - Mixture preparation - injection
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 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
– Unplug electrical connector -2- from air mass meter -G70- .
– Detach hose -1-.
– Release hose clip -3- and detach air hose.
– Unscrew bolt -4- and remove air cleaner housing.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torque
⇒ “5.1 Air cleaner - exploded view”, page 15
Note
♦
Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
♦
Use silicone-free lubricant when installing air hose.
♦
Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
– Disconnect water drain hose -arrow- from air cleaner (bottom
section) and clean any dirt or leaves out of connection and
hose.
5. Air cleaner 19
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