2.0l - Fuel Injection System - Engine Code(s): Bpy & Cdma (roadster) Audi TT 8J

SAFETY PRECAUTIONS

If special testing equipment is required during road test, note the following

Scheme 601

To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following

Scheme 602

1. The battery must be disconnected before opening the fuel system, for safety reasons. The fuel pump may be activated by the driver's door contact switch.
2. Individuals with a pacemaker must not stay in the danger area of high voltage systems, e.g. ignition systems, xenon light.
3. Fuel lines must not be opened when engine is running.
4. Only disconnect and reconnect wires for injection and ignition system, including test leads, when ignition is switched off.
5. If engine is to be cranked at starting RPM without starting (e.g. for compression testing), disconnect connectors from ignition coils and remove fuse for electric fuel pump.
6. It is possible that the control module will recognize a malfunction and store a DTC during some tests. Therefore after completing all checks and repairs the DTC memory must be checked and if necessary erased.
7. If the DTC memory was erased, the readiness code must be generated.
8. Cleaning the engine should only be performed with ignition switched off.
9. The battery must only be disconnected and connected with the ignition switched off, since the Engine Control Module can otherwise be damaged.
10. If engine is to be cranked at starting RPM without starting (e.g. for compression testing), disconnect the four connectors for ignition coils, using the ignition coil puller T40039. Refer to «IGNITION COILS WITH POWER OUTPUT STAGES»(/audi/tt/8j-2006-2010/remont/ignition-system/#20l-ignitionglow-plug-system-engine-codes-bpy-cdma-roadster-as-of-012008__ignition-coils-with-power-output-stages) . Also remove fuse from Fuel Pump (FP) Control Module -J538-.

Note. The fuse is located in the fuse holder in the right of the luggage compartment. By removing fuse -SF 6-, the voltage supply to terminal 30 for the Fuel Pump (FP) Control Module -J538- is interrupted.

CLEAN WORKING CONDITIONS

Even minor contamination can lead to malfunctions in the fuel injection system. Therefore when working on the fuel supply/injection system, pay careful attention to the following rules of cleanliness

1. Before loosening, connections and surrounding areas must be cleaned thoroughly with engine or brake cleaner, and then cleaned area must be dried completely.
2. Plug open lines and connections immediately with appropriate protective caps.
3. Place parts that have been removed on a clean surface and cover them. Use lint-free cloths.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored unpacked (e.g. in tool boxes etc.).
5. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.

BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM

High fuel pressure, reducing

Connect Vehicle Diagnosis, testing & info. system VAS 5051B.

Start engine and run at idle speed.

Select "engine electronics" in OBD.

Then select "Measured values" read out.

Select measured value block 140.

With the engine running at idle, the fuel pressure will be displayed in display field 3.

1. Specified value: Between 45 and 55 bar

The fuse is located in the fuse holder in the right of the luggage compartment.

With the engine running at idle, pull out -SF 6- fuse from the fuel pump control module -J538-.

Note. By removing fuse -SF 6-, the voltage supply to terminal 30 for the Fuel Pump (FP) Control Module -J538- is interrupted.

Check the fuel pressure on the tester.

1. The fuel pressure decreases rapidly because the mechanical high pressure pump is no longer supplied with fuel from the transfer fuel pump -G6-.

Switch ignition off as soon as the fuel pressure drops to approximately 8 bar.

Note. The fuel pressure must not drop below 6 bar, because otherwise the engine will shut off (risk of catalytic converter damage).

After reducing fuel pressure, place a clean cloth around the connection and open the high pressure system immediately. Escaping fuel must be absorbed.

Perform the following steps are completing all work

Install fuse.

Erase the DTC memory and, using "Guided Fault Finding", generate the readiness code in the engine control module Vehicle Diagnosis and Service SystemVAS 5052 A.

