Audi TT 54 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 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr.
4-valve turbo)
Engine ID
Edition 01.2008
BWA BPY
CDLBCDLACDM
A
Service Department. Technical Information
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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
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.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A005TT00720
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 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
Contents
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety precautions and rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General notes on self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Rules for cleanliness and instructions for working on fuel system . . . . . . . . . . . . . . . . . . . . 3
1.4 Important: Required procedure prior to opening high-pressure injection system . . . . . . . . 4
2 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Overviews - fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Air cleaner / engine cover panel - exploded view (engines with code letters BWA and
BPY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 Removing and installing engine cover panel with air filter element - engines with code letters
BWA and BPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Removing and installing air mass meter G70 - engines with code letters BWA and BPY . . 22
2.6 Air cleaner - exploded view (engines with code letters CDLA, CDLB and CDMA) . . . . . . 23
2.7 Removing and installing engine cover panel - engines with code letters CDLA, CDLB and
CDMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.8 Removing and installing air filter element - engines with code letters CDLA, CDLB and
CDMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.9 Removing and installing air cleaner housing - engines with code letters CDLA, CDLB and
CDMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.10 Removing and installing air mass meter G70 - engines with code letters CDLA, CDLB and
CDMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.11 Intake manifold - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.12 Fuel rail - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.13 Removing and installing intake manifold with fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.14 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.15 Checking fuel pressure (low pressure) up to high-pressure pump . . . . . . . . . . . . . . . . . . . . 37
2.16 Checking fuel pressure and residual pressure (up to high-pressure pump) . . . . . . . . . . . . 38
2.17 High-pressure pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.18 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.19 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.20 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.21 Removing and installing intake manifold flap motor V157 with intake manifold flap
potentiometer G336 - engines with code letters BWA and BPY . . . . . . . . . . . . . . . . . . . . 49
2.22 Removing and installing intake manifold flap motor V157 with intake manifold flap
potentiometer G336 - engines with code letters CDLA, CDLB and CDMA . . . . . . . . . . . . 50
2.23 Removing and installing Lambda probe G39 and Lambda probe heater Z19 before catalytic
converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.24 Removing and installing Lambda probe after catalytic converter G130 and Lambda probe 1
heater, after catalytic converter Z29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.1 Wiring and component check with test box V.A.G 1598/42 . . . . . . . . . . . . . . . . . . . . . . . . 55
3.2 Renewing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1 General notes and safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.1 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.2 Ignition system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.3 Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Contents i
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
ii Contents
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
24 – Mixture preparation - injection
1 Safety precautions and rules for
cleanliness
1.1 General notes on self-diagnosis
♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and fault finding the fault memory must be
interrogated. The vacuum hoses and connections must also
be checked (unmetered air).
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. Clamping-type or screw-type clips must not
be used.
♦ A voltage of at least 11.5 V is required for proper operation of
the electrical components.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and will
damage the Lambda probe.
♦ The vehicles are fitted with a crash/fuel shut-off system. This
system is designed to reduce the risk of a vehicle fire after a
crash by deactivating the fuel pump via the fuel pump relay.
♦ At the same time, this system also improves the engine's start‐
ing performance. When the driver's door is opened, the fuel
pump is activated for 2 seconds in order to build up pressure
in the fuel system ⇒ page 2 .
Audi TT 2007 ➤
1. Safety precautions and rules for cleanliness 1
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
1.2 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.
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.
♦ 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.
WARNING
The fuel system is pressurised. The fuel pressure in the highpressure part of the injection system must be reduced to a
residual pressure prior to opening; for procedure see
⇒ page 4 .
The connection must be opened immediately after reducing
the pressure; wrap a cloth around the connection and allow the
residual pressure (approx. 6 bar) to dissipate.
To avoid any risk of injuries to persons and/or damage to the fuel
injection and ignition system, always observe the following safety
precautions.
