Audi TT 55 User Manual
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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.
Service
Workshop Manual
Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 1.8
ltr., 2.0 ltr. 4-valve turbo with timing chain)
Engine ID
Edition 06.2010
CDAACCZACCTACESACET
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.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A005TT02120
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. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
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 Safety precautions for vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Rules for cleanliness and instructions for working on fuel system . . . . . . . . . . . . . . . . . . . . 3
1.5 Important: Required procedure prior to opening high-pressure injection system . . . . . . . . 4
1.6 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Overviews - fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Overview - fitting locations (engine codes CDAA, CCZA and CCTA) . . . . . . . . . . . . . . . . 8
3.2 Overview - fitting locations (engine codes CESA and CETA) . . . . . . . . . . . . . . . . . . . . . . 19
4 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1 Air cleaner - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.3 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5 Intake manifold (engine codes CDAA, CCZA and CCTA) . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.1 Intake manifold - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.2 Fuel rail - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6 Intake manifold (engine codes CESA and CETA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1 Intake manifold - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2 Fuel rail - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3 Removing and installing intake manifold with fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.1 High-pressure pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.1 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.2 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9 Components of injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.1 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.2 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9.3 Checking fuel pressure and residual pressure (up to high-pressure pump) . . . . . . . . . . . . 62
9.4 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.5 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.6 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.7 Checking intake manifold change-over function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.8 Checking dual non-return valve of activated charcoal filter solenoid valve 1 N80 . . . . . . 68
10 Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
10.1 Lambda probes - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
10.2 Removing and installing Lambda probe G39 and Lambda probe heater Z19 before catalytic
converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10.3 Removing and installing Lambda probe after catalytic converter G130 and Lambda probe 1
heater after catalytic converter Z29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
11 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
11.1 Wiring and component check with test box V.A.G 1598/42 . . . . . . . . . . . . . . . . . . . . . . . . 75
11.2 Renewing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1 General notes and safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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 ➤
Direct petrol injection and ignition system (4-cyl. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.1 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.2 Ignition system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.3 Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.4 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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 ➤
Direct petrol injection and ignition system (4-cyl. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
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 event memory must
be interrogated. The vacuum hoses and connections must al‐
so be checked (unmetered air).
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. O-type clips 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 .
06.2010
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. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
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.
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.
♦ 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.
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.
Caution
To prevent damage to the electronic components when dis‐
connecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
– Disconnect battery ⇒ Rep. Gr. 27 .
To prevent injuries to persons and/or damage to the fuel injection
and ignition system, the following must be noted:
2 Rep. Gr.24 - Mixture preparation - injection
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Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
♦ 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 event memory should therefore be inter‐
rogated and (if necessary) erased after completing the tests
and any repair work that may be required.
♦ If the event memory has been erased, you must generate the
readiness code again.
♦ Always switch off the ignition before cleaning the engine.
♦ 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 84 . Also remove fuse for fuel pump control
unit -J538- .
Note
♦
The fuse is located in the fuse holder in the luggage compart‐
ment (right-side).
♦
Removing the fuse will interrupt the voltage supply “termi‐
nal 30” for the fuel pump control unit -J538- . ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations
1.3 Safety precautions for vehicles with start/stop system
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).
1.4 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:
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
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. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
♦ 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. Do not use fluffy 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.
1.5 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, etc.) the
fuel pressure in the high-pressure section must be reduced.
The procedure is described below.
Reducing fuel pressure in high-pressure section
– Connect a vehicle diagnostic tester.
– 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 35 and 45 bar
– The fuse is located in the fuse holder in the luggage compart‐
ment (right-side).
4 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
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. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
– Remove luggage compartment trim (rear right) ⇒ Rep. Gr.
70 .
– With engine idling, pull out fuse for fuel pump control unit -
J538- ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
– 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
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 event memory and generate readiness code in engine
control unit in “Guided Functions” mode.
1.6 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 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 ➤
Direct petrol injection and ignition system (4-cyl. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
♦ 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 an entry is stored in the event memory, check the 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 pressure with the hand vacuum
pump -VAS 6213- or if the pressure drops again immediately,
check the hand vacuum pump and connecting hoses for leaks.