ON BOARD DIAGNOSTICS

1. The engine control module is equipped with On Board Diagnostics (OBD). Before repairs such as fault finding, check the DTC memory first. Also the vacuum hoses and connections must be checked (unmetered air).
2. Fuel hoses in engine compartment must only be secured with spring-type clips. The use of clamp or screw type clips is not permissible.
3. For the electric components to work properly, a voltage of at least 11.5 Volts is required.
4. Do not use sealants containing silicone. Particles of silicone drawn into the engine, will not be burnt in the engine and damage the oxygen sensor.
5. The vehicles have a crash fuel shut-off. It reduces the risk of fire in an accident because the fuel pump relay switches the fuel pump off.
6. At the same time, with this set-up, an improvement in the comfort of engine startability is also attained. When the driver-side door is opened, the Fuel Pump (FP) is activated for 2 seconds so that pressure builds in the fuel system, observe safety measures. Refer to «SAFETY PRECAUTIONS»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__safety-precautions) .

FUEL INJECTOR CLEANING

Remove fuel injectors. Refer to FUEL INJECTORS .

Note. Follow the safety precautions and the instructions for the ultrasonic device.

The ultrasonic device must be filled with the included cleaner.

Note. Fill the ultrasonic device up to the upper edge of the holes with cleaner (see the magnified area of the illustration).

Insert fuel injectors -1- into the bracket -2- as far as the stop.

Scheme 603

Dip the fuel injectors with the bracket into the cleaner.

Adjust the temperature to 50 degrees using the knob -4-.

Set a cleaning time of 30 minutes using the knob -5-.

Switch the ultrasonic device on with the button -3-.

Note. The time begins counting down once the cleaning temperature reaches 50 degrees.

Replace the combustion chamber seal (teflon seal after cleaning each fuel injector. Refer to TEFLON COMBUSTION CHAMBER SEAL .

Then install the fuel injector valves. Refer to FUEL INJECTORS .

DESCRIPTION AND OPERATION

Engine Codes BWA and BPY

Engine Code CDMA

All

COMPONENT LOCATION OVERVIEW

Components A through N are not depicted in the exploded view illustration.