2 Rep. Gr.24 - Mixture preparation - injection
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Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
♦ For safety reasons, the battery must be disconnected before
opening the fuel system to prevent the fuel pump from being
activated by the contact switch on the driver's door.
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as the
ignition system and gas-discharge headlights.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off the ignition before connecting or discon‐
necting injection or ignition system wiring or tester cables.
♦ If engine is to be operated at cranking speed without it starting
(e.g. compression test), unplug connectors from ignition coils
and remove fuse for electric fuel pump.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. The fault memory should therefore be inter‐
rogated and (if necessary) erased after completing the tests
and any repair work that may be required.
♦ If the fault memory has been erased, you must generate the
readiness code again.
♦ 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.
♦ If the engine has to be operated at the starting speed without
actually starting (e.g. to test compression pressure), detach
the four connectors from the ignition coils using assembly tool
-T40039- ⇒ page 64 . Also remove fuse for fuel pump control
unit -J538- .
Audi TT 2007 ➤
Note
♦
The fuse is located in the fuse holder in the luggage compart‐
ment (right-side).
♦
Removing fuse -SF 6- will interrupt the voltage supply “termi‐
nal 30” for the fuel pump control unit -J538- .
1.3 Rules for cleanliness and instructions for working on fuel system
Even small amounts of dirt can cause faults in the injection sys‐
tem. When working on the fuel supply/injection system, pay care‐
ful 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.
♦ Plug open lines and connections with suitable protective caps
immediately.
♦ Place parts that have been removed on a clean surface and
cover them over. Use only lint-free cloths.
♦ 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.
1. Safety precautions and rules for cleanliness 3
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Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
1.4 Important: Required procedure prior to opening high-pressure injection system
Caution
The injection system consists of a high-pressure section (max‐
imum approx. 150 bar) and a low-pressure section (approx. 7
bar).
Prior to opening the high-pressure section (e.g. when removing
the high-pressure pump, fuel rail, injectors, fuel pipes or fuel
pressure sender -G247- , the fuel pressure in the high-pressure
section must be reduced to a residual pressure of approx. 7
bar. The procedure is described below.
Reducing fuel pressure in high-pressure section
– Connect up the vehicle diagnostic, testing and information
system -VAS 5051B- .
– Start engine and run at idling speed.
– Select “Engine electronics” in vehicle self-diagnosis.
– Then select function read “Measured values”.
– Select measured value block 140.
– With engine idling the fuel pressure is displayed in zone 3.
♦ Specification: between 45 and 55 bar
4 Rep. Gr.24 - Mixture preparation - injection
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Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
– The fuse is located in the fuse holder in the luggage compart‐
ment (right-side).
– With engine idling, pull out fuse -SF 6- for fuel pump control
unit -J538- .
Note
Removing fuse -SF 6- will interrupt the voltage supply “termi‐
nal 30” for the fuel pump control unit -J538- .
– Observe fuel pressure displayed on tester.
• The fuel pressure will decrease very quickly because the me‐
chanical high-pressure pump is no longer being supplied with
fuel by the fuel system pressurisation pump -G6- .
– Switch off ignition as soon as fuel pressure has dropped to
approx. 8 bar.
Note
Audi TT 2007 ➤
Fuel pressure must not fall below 6 bar, otherwise the engine will
stall (this could damage the catalytic converter).
WARNING
The fuel lines are still filled with fuel, however the fuel is no
longer under high pressure. Wear safety goggles and protec‐
tive clothing when opening the fuel system to avoid possible
injury and skin contact.
Before opening the high-pressure section, wrap a cloth around
the connection.
– The high-pressure system must be opened “immediately” after
reducing the fuel pressure; wrap a clean cloth around the con‐
nection. Catch the escaping fuel.
The following operations must be performed after completing re‐
pair work:
– Refit fuse.
– Erase fault memory and generate readiness code in engine
control unit in “Guided Functions” mode, using vehicle diag‐
nostic and service information system -VAS 5052 A- .
