Audi TT 6 User Manual
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Service
Workshop Manual
Audi TT 1999 ➤
Motronic injection and ignition system (6-cyl.)
Engine ID
Edition 12.2004
BHE BPF
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
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 A0057007220
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 1999 ➤
Motronic injection and ignition system (6-cyl.) - Edition 12.2004
Contents
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Servicing Motronic injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Overview - fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Dismantling and assembling air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Intake manifold - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.8 Wiring and component check on engine control unit with test box V.A.G 1598/31 . . . . . . 22
1.9 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.10 Checking system pressure, fuel pressure regulator and residual pressure . . . . . . . . . . . . 26
1.11 Dismantling and assembling fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.12 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.13 Checking injection quantity and spray pattern of injectors; checking for leaks . . . . . . . . . . 32
1.14 Removing and installing Lambda probes (before catalytic converter) . . . . . . . . . . . . . . . . 34
1.15 Removing and installing Lambda probes (after catalytic converter) . . . . . . . . . . . . . . . . . . 36
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1 Checking ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.4 Removing and installing parts of the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.5 Removing and installing ignition coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.6 Removing and installing spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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 1999 ➤
Motronic injection and ignition system (6-cyl.) - Edition 12.2004
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.
Motronic injection and ignition system (6-cyl.) - Edition 12.2004
24 – Mixture preparation - injection
1 Servicing Motronic injection system
1.1 Safety precautions
To prevent injuries to persons and/or damage to the fuel injection
and ignition system, the following must be noted:
♦ Always switch off the ignition before connecting or discon‐
necting injection or ignition system wiring or tester cables.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. Therefore, interrogate and, if necessary,
erase the fault memory after all repairs and tests.
♦ 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.
Audi TT 1999 ➤
WARNING
The fuel system is pressurised. Before opening the system
place a cloth around the connection. Then dissipate pressure
by carefully unfastening the connection.
Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
♦ To avoid any risk of accident, observe the following pre‐
cautions when using test instruments while road testing
the vehicle:
Audi TT Coupé:
♦ To read measured value blocks, use only the vehicle di‐
agnostic, testing and information system -VAS 5051 A- or
the vehicle diagnostic and information system VAS 5052- . Test equipment must always be secured on
the rear seat and operated from that position by a second
person.
♦ On account of the limited space available, the front pas‐
senger's seat is to be moved forwards as far as it will go
and the engaged backrest folded forwards as far as it will
go with the backrest adjuster handwheel. Do not operate
the release lever to tilt the backrest forward.
Audi TT Roadster:
♦ In the Audi TT Roadster, only use the vehicle diagnostic
and information system -VAS 5052- with the passenger's
airbag deactivated.
♦ Deactivate front passenger's airbag via the key switch in
glove box or the self-diagnosis ⇒ Body, self-diagnosis;
Rep. Gr. 01 ; Adaption .
♦ Reactivate front passenger's airbag on completion of
work.
1. Servicing Motronic injection system 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 1999 ➤
Motronic injection and ignition system (6-cyl.) - Edition 12.2004
1.2 Rules for cleanliness
When working on the fuel supply/injection system, pay careful at‐
tention to the following “6 rules”:
♦ Thoroughly clean all unions and the adjacent areas before
disconnecting.
♦ Place parts that have been removed on a clean surface and
cover them over. Do not use fluffy cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).
♦ When the system is open: Do not work with compressed air if
this can be avoided. Do not move vehicle unless absolutely
necessary.
♦ Unplugged electrical connectors; keep them clean and dry.
Make sure connections are dry when attaching.
1.3 Technical data
Engine code letters BHE (3.2 ltr. / 4V / 184 kW
engine)
Idling speed
650 ... 750 rpm
1)
Cannot be adjusted; regulated by idling speed stabi‐
lisation
Speed governing by
approx. 6,500 rpm
deactivation of fuel injectors
Fuel pressure at idling
speed
Vacuum hose
connected
Vacuum hose
approx. 3.5 bar
approx. 4.0 bar
disconnected
Residual pressure after 10 minutes at least 3.0 bar
Injectors Spray pattern Two-hole nozzle / same for all injectors
1) Current values ⇒ Data sheets for exhaust emission test.