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
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. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
2 Technical data
Engine data 1.8 ltr. and 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
Pressure in high-pressure
fuel circuit (generated by
mechanical single-plunger
pump) at a coolant temper‐
ature of approx. 85°C.
in fuel tank)
640 ... 800 rpm
6500 rpm
3.0 to 7.0 bar (identical for all operating
conditions)
approx. 40 bar at idling speed
approx. 150 bar in certain parts of operating
range.
2. Technical data 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 ➤
Direct petrol injection and ignition system (4-cyl. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
3 Overviews - fitting locations
3.1 Overview - fitting locations (engine co‐
des CDAA, CCZA and CCTA)
Components A to K are not shown in the overview.
1 - Camshaft control valve 1 N205-
❑ Fitting location
⇒ page 14
❑ Removing and installing
⇒ Rep. Gr. 15
2 - Charge pressure control
solenoid valve -N75-
❑ Located directly on tur‐
bocharger ⇒ page 17
❑ Removing and installing
⇒ Rep. Gr. 21
3 - Turbocharger air recircula‐
tion valve -N249-
❑ Located directly on tur‐
bocharger ⇒ page 17
❑ Removing and installing
⇒ Rep. Gr. 21
4 - Ignition coils with output
stages
❑ Removing and installing
⇒ page 84
❑ 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.
5 - Engine control unit -J623-
❑ Fitting location ⇒ page 11
❑ Removing and installing ⇒ page 77
6 - Lambda probe -G39- and Lambda probe heater -Z19-
❑ Fitting location ⇒ page 17
❑ Lambda probes - overview ⇒ page 71
7 - High-pressure pump
❑ Fitting location (engine code CDAA, 1.8 ltr.) ⇒ page 12
❑ Fitting location (engine codes CCZA and CCTA, 2.0 ltr.) ⇒ page 12
❑ Removing and installing ⇒ page 50
8 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
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. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
8 - Fuel pressure regulating valve -N276-
❑ Fitting location (engine code CDAA, 1.8 ltr.) ⇒ page 12
❑ Fitting location (engine codes CCZA and CCTA, 2.0 ltr.) ⇒ page 12
9 - Electrical connector for Lambda probe -G39- and Lambda probe heater -Z19-
❑ Fitting location ⇒ page 16
10 - Air mass meter -G70- and intake air temperature sender 2 -G299-
❑ Removing and installing ⇒ page 65
11 - Radiator outlet coolant temperature sender -G83-
❑ Fitting location ⇒ page 16
12 - Vacuum unit for air flow control flaps (intake manifold flaps)
❑ Fitting location ⇒ page 13
13 - Intake manifold flap valve -N316-
❑ Fitting location ⇒ page 13
14 - Engine speed sender -G28-
❑ Fitting location ⇒ page 15
❑ Removing and installing ⇒ page 85
❑ 4.5 Nm
15 - Charge pressure sender -G31-
❑ Fitting location ⇒ page 16
16 - Electrical connectors
❑ From knock sensor 1 -G61- , fitting location ⇒ page 15
❑ From Hall sender -G40- , fitting location ⇒ page 15
❑ For injectors, fitting location ⇒ page 15
17 - 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 throttle valve module -J338- has been renewed, it must be re-adapted to engine control unit -J623- ,
see vehicle diagnostic, testing and information system -VAS 5051B-
18 - Activated charcoal filter solenoid valve 1 -N80-
❑ Fitting location ⇒ page 13
19 - Intake air temperature sender -G42-
20 - Knock sensor 1 -G61-
❑ Fitting location ⇒ page 13
❑ 20 Nm
❑ Removing and installing ⇒ page 85
21 - Coolant temperature sender -G62-
❑ Fitting location ⇒ page 15
❑ Removing and installing ⇒ Rep. Gr. 19
22 - Hall sender -G40- (camshaft position sensor)
23 - Fuel pressure sender -G247-
❑ 27 Nm
❑ Fitting location ⇒ page 13
❑ Removing and installing ⇒ page 59
24 - Valve for oil pressure control -N428-
❑ Fitting location ⇒ page 14
❑ Removing and installing ⇒ Rep. Gr. 17
3. Overviews - 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 ➤
Direct petrol injection and ignition system (4-cyl. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
25 - Oil pressure switch
❑ Oil pressure switch for reduced oil pressure -F378❑ Oil pressure switch -F22❑ Fitting location ⇒ page 14
❑ Removing and installing ⇒ Rep. Gr. 17
26 - Intake manifold flap potentiometer -G336-
❑ Fitting location ⇒ page 14
A - Diagnostic connector
❑ In driver's knee restraint
B - Fuel pump control unit -J538-