1. Safety precautions and rules for cleanliness 5
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
2 Injection system
2.1 Technical data
Engine data 2.0 ltr. turbo FSI engine
Idling speed is not adjustable; con‐
trolled by the idling speed stabili‐
sation
Maximum rpm governed by deac‐
tivation of fuel injectors
Fuel pressure Initial fuel pressure up to
high-pressure pump (gen‐
erated by electric fuel pump
in fuel tank)
Pressure in high-pressure
fuel circuit (generated by
mechanical single-plunger
pump) at a coolant temper‐
ature of approx. 85°C.
640 ... 800 rpm
6500 rpm
approx. 6.0 bar (identical for all operating
conditions)
approx. 50 bar at idling speed
approx. 110 bar in certain parts of operating
range.
2.2 Overviews - fitting locations
Overview of fitting locations - engines with code letters BWA and
BPY ⇒ page 6
Overview of fitting locations - engines with code letters CDLA,
CDLB and CDMA ⇒ page 9
2.2.1 Overview of fitting locations - engines with code letters BWA and BPY
Components A to N are not shown in the exploded view.
6 Rep. Gr.24 - Mixture preparation - injection
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
1 - Solenoid valve for charge
pressure control -N75-
❑ Located directly on tur‐
bocharger ⇒ page 17
2 - Turbocharger air recircula‐
tion valve -N249-
❑ Located directly on tur‐
bocharger ⇒ page 17
3 - Ignition coils with output
stages
❑ Removing and installing
⇒ page 64
❑ Ignition coil 1 with output
stage -N70-
❑ Ignition coil 2 with output
stage -N127-
❑ Ignition coil 3 with output
stage -N291-
❑ Ignition coil 4 with output
stage -N292-
❑ Puller -T40039- is re‐
quired for removing igni‐
tion coils from cylinder
head.
4 - Lambda probe -G39- and
Lambda probe heater -Z19-
❑ Fitting location
⇒ page 16
❑ Removing and installing
⇒ page 52
5 - Engine control unit -J623-
❑ Removing and installing
⇒ page 57
6 - Single-plunger high-pressure pump
❑ Removing and installing ⇒ page 42
7 - Fuel pressure regulating valve -N276-
8 - Inlet camshaft control valve 1 -N205-
❑ Removing and installing ⇒ Rep. Gr. 15
9 - 6-pin connector
❑ For Lambda probe -G39- and Lambda probe heater -Z19- (black) ⇒ page 16
10 - Fuel pressure sender for low pressure -G410-
❑ 15 Nm
11 - Coolant temperature sender -G62-
❑ Fitting location ⇒ page 13
Audi TT 2007 ➤
12 - Engine speed sender -G28-
❑ Oil pressure sender -G10❑ Electrical connectors for knock sensor 1 -G61- and for knock sensor 2 -G66❑ Fitting location ⇒ page 15
13 - Intake manifold flap motor -V157- with intake manifold flap potentiometer -G336-
❑ After the fuel rail has been removed or renewed, intake manifold flap potentiometer -G336- must be
adapted to the engine control unit -J623- ; see vehicle diagnostic and service information system -VAS
5052- , “Guided Functions”
❑ Removing and installing ⇒ page 49
2. Injection system 7
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Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
14 - Activated charcoal filter solenoid valve 1 -N80-
15 - Charge pressure sender -G31-
❑ Fitting location ⇒ page 15
16 - Connector
❑ For Hall sender -G40- and fuel pressure sender -G247❑ Fitting location ⇒ page 15
17 - 8-pin connector for injectors
❑ Fitting location ⇒ page 15
18 - Throttle valve module -J338- , 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-