Scheme 604

1. Wastegate Bypass Regulator Valve -N75- Installed directly on turbocharger (Scheme 627)
2. Turbocharger Recirculating Valve -N249- Installed directly on turbocharger (Scheme 627)
3. Ignition Coils with Power Output Stages Removing and installing. Refer to «IGNITION COILS WITH POWER OUTPUT STAGES»(/audi/tt/8j-2006-2010/remont/ignition-system/#20l-ignitionglow-plug-system-engine-codes-bpy-cdma-roadster-as-of-012008__ignition-coils-with-power-output-stages). Ignition Coil 1 with Power Output Stage -N70- Ignition Coil 2 with Power Output Stage -N127- Ignition Coil 3 with Power Output Stage -N291- Ignition Coil 4 with Power Output Stage -N292- The ignition coils must be pulled out of the cylinder head using the ignition coil puller T40039
4. Heated Oxygen Sensor -G39- and Oxygen Sensor Heater -Z19- Component location (Scheme 624) Removing and installing, refer to «HEATED OXYGEN SENSOR AND OXYGEN SENSOR HEATER BEFORE CATALYTIC CONVERTER»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__heated-oxygen-sensor-and-oxygen-sensor)
5. Engine Control Module -J623- Removing and installing, refer to «ENGINE CONTROL MODULE»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__engine-control-module)
6. Single Piston High Pressure Pump Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__high-pressure-pump)
7. Fuel Pressure Regulator Valve -N276
8. Camshaft Adjustment Valve 1 -N205- Removing and installing, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-roadster)
9. 6-Pin Harness Connector For Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19- (black) (Scheme 623)
10. Low Fuel Pressure Sensor -G410- 15 Nm
11. Engine Coolant Temperature Sensor -G62- Component location (Scheme 609)
12. Engine Speed Sensor -G28- Oil Pressure Sensor -G10- Electrical connectors on Knock Sensor (KS) 1 -G61- and Knock Sensor (KS) 2 -G66- Component location (Scheme 618)
13. Intake Flap Motor -V157- with Intake Manifold Runner Position Sensor -G336- The intake manifold runner position sensor -G336- must be adapted to the engine control module -J623- after removing or replacing the fuel rail vehicle diagnosis, testing and information system VAS 5052 "Guided Function". Removing and installing, refer to «INTAKE FLAP MOTOR AND INTAKE MANIFOLD RUNNER POSITION SENSOR»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__intake-flap-motor-and-intake-manifold)
14. EVAP Canister Purge Regulator Valve 1 -N80
15. Charge Air Pressure Sensor -G31- Component location (Scheme 620)
16. Connector For Camshaft Position (CMP) Sensor -G40- and Fuel Pressure Sensor -G247- Component location (Scheme 619)
17. Fuel Injector 8-Pin Harness Connector Component location (Scheme 619)
18. Throttle Valve Control Module -J338-, Throttle Drive for Electronic Power Control -G186-, Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) -G187- and Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) -G188- After replacing the throttle valve control module -J338-, it must be adapted to the engine control module -J623- see vehicle diagnosis and service system VAS 5052 "Guided Function".
19. Intake Air Temperature Sensor -G42
20. Fuel Pressure Sensor -G247- 22 Nm Component location (Scheme 611) Removing and installing, refer to «FUEL PRESSURE SENSOR»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__fuel-pressure-sensor)
21. Camshaft Position Sensor -G40- Electrical harness connector (Scheme 612)
22. A - Mass Air Flow Sensor -G70- In upper section of air filter (Scheme 613) Removing and installing, refer to «MASS AIR FLOW SENSOR»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__mass-air-flow-sensor)
23. B - Fuel Pump Control Module -J538- (Scheme 615) If Fuel Pump (FP) Control Module -J538- is replaced, a fuel pump adaptation must be performed. Basic setting measured values block 103. Refer to «Diagnosis and Testing»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) or via Vehicle Diagnosis and Service System VAS 5052 "Guided Functions".
24. C - Brake Light Switch - F- and Brake Pedal Switch -F63- Component location (Scheme 617) Removing and installing, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster)
25. D - Throttle Position Sensor -G79- and Accelerator Pedal Position Sensor 2 -G185- Component location (Scheme 608) On accelerator pedal (both sensors are stored in one housing) If the accelerator pedal module or engine control module is replaced in vehicles with automatic transmission, the kick-down function must be adapted. Removing and installing, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster)
26. E - Clutch Position Sensor -G476- Component location (Scheme 616) Remove and install.
27. F - E-Box Relay and Fuse Carrier Relay and fuse assignment.
28. G - Coolant Fan Control Module -J293- Component location (Scheme 621)
29. H - Fuel Injector In fuel rail pipe Removing and installing, refer to «FUEL INJECTORS»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__fuel-injectors) Cylinder 1 Fuel Injector -N30- Cylinder 2 Fuel Injector -N31- Cylinder 3 Fuel Injector -N32- Cylinder 4 Fuel Injector -N33- Fuel injectors referred to here are high pressure fuel injectors. They inject fuel directly into the cylinder under high pressure (max. approximately 110 bar).
30. I - Oxygen Sensor After Catalytic Converter -G130- and Oxygen Sensor Heater 1 After Catalytic Converter -Z29- Component location (Scheme 626) Removing and installing, refer to «OXYGEN SENSOR AFTER CATALYTIC CONVERTER AND OXYGEN SENSOR 1 HEATER»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__oxygen-sensor-after-catalytic-converter-and)
31. J - Knock Sensor I -G61- For cylinder 1 and 2 20 Nm Component location (Scheme 619)
32. K - Knock Sensor 2 -G66- For cylinder 3 and 4 20 Nm Component location (Scheme 619)
33. L - Oil Pressure Switch -F1- Component location (Scheme 619) Checking, removing and installing, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/lubrication-system/#20l-lubrication-engine-codes-bpy-roadster)
34. M - Engine Coolant Temperature Sensor (on Radiator) -G83- Component location (Scheme 610)
35. N - After-Run Coolant Pump -V51- Component location (Scheme 622)