❑ Fitting location ⇒ page 11
C - Brake light switch - F- and brake pedal switch -F63-
❑ Fitting location ⇒ page 12
❑ Removing and installing ⇒ Rep. Gr. 45
D - Clutch position sender -G476-
❑ Only fitted on vehicles with manual gearbox
❑ Fitting location ⇒ page 12
❑ Removing and installing, see Power transmission, clutch ⇒ Rep. Gr. 30
E - Accelerator position sender -G79- and accelerator position sender 2 -G185-
❑ Fitting location ⇒ page 11
❑ 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
F - Radiator fan control unit -J293-
❑ Fitting location ⇒ page 16
G - Injectors
❑ Removing and installing ⇒ page 53
❑ Injector, cylinder 1 -N30❑ Injector, cylinder 2 -N31❑ Injector, cylinder 3 -N32❑ Injector, cylinder 4 -N33-
H - Continued coolant circulation pump -V51-
❑ Fitting location ⇒ page 18
❑ Removing and installing ⇒ Rep. Gr. 19
I - Lambda probe after catalytic converter -G130- and Lambda probe heater 1 after catalytic converter -Z29-
❑ Fitting location ⇒ page 17
❑ Lambda probes - overview ⇒ page 71
J - Electrical connector for Lambda probe after catalytic converter -G130- and Lambda probe 1 heater after
catalytic converter -Z29-
❑ Fitting location ⇒ page 17
K - Relay and fuse holder in electronics box
❑ Relay and fuse assignment see ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
10 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
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. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
Engine control unit -J623-
Accelerator position sender -G79- and accelerator position send‐
er 2 -G185-
2 - Electrical connector for accelerator pedal module
Removing and installing ⇒ Rep. Gr. 20
Fuel pump control unit -J538- -2-
1 - Connector for fuel pump control unit -J538-
2 - Fuel pump control unit -J538-
3 - Fuel system pressurisation pump -G6-
3. Overviews - 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 ➤
Direct petrol injection and ignition system (4-cyl. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
Clutch position sender -G476-
Removing and installing ⇒ Rep. Gr. 30
Brake light switch -F- and brake pedal switch -F63-
High-pressure pump -2-
1 - Fuel pressure regulating valve -N276-
Note
Illustration shows pump of engine code CDAA, 1.8 ltr.
High-pressure pump -2-
1 - Fuel pressure regulating valve -N276-
Note
Illustration shows pump of engine codes CCZA and CCTA, 2.0
ltr.
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.
Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
Activated charcoal filter solenoid valve 1 -N80- -1-
Fitting location of knock sensor 1 -G61-
1 - Electrical connector for knock sensor 1 -G61-
2 - Knock sensor 1 -G61-
Fitting location: below intake manifold and coolant pump
Intake manifold flap valve -N316- -2-
1 - Vacuum unit for intake manifold flaps
Note
Intake manifold flaps are the same as air flow control flaps.
Fuel pressure sender -G247- -1-
Removing and installing ⇒ page 59
3. Overviews - fitting locations 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. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
Intake manifold flap potentiometer -G336- -1-
Oil pressure switch
1 - Oil pressure switch for reduced oil pressure -F378-
2 - Electrical connector for oil pressure switch for reduced oil
pressure -F378-
3 - Oil pressure switch -F22-
4 - Electrical connector for oil pressure switch -F22-
Valve for oil pressure control -N428- -3-
Camshaft control valve 1 -N205- -arrow-
Removing and installing ⇒ Rep. Gr. 45
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.
Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
Engine speed sender -G28- -1-
Hall sender -G40- -1-
Electrical connectors
1 - From Hall sender -G40- and intake manifold flap potentiometer
-G336-
2 - From knock sensor 1 -G61-
3 - 8-pin connector for injectors
Coolant temperature sender -G62- -1-
Fitting location: below intake manifold in coolant pump
3. Overviews - fitting locations 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. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
Radiator outlet coolant temperature sender -G83- -1-
Charge pressure sender -G31- -2-
Radiator fan control unit -J293-
1 - Connector for radiator fan control unit -J293-
Note
♦
The radiator fan control unit -J293- is integrated into the radi‐
ator fan -V7- .