❑ After the throttle valve module -J338- has been renewed, it must be adapted to the engine control unit -
J623- , see vehicle diagnostic and service information system -VAS 5052- “Guided Functions”
19 - Intake air temperature sender -G42-
20 - Fuel pressure sender -G247-
❑ 22 Nm
❑ Fitting location ⇒ page 13
❑ Removing and installing ⇒ page 36
21 - Hall sender -G40- (camshaft position sensor)
❑ Electrical connector ⇒ page 13
A - Air mass meter -G70-
❑ In air cleaner (top section) ⇒ page 14
❑ Removing and installing ⇒ page 22
B - Fuel pump control unit -J538-
❑ ⇒ page 14
❑ Adaption of fuel pump must be performed after renewing fuel pump control unit -J538- . Basic setting,
measured value block 103, see ⇒ Rep. Gr. 20 or via vehicle diagnosis and service information system
-VAS 5052- “Guided Functions”
C - Brake light switch - F- and brake pedal switch -F63-
❑ Fitting location ⇒ page 15
❑ Removing and installing ⇒ Rep. Gr. 45
D - Accelerator position sender -G79- and accelerator position sender 2 -G185-
❑ Fitting location ⇒ page 12
❑ On accelerator pedal (both senders are accommodated in one housing)
❑ If accelerator pedal module or engine control unit is renewed, kick-down function must be adapted on
vehicles with automatic gearbox
❑ Removing and installing ⇒ Rep. Gr. 20
E - Clutch position sender -G476-
❑ Fitting location ⇒ page 14
❑ Removing and installing, see Power transmission, clutch ⇒ Rep. Gr. 30
F - Relay and fuse holder in electronics box
❑ Relay and fuse assignment see ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
G - Radiator fan control unit -J293-
❑ Fitting location ⇒ page 16
H - Injectors
❑ In fuel rail
❑ Removing and installing ⇒ page 44
❑ Injector, cylinder 1 -N30-
8 Rep. Gr.24 - Mixture preparation - injection
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Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
❑ Injector, cylinder 2 -N31❑ Injector, cylinder 3 -N32❑ Injector, cylinder 4 -N33-
The fuel injectors are high-pressure injectors. They inject fuel at high pressure (maximum approx. 110 bar)
directly into the cylinder.
I - Lambda probe after catalytic converter -G130- and Lambda probe heater 1 after catalytic converter -Z29-
❑ Fitting location ⇒ page 17
❑ Removing and installing ⇒ page 53
J - Knock sensor 1 -G61-
❑ For cylinders 1 and 2
❑ 20 Nm
❑ Fitting location ⇒ page 15
K - Knock sensor 2 -G66-
❑ For cylinders 3 and 4
❑ 20 Nm
❑ Fitting location ⇒ page 15
L - Oil pressure switch -F1-
❑ Fitting location ⇒ page 15
❑ Removing, installing and testing ⇒ Rep. Gr. 17
M - Radiator outlet coolant temperature sender -G83-
❑ Fitting location ⇒ page 13
N - Continued coolant circulation pump -V51-
❑ Fitting location ⇒ page 16
2.2.2 Overview of fitting locations - engines with code letters CDLA, CDLB and CDMA
Components A to L are not shown in the overview.
2. Injection system 9
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Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
1 - Solenoid valve for charge
pressure control -N75-
❑ Located directly on tur‐
bocharger ⇒ page 17
2 - Ignition coils with output
stages
❑ Removing and installing
⇒ page 64
❑ Ignition coil 1 with output
stage -N70-
❑ Ignition coil 2 with output
stage -N127-
❑ Ignition coil 3 with output
stage -N291-
❑ Ignition coil 4 with output
stage -N292-
❑ Puller -T40039- is re‐
quired for removing igni‐
tion coils from cylinder
head.