Scheme 605

1. Mass Air Flow Sensor -G70- Removing and installing, refer to «MASS AIR FLOW SENSOR»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__mass-air-flow-sensor)
2. 3 Nm
3. Upper Air Filter Housing/Engine Cover Clean air filter housing-upper section of salt residue, dirt and leaves
4. Spring-Type Clip
5. Intake Air Guide To air filter housing Clean dirt and leaves from intake air guide
6. Filter Element Always use a genuine air filter element Removing and installing, refer to «ENGINE COVER WITH AIR FILTER»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__engine-cover-with-air-filter) Observe change intervals
7. Lower Air Filter Housing Clean air filter housing-lower section of salt residue, dirt and leaves
8. 3 Nm
9. Heat Shield
10. Rubber Boot Note installation marking
11. Air Guide Hose Note installation marking To turbocharger Check air duct hose for dirt and leaves

Components A through L are not shown in the exploded view illustration.

Scheme 606

1. Wastegate Bypass Regulator Valve -N75- Installed directly on turbocharger (Scheme 627)
2. Ignition Coils with Power Output Stages Removing and installing, refer to «IGNITION COILS WITH POWER OUTPUT STAGES»(/audi/tt/8j-2006-2010/remont/ignition-system/#20l-ignitionglow-plug-system-engine-codes-bpy-cdma-roadster-as-of-012008__ignition-coils-with-power-output-stages) Ignition Coil 1 with Power Output Stage -N70- Ignition Coil 2 with Power Output Stage -N127- Ignition Coil 3 with Power Output Stage -N291- Ignition Coil 4 with Power Output Stage -N292- The ignition coils must be pulled out of the cylinder head using the ignition coil puller T40039
3. Heated Oxygen Sensor -G39- and Oxygen Sensor Heater -Z19- Component location (Scheme 624) Removing and installing, refer to «HEATED OXYGEN SENSOR AND OXYGEN SENSOR HEATER BEFORE CATALYTIC CONVERTER»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__heated-oxygen-sensor-and-oxygen-sensor)
4. Engine Control Module -J623- Removing and installing, refer to «ENGINE CONTROL MODULE»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__engine-control-module)
5. Low Fuel Pressure Sensor -G410- 15 Nm
6. Single Piston High Pressure Pump Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__high-pressure-pump)
7. Fuel Pressure Regulator Valve -N276
8. Camshaft Adjustment Valve 1 -N205- Removing and installing, refer to «Removal and Installation»(ref-505813-S30772019442012100100000)
9. 6-Pin Harness Connector For Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19- (black) (Scheme 623)
10. Mass Air Flow Sensor -G70- Removing and installing, refer to «MASS AIR FLOW SENSOR»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster)
11. Engine Coolant Temperature Sensor -G62- Component location (Scheme 609)
12. Engine Speed Sensor -G28- Eectrical connectors on Knock Sensor (KS) 1 -G61- and Knock Sensor (KS) 2 -G66- Component location (Scheme 618)
13. Intake Flap Motor -V157- with Intake Manifold Runner Position Sensor -G336- The intake manifold runner position sensor -G336- must be adapted to the engine control module -J623- after removing or replacing the fuel rail vehicle diagnosis, testing and information system VAS 5052 "Guided Function". Removing and installing, refer to «INTAKE FLAP MOTOR AND INTAKE MANIFOLD RUNNER POSITION SENSOR»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__intake-flap-motor-and-intake-manifold)
14. Charge Air Pressure Sensor -G31- Component location (Scheme 620)
15. Electrical Harness Connectors For the fuel injectors, camshaft position sensor -G40- and fuel pressure sensor -G247- Component location (Scheme 619)
16. EVAP Canister Purge Regulator Valve -N80- Component location (Scheme 630)
17. Turbocharger Recirculating Valve -N249- Component location (Scheme 630) Removing and installing, refer to «Removal and Installation»(ref-505805-S25714808202012100100000)
18. Throttle Valve Control Module -J338- and Throttle Drive for EPC -G186- Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) -G187- and Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) -G188- After replacing the throttle valve control module -J338-, it must be adapted to the engine control module -J623- see vehicle diagnosis and service system VAS 5052 "Guided Function".
19. Intake Air Temperature Sensor -G42
20. After-Run Coolant Pump -V51- Component location (Scheme 622)
21. Engine Coolant Temperature Sensor (on Radiator) -G83- Component location (Scheme 610)
22. Fuel Pressure Sensor -G247- 22 Nm Component location (Scheme 611) Removing and installing, refer to «FUEL PRESSURE SENSOR»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__fuel-pressure-sensor)
23. Camshaft Position Sensor -G40- Component location (Scheme 612)
24. A - Fuel Pump Control Module -J538- Component location (Scheme 615) If Fuel Pump (FP) Control Module -J538- is replaced, a fuel pump adaptation must be performed. Basic setting measured values block 103. Refer to «Diagnosis and Testing»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) or via Vehicle Diagnosis and Service System VAS 5052 "Guided Functions"
25. B - Brake Light Switch - F- and Brake Pedal Switch -F63- Component location (Scheme 617) Removing and installing, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster)
26. C - Throttle Position Sensor -G79- and Accelerator Pedal Position Sensor 2 -G185- Component location (Scheme 608) On accelerator pedal (both sensors are stored in one housing) If the accelerator pedal module or engine control module is replaced in vehicles with automatic transmission, the kick-down function must be adapted. Removing and installing, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster)
27. D - Clutch Position Sensor -G476- Component location (Scheme 616) Remove and install.
28. E - E-Box Relay and Fuse Carrier Relay and fuse assignment
29. F - Coolant Fan Control Control Module -J293- Component location (Scheme 621)
30. G - Fuel Injector In fuel rail pipe Removing and installing, refer to «FUEL INJECTORS»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__fuel-injectors) Cylinder 1 Fuel Injector -N30- Cylinder 2 Fuel Injector -N31- Cylinder 3 Fuel Injector -N32- Cylinder 4 Fuel Injector -N33- Fuel injectors referred to here are high pressure fuel injectors. They inject fuel directly into the cylinder under high pressure (max. approximately 110 bar).
31. H - Oxygen Sensor After Catalytic Converter -G130- and Oxygen Sensor Heater 1 After Catalytic Converter -Z29- Component location (Scheme 626) Removing and installing, refer to «OXYGEN SENSOR AFTER CATALYTIC CONVERTER AND OXYGEN SENSOR 1 HEATER»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__oxygen-sensor-after-catalytic-converter-and)
32. I - Knock Sensor I -G61- For cylinder 1 and 2 20 Nm Component location (Scheme 619)
33. J - Knock Sensor 2 -G66- For cylinder 3 and 4 20 Nm Component location (Scheme 619)
34. K - Oil Pressure Switch -F1- Component location (Scheme 619) Checking, removing and installing, refer to «Removal and Installation»(ref-505814-S32886081642012100100000)
35. L - Exhaust Flap Valve 1 -N321- Component location (Scheme 632)