♦
The fan shown in the illustration on the left is the radiator fan
-V7- .
♦
The fan shown in the illustration on the right is the radiator fan
on right of radiator -V35- .
Electrical connector
1 - For Lambda probe -G39- and Lambda probe heater -Z19-
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.
Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
Fitting location of Lambda probe
1 - Lambda probe -G39- and Lambda probe heater -Z19-
Electrical connector (behind cover) for Lambda probe after cata‐
lytic converter -G130- and Lambda probe 1 heater after catalytic
converter -Z29-
Fitting location of Lambda probe
1 - Lambda probe after catalytic converter -G130- with Lambda
probe 1 heater after catalytic converter -Z29-
Note
The arrow in the illustration points in the direction of travel.
Components on turbocharger
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)
3. Overviews - fitting locations 17
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
Pay attention to installation position of turbocharger air recircula‐
tion valve -N249-
Continued coolant circulation pump -V51-
Removing and installing ⇒ Rep. Gr. 19
18 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. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
3.2 Overview - fitting locations (engine codes CESA and CETA)
1 - Camshaft control valve 1 N205-
❑ Fitting location
⇒ page 25
❑ Removing and installing
⇒ Rep. Gr. 15
2 - Charge pressure control
solenoid valve -N75-
❑ Located directly on tur‐
bocharger ⇒ page 29
❑ Removing and installing
⇒ Rep. Gr. 21
3 - Turbocharger air recircula‐
tion valve -N249-
❑ Located directly on tur‐
bocharger ⇒ page 29
❑ Removing and installing
⇒ Rep. Gr. 21
4 - Actuators for camshaft ad‐
justment
❑ Actuator 1 for camshaft
adjustment -F366-
❑ Actuator 2 for camshaft
adjustment -F367-
❑ Actuator 3 for camshaft
adjustment -F368-
❑ Actuator 4 for camshaft
adjustment -F369-
❑ Actuator 5 for camshaft
adjustment -F370-
❑ Actuator 6 for camshaft
adjustment -F371-
❑ Actuator 7 for camshaft
adjustment -F372-
❑ Actuator 8 for camshaft adjustment -F373❑ Fitting location ⇒ page 26
❑ Removing and installing ⇒ Rep. Gr. 15
5 - Ignition coils with output stages
❑ Removing and installing ⇒ page 84
❑ 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 required for removing ignition coils from cylinder head.
6 - Engine control unit -J623-
❑ Fitting location ⇒ page 22
❑ Removing and installing ⇒ page 77
7 - Lambda probe -G39- and Lambda probe heater -Z19-
❑ Fitting location ⇒ page 28
❑ Lambda probes - overview ⇒ page 71
3. Overviews - fitting locations 19
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
8 - High-pressure pump
❑ Fitting location ⇒ page 23
❑ Removing and installing ⇒ page 50
9 - Fuel pressure regulating valve -N276-
❑ Fitting location ⇒ page 23
10 - Electrical connector for Lambda probe -G39- and Lambda probe heater -Z19-
❑ Fitting location ⇒ page 28
11 - Radiator outlet coolant temperature sender -G83-
❑ Fitting location ⇒ page 27
12 - Vacuum unit for air flow control flaps (intake manifold flaps)
❑ Fitting location ⇒ page 24
13 - Intake manifold flap valve -N316-
❑ Fitting location ⇒ page 24
14 - Engine speed sender -G28-
❑ Fitting location ⇒ page 26
❑ Removing and installing ⇒ page 85
❑ 4.5 Nm
15 - Charge pressure sender -G31-
❑ Fitting location ⇒ page 27
16 - Electrical connectors
❑ From knock sensor 1 -G61- , fitting location ⇒ page 27
❑ From Hall sender -G40- , fitting location ⇒ page 27
❑ For injectors, fitting location ⇒ page 15
17 - 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 throttle valve module -J338- has been renewed, it must be re-adapted to engine control unit -J623-
using a vehicle diagnostic tester
18 - Activated charcoal filter solenoid valve 1 -N80-
❑ Fitting location ⇒ page 23
19 - Intake air temperature sender -G42-
20 - Knock sensor 1 -G61-
❑ Fitting location ⇒ page 24