Injection quantity (30 sec.) 128 … 140 ml
BPF (3.2 ltr. / 4V / 184 kW
engine)
2 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 1999 ➤
Motronic injection and ignition system (6-cyl.) - Edition 12.2004
1.4 Overview - fitting locations
1 - 3-pin connector
❑ For knock sensor 1 -
G61-
2 - Knock sensor 1 -G61-
❑ Fitting location
⇒ page 8
3 - Lambda probe, before cat‐
alytic converter -G39- with
Lambda probe heater -Z19-
❑ Fitting location
⇒ page 6
❑ Removing and installing
⇒ page 34
4 - Lambda probe, after cata‐
lytic converter -G130- with
Lambda probe heater 1, after
catalytic converter -Z29-
❑ Fitting location
⇒ page 6
❑ Removing and installing
⇒ page 36
5 - Motronic control unit -J220-
❑ Removing and installing
⇒ page 23
6 - Lambda probe 2, before
catalytic converter -G108- with
Lambda probe 2 heater -Z28-
❑ Fitting location
⇒ page 6
❑ Removing and installing
⇒ page 34
7 - Lambda probe 2, after cat‐
alytic converter -G131- with
Lambda probe 2 heater, after
catalytic converter -Z30-
❑ Fitting location ⇒ page 6
❑ Removing and installing ⇒ page 36
8 - Heater element (crankcase breather) -N79-
9 - Throttle valve module -J338-
❑ Including throttle valve drive (electric throttle operation) -G186- , angle sender for throttle valve drive -
G187- and angle sender 2 for throttle valve drive -G188-
10 - Instrument cluster
❑ With exhaust emissions warning lamp -K83-
11 - Accelerator position sender -G79- and accelerator position sender 2 -G185-
Fitting location ⇒ page 5
12 - Brake light switch -F- / brake pedal switch -F47- , clutch pedal switch -F36-
❑ Fitting location of brake light switch -F- / brake pedal switch -F47- ⇒ page 5
❑ Fitting location of clutch pedal switch -F36- ⇒ page 6
13 - Fuel pump relay -J17-
❑ Fitting location ⇒ page 6
1. Servicing Motronic injection system 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 1999 ➤
Motronic injection and ignition system (6-cyl.) - Edition 12.2004
14 - Secondary air pump relay -J299-
Fitting location ⇒ page 7
15 - Motronic current supply relay -J271-
16 - Air mass meter -G70-
17 - Hall sender 2 -G163-
❑ Black connector
18 - Exhaust camshaft control valve 1 -N318-
❑ Brown connector
19 - Inlet camshaft control valve 1 -N205-
❑ Black connector
20 - Hall sender -G40-
❑ Black connector
21 - Coolant temperature sender -G62-
❑ Fitting location ⇒ page 8
❑ If necessary, release cooling system pressure before removal
22 - Engine speed sender -G28-
❑ Fitting location ⇒ page 7
23 - Vacuum unit for intake manifold change-over
24 - Fuel pressure regulator
❑ Checking ⇒ page 26
25 - Secondary air pump motor -V101-
26 - Intake manifold change-over valve -N156-
❑ Fitting location ⇒ page 7
27 - Secondary air inlet valve -N112-
❑ Fitting location ⇒ page 7
28 - Knock sensor 2 -G66-
❑ Fitting location ⇒ page 8
29 - 3-pin connector
❑ For engine speed sender -G28❑ Fitting location ⇒ page 7
30 - Ignition coils with output stages
❑ Cylinder 1 ignition coil 1 with output stage -N70❑ Cylinder 2 ignition coil 2 with output stage -N127❑ Cylinder 3 ignition coil 3 with output stage -N291❑ Cylinder 4 ignition coil 4 with output stage -N292❑ Cylinder 5 ignition coil 5 with output stage -N323❑ Cylinder 6 ignition coil 6 with output stage -N324-
31 - Injectors
❑ Cylinder 1 injector, cylinder 1 -N30❑ Cylinder 2 injector, cylinder 2 -N31❑ Cylinder 3 injector, cylinder 3 -N32❑ Cylinder 4 injector, cylinder 4 -N33❑ Cylinder 5 injector, cylinder 5 -N83❑ Cylinder 6 injector, cylinder 6 -N84❑ Checking injection quantity and spray pattern; checking for leaks ⇒ page 32
❑ Removing and installing ⇒ page 30
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.