Scheme 607

2 - Accelerator pedal module, electrical connector

Removing and installing. Refer to Removal and Installation

Scheme 608

Scheme 609

Scheme 610

1. Removing and installing, refer to «FUEL PRESSURE SENSOR»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__fuel-pressure-sensor)

Scheme 611

Scheme 612

Scheme 613

Scheme 614

1. If Fuel Pump Control Module -J538- is replaced, a fuel pump adaptation must be performed. Basic setting, measuring value block 103. Refer to «Diagnosis and Testing»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) .

Scheme 615

Remove and install. .

Scheme 616

Removing and installing. Refer to Removal and Installation .

Scheme 617

1 - 3-pin harness connector (green) for Knock Sensor (KS) 1 -G61

2 - 3-pin harness connector (brown) for Knock Sensor (KS) 2 -G66

3 - Oil pressure switch -F1

4 - Engine speed (RPM) sensor -G28

5 - 3-pin connector (gray) for Engine Speed (RPM) Sensor -G28

Scheme 618

1 - Knock Sensor (KS) I -G61

2 - Knock Sensor (KS) II -G66

3 - Oil pressure switch -F1

4 - 3-pin harness connector (brown) for Knock Sensor (KS) 2 -G66

5 - 3-pin connector (gray) for Engine Speed (RPM) Sensor -G28

6 - Electrical connector for Camshaft Position (CMP) Sensor -G40- and Fuel Pressure Sensor -G247

7 - 8-pin harness connector for fuel injectors

Scheme 619

Scheme 620

1 - Coolant Fan Control Module -J293-, connector

Note. The Coolant Fan Control Module -J293- is integrated in the Coolant Fan -V7-.