❑ 20 Nm
❑ Removing and installing ⇒ page 85
21 - Coolant temperature sender -G62-
❑ Fitting location ⇒ page 27
❑ Removing and installing ⇒ Rep. Gr. 19
22 - Hall sender -G40- (camshaft position sensor)
23 - Fuel pressure sender -G247-
❑ 27 Nm
❑ Fitting location ⇒ page 24
❑ Removing and installing ⇒ page 59
24 - Intake manifold pressure sender -G71-
❑ Fitting location ⇒ page 24
25 - Oil pressure switch
❑ Oil pressure switch for reduced oil pressure -F378-
20 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
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. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
❑ Oil pressure switch -F22❑ Fitting location ⇒ page 25
❑ Removing and installing ⇒ Rep. Gr. 17
26 - Intake manifold flap potentiometer -G336-
❑ Fitting location ⇒ page 25
27 - Valve for oil pressure control -N428-
❑ Fitting location ⇒ page 25
❑ Removing and installing ⇒ Rep. Gr. 17
A - Diagnostic connector
❑ In driver's knee restraint
B - Fuel pump control unit -J538-
❑ Fitting location ⇒ page 22
C - Brake light switch - F- and brake pedal switch -F63-
❑ Fitting location ⇒ page 23
❑ Removing and installing ⇒ Rep. Gr. 45
D - Clutch position sender -G476-
❑ Only fitted on vehicles with manual gearbox
❑ Fitting location ⇒ page 23
❑ Removing and installing, see Power transmission, clutch ⇒ Rep. Gr. 30
E - Accelerator position sender -G79- and accelerator position sender 2 -G185-
❑ Fitting location ⇒ page 22
❑ 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
F - Radiator fan control unit -J293-
❑ Fitting location ⇒ page 28
G - Injectors
❑ Removing and installing ⇒ page 53
❑ Injector, cylinder 1 -N30❑ Injector, cylinder 2 -N31❑ Injector, cylinder 3 -N32❑ Injector, cylinder 4 -N33-
H - Continued coolant circulation pump -V51-
❑ Fitting location ⇒ page 29
❑ Removing and installing ⇒ Rep. Gr. 19
I - Exhaust flap 1 valve -N321-
❑ Fitting location ⇒ page 30
J - Lambda probe after catalytic converter -G130- and Lambda probe heater 1 after catalytic converter -Z29-
❑ Fitting location ⇒ page 29
❑ Lambda probes - overview ⇒ page 71
K - Electrical connector for Lambda probe after catalytic converter -G130- and Lambda probe 1 heater after
catalytic converter -Z29-
❑ Fitting location ⇒ page 28
3. Overviews - fitting locations 21
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
Engine control unit -J623-
Accelerator position sender -G79- and accelerator position send‐
er 2 -G185-
2 - Electrical connector for accelerator pedal module
Removing and installing ⇒ Rep. Gr. 20
Fuel pump control unit -J538- -2-
1 - Connector for fuel pump control unit -J538-
2 - Fuel pump control unit -J538-
3 - Fuel system pressurisation pump -G6-
22 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. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
Clutch position sender -G476-
Removing and installing ⇒ Rep. Gr. 30
Brake light switch -F- and brake pedal switch -F63-
Removing and installing ⇒ Rep. Gr. 45
High-pressure pump
1 - Fuel pressure regulating valve -N276-
2 - High-pressure pump
Activated charcoal filter solenoid valve 1 -N80- -1-
3. Overviews - fitting locations 23
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. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
Fitting location of knock sensor 1 -G61-
1 - Electrical connector for knock sensor 1 -G61-
2 - Knock sensor 1 -G61-
Fitting location: below intake manifold and coolant pump
Intake manifold flap valve -N316-
1 - Vacuum unit for intake manifold flaps
2 - Intake manifold flap valve -N316-
Note
Intake manifold flaps are the same as air flow control flaps.
Intake manifold pressure sender -G71- -1- and fuel pressure
sender -G247- -2-
1 - Intake manifold pressure sender -G71-
2 - Fuel pressure sender -G247-
Intake manifold pressure sender -G71- -1-
24 Rep. Gr.24 - Mixture preparation - injection
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