Motronic injection and ignition system (6-cyl.) - Edition 12.2004
32 - Activated charcoal filter solenoid valve 1 -N80-
Fitting location of accelerator position sender -G79- and acceler‐
ator position sender 2 -G185-
Note
Diagram shows set-up on left-hand drive vehicles.
Audi TT 1999 ➤
Fitting location of brake light switch -F- and brake pedal switch F47-
♦ On pedal bracket
1. Servicing Motronic injection system 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 1999 ➤
Motronic injection and ignition system (6-cyl.) - Edition 12.2004
Fitting location of clutch pedal switch -F36-
♦ On pedal bracket
Fitting location of Lambda probes before catalytic converter
♦ In front exhaust pipe
1 - Lambda probe 2, before catalytic converter -G108- with
Lambda probe 2 heater -Z28-
2 - Lambda probe, before catalytic converter -G39- with Lamb‐
da probe heater -Z19-
Fitting location of Lambda probes after catalytic converter
♦ In catalytic converter
1 - Lambda probe, after catalytic converter -G130- with Lamb‐
da probe heater 1, after catalytic converter -Z29-
2 - Lambda probe 2, after catalytic converter -G131- with Lamb‐
da probe 2 heater, after catalytic converter -Z30-
Fitting location of fuel pump relay -J17-
♦ In the micro central electrics (left-side) under the dash panel:
position 4.
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.
Motronic injection and ignition system (6-cyl.) - Edition 12.2004
Fitting location: Motronic current supply relay -J271- and secon‐
dary air pump relay -J299-
♦ Beneath cover on left at bulkhead.
1 - Secondary air pump relay -J299-
2 - Motronic current supply relay -J271-
Note
To remove dust cover, detach relay carrier at bulkhead and lower.
Fitting location: engine speed sender -G28- with 3-pin connector
1 - 3-pin connector
2 - Engine speed sender -G28-
Audi TT 1999 ➤
Fitting location of secondary air inlet valve -N112-
♦ At vacuum reservoir (at front of engine)
Fitting location of intake manifold change-over valve -N156-
♦ At vacuum reservoir (at front of engine)
1. Servicing Motronic injection system 7
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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 1999 ➤
Motronic injection and ignition system (6-cyl.) - Edition 12.2004
Fitting location of coolant temperature sender -G62-
♦ At front left on cylinder head
Fitting location: knock sensor 1 -G61-
♦ At rear right on cylinder block.
1 - Knock sensor 1 -G61-
2 - 3-pin connector
Fitting location: knock sensor 2 -G66-
♦ At front on cylinder block
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.
Motronic injection and ignition system (6-cyl.) - Edition 12.2004
1.5 Dismantling and assembling air cleaner
1 - Seal
2 - Air mass meter -G70-
3 - Cross-head screw
4 - Air intake hose
5 - 5-pin connector
6 - Cross-head screw
7 - Air cleaner housing (top
section)
8 - Filter element
9 - Nut -10 Nm-
10 - Air intake connection
11 - Air cleaner housing (bot‐
tom section)
12 - Bolt, 10 Nm
Audi TT 1999 ➤
1. Servicing Motronic injection system 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 1999 ➤
Motronic injection and ignition system (6-cyl.) - Edition 12.2004
1.6 Intake manifold - exploded view of components
1 - Change-over barrel
2 - Bearing bush
3 - O-ring
❑ Renew
4 - Panel bolt
5 - Bearing cap
6 - Intake manifold
7 - 20 Nm
8 - 20 Nm
9 - Seal
10 - Connection for crankcase
breather
❑ With heater element
(crankcase breather) N79-
11 - O-ring
12 - Throttle valve module J338-
13 - 10 Nm
14 - 20 Nm
15 - Heat shield for exhaust
manifold
❑ With support for intake
manifold
16 - Gasket
❑ Renew
❑ Insert into manifold
17 - 13 Nm
18 - Panel bolt
19 - Vacuum unit
20 - Vacuum connection
❑ To intake manifold change-over valve -N156-
21 - O-ring
❑ Renew
22 - Bearing bush
1.7 Removing and installing intake manifold
Special tools and workshop equipment required
10 Rep. Gr.24 - Mixture preparation - injection
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