3 - Lambda probe -G39- and
Lambda probe heater -Z19-
❑ Fitting location
⇒ page 16
❑ Removing and installing
⇒ page 52
4 - Engine control unit -J623-
❑ Removing and installing
⇒ page 57
5 - Fuel pressure sender for
low pressure -G410-
❑ 15 Nm
6 - Single-plunger high-pres‐
sure pump
❑ Removing and installing ⇒ page 42
7 - Fuel pressure regulating valve -N276-
8 - Inlet camshaft control valve 1 -N205-
❑ Removing and installing ⇒ Rep. Gr. 15
9 - 6-pin connector
❑ For Lambda probe -G39- and Lambda probe heater -Z19- (black) ⇒ page 16
10 - Air mass meter -G70-
❑ Removing and installing ⇒ page 26
11 - Coolant temperature sender -G62-
❑ Fitting location ⇒ page 13
12 - Engine speed sender -G28-
❑ Electrical connectors for knock sensor 1 -G61- and for knock sensor 2 -G66❑ Fitting location ⇒ page 15
13 - Intake manifold flap motor -V157- with intake manifold flap potentiometer -G336-
❑ After the fuel rail has been removed or renewed, intake manifold flap potentiometer -G336- must be
adapted to the engine control unit -J623- ; see vehicle diagnostic and service information system -VAS
5052- , “Guided Functions”
❑ Removing and installing ⇒ page 49
10 Rep. Gr.24 - 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 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
14 - Charge pressure sender -G31-
❑ Fitting location ⇒ page 15
15 - Electrical connectors
❑ For injectors, Hall sender -G40- and fuel pressure sender -G247❑ Fitting location ⇒ page 15
16 - Activated charcoal filter solenoid valve 1 -N80-
❑ Fitting location ⇒ page 18
17 - Turbocharger air recirculation valve -N249-
❑ Fitting location ⇒ page 18
❑ Removing and installing ⇒ Rep. Gr. 21
18 - Throttle valve module -J338- , throttle valve drive for electric throttle operation -G186-
❑ Throttle valve drive angle sender 1 for electric throttle -G187- and throttle valve drive angle sender 2 for
electric throttle -G188-
❑ After the throttle valve module -J338- has been renewed, it must be adapted to the engine control unit -
J623- , see vehicle diagnostic and service information system -VAS 5052- “Guided Functions”
19 - Intake air temperature sender -G42-
20 - Continued coolant circulation pump -V51-
❑ Fitting location ⇒ page 16
21 - Radiator outlet coolant temperature sender -G83-
❑ Fitting location ⇒ page 13
22 - Fuel pressure sender -G247-
❑ 22 Nm
❑ Fitting location ⇒ page 13
❑ Removing and installing ⇒ page 36
23 - Hall sender -G40- (camshaft position sensor)
❑ Fitting location ⇒ page 13
A - Fuel pump control unit -J538-
❑ Fitting location ⇒ page 14
❑ Adaption of fuel pump must be performed after renewing fuel pump control unit -J538- . Basic setting for
measured value block 103, see ⇒ Rep. Gr. 20 or via vehicle diagnosis and service information system
-VAS 5052- “Guided Functions”
B - Brake light switch - F- and brake pedal switch -F63-
❑ Fitting location ⇒ page 15
❑ Removing and installing ⇒ Rep. Gr. 45
C - Accelerator position sender -G79- and accelerator position sender 2 -G185-
❑ Fitting location ⇒ page 12
❑ On accelerator pedal (both senders are accommodated in one housing)
❑ If accelerator pedal module or engine control unit is renewed, kick-down function must be adapted on
vehicles with automatic gearbox
❑ Removing and installing ⇒ Rep. Gr. 20
D - Clutch position sender -G476-
❑ Fitting location ⇒ page 14
❑ Removing and installing, see Power transmission, clutch ⇒ Rep. Gr. 30
E - Relay and fuse holder in electronics box
❑ Relay and fuse assignment see ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
F - Radiator fan control unit -J293-
❑ Fitting location ⇒ page 16
2. Injection system 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 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
G - Injectors
❑ In fuel rail
❑ Removing and installing ⇒ page 44
❑ Injector, cylinder 1 -N30❑ Injector, cylinder 2 -N31❑ Injector, cylinder 3 -N32❑ Injector, cylinder 4 -N33-
The fuel injectors are high-pressure injectors. They inject fuel at high pressure (maximum approx. 110 bar)
directly into the cylinder.
H - Lambda probe after catalytic converter -G130- and Lambda probe heater 1 after catalytic converter -Z29-
❑ Fitting location ⇒ page 17
❑ Removing and installing ⇒ page 53
I - Knock sensor 1 -G61-
❑ For cylinders 1 and 2
❑ 20 Nm
❑ Fitting location ⇒ page 15
J - Knock sensor 2 -G66-
❑ For cylinders 3 and 4
❑ 20 Nm
❑ Fitting location ⇒ page 15
K - Oil pressure switch -F1-
❑ Fitting location ⇒ page 15
❑ Removing, installing and testing ⇒ Rep. Gr. 17
L - Exhaust flap 1 valve -N321-
❑ Fitting location ⇒ page 19
Accelerator position sender -G79- and accelerator position send‐
er 2 -G185-
2 - Electrical connector for accelerator pedal module
Removing and installing ⇒ Rep. Gr. 20
12 Rep. Gr.24 - 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.
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
Coolant temperature sender -G62- -1-
Radiator outlet coolant temperature sender -G83- -1-
Audi TT 2007 ➤
Fuel pressure sender -G247- -1-
• Removing and installing ⇒ page 36
Hall sender -G40- -1-
2. Injection system 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 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
Air mass meter -G70- -1- “engines with code letters BWA and
BPY”
Air mass meter -G70- -1- “engines with code letters CDLA, CDLB
and CDMA”
Fuel pump control unit -J538- -1-
• Adaption of fuel pump must be performed after renewing fuel
pump control unit -J538- . Basic setting, measured value block
103, refer to ⇒ Rep. Gr. 20
Clutch position sender -G476-
Removing and installing, see Power transmission, clutch ⇒ Rep.
Gr. 30
14 Rep. Gr.24 - 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.
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
Brake light switch -F- and brake pedal switch -F63-
Removing and installing ⇒ Rep. Gr. 45
Electrical connectors
1 - 3-pin connector (green) for knock sensor 1 -G61-
2 - 3-pin connector (brown) for knock sensor 2 -G66-
3 - Oil pressure switch -F1-
4 - Engine speed sender -G28-
5 - 3-pin electrical connector (grey) for engine speed sender G28-
Audi TT 2007 ➤
Fitting locations of components below intake manifold
1 - Knock sensor 1 -G61-
2 - Knock sensor 2 -G66-
3 - Oil pressure switch -F1-
4 - 3-pin connector (brown) for knock sensor 2 -G66-
5 - 3-pin electrical connector (grey) for engine speed sender G28-
6 - Electrical connector for Hall sender -G40- and fuel pressure
sender -G247-
7 - 8-pin connector for injectors
Charge air pressure sender -G31- -2-
2. Injection system 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 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
Radiator fan control unit -J293-
1 - Connector for radiator fan control unit -J293-
Note
The radiator fan control unit -J293- is integrated into the radiator
fan -V7- .
Continued coolant circulation pump -V51-
Electrical connector -arrow-
- Lambda probe -G39- and Lambda probe heater -Z19-
Lambda probe -G39- -arrow-
16 Rep. Gr.24 - 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.
Direct petrol injection and ignition system (4-cyl. 2.0 ltr. 4-valve turbo) - Edition 01.2008
Electrical connector -arrow-
- Lambda probe, after catalytic converter -G130- and Lambda
probe heater 1, after catalytic converter -Z29- on right-side un‐
derbody
Lambda probe after catalytic converter -arrow-
- Lambda probe, after catalytic converter -G130- and Lambda
probe heater 1, after catalytic converter -Z29-
Audi TT 2007 ➤
Components on turbocharger “engines with code letters BWA and
BPY”
1 - Removing and installing turbocharger ⇒ Rep. Gr. 21
2 - Tighten charge pressure control solenoid valve -N75- to 3 Nm
3 - Tighten turbocharger air recirculation valve -N249- to 7 Nm
(note installation position, refer to next illustration)
Note installation position of turbocharger air recirculation valve N249- “engines with code letters BWA and BPY”
2. Injection system 17
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