Scheme 621

Scheme 622

Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19

Scheme 623

Scheme 624

Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) -Z29- on right of vehicle floor

Scheme 625

Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) -Z29

Scheme 626

1 - Turbocharger, removing and installing, refer to Removal and Installation

2 - Tighten wastegate bypass regulator valve -N75- to 3 Nm.

3 - Tighten turbocharger recirculating valve -N249- to 7 Nm (observe installation location, next illustration)

Scheme 627

Scheme 628

1 - Turbocharger, removing and installing, refer to Removal and Installation

2 - Tighten wastegate bypass regulator valve -N75- to 3 Nm.

Scheme 629

1 - Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80

2 - Turbocharger Recirculating Valve -N249

Scheme 630

Markings -arrows- must align.

Scheme 631

1 - Exhaust flap valve 1 -N321- connector

Check vacuum diaphragm for the exhaust flap. Refer to Diagnosis and Testing .

Scheme 632

1. Gasket Secured in bottom part of air filter housing
2. Front Air Guide Clean off dirt, leaves and salt residue
3. Bolt 2 Nm
4. Air Duct Lower Section Clean off dirt, leaves and salt residue
5. Air Duct Cover
6. Bolt 5 Nm
7. Bolt 3 Nm
8. Air Guide Hose
9. Mass Air Flow Sensor -G70- Removing and installing, refer to «MASS AIR FLOW SENSOR»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster)
10. Seal Replace if damaged
11. Air Filter Housing Upper Section Clean air filter housing-upper section of salt residue, dirt and leaves
12. Air Filter Element Removing and installing, refer to «AIR FILTER»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__air-filter) Always use a genuine air filter element Observe change intervals
13. Air Filter Housing Lower Section Clean air filter housing-lower section of salt residue, dirt and leaves Removing and installing, refer to «AIR FILTER HOUSING»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__air-filter-housing) Clean off dirt, leaves and salt residue
14. Bolt 10 Nm
15. Rubber Grommet
16. Bolt 10 Nm
17. Air Filter Housing Bracket
18. Retaining Pin 10 Nm
19. Rubber Grommet

Scheme 633

1. Intake Air Temperature Sensor -G42- Bolt 5 Nm
2. Intake Air Temperature Sensor -G42
3. Intake Manifold Removing and installing, refer to «INTAKE MANIFOLD WITH FUEL RAIL»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__intake-manifold-with-fuel-rail)
4. EVAP Canister Purge Regulator Valve -N80
5. Single-Piston High-Pressure Pump Bolt 3 pieces 10 Nm
6. Fuel Pressure Regulator Valve -N276
7. Mechanical Single-Piston High-Pressure Pump With Fuel Pressure Regulator Valve -N276- and Low Fuel Pressure Sensor -G410- An electrical fuel pump, located in the fuel tank, supplies fuel to the mechanical high-pressure pump at a pressure of approximately 6 bar. When installing the high-pressure pump, make sure that no dirt enters the fuel system. The fuel system must be pressureless, releasing fuel pressure. Refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__before-opening-high-pressure-fuel-injection) . Do not install fuel lines with tension Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__high-pressure-pump)
8. Fuel Return Line to Fuel Tank Connection Do not install fuel line with tension (be aware of cleanliness)
9. Fuel Supply Line to Fuel Rail Replace connecting piece Tighten connections to 30 Nm Do not install fuel line with tension (be aware of cleanliness). Torque specification: 27 Nm.
10. Intake Flap Motor -V157- with Intake Manifold Runner Position Sensor -G336- After replacing the fuel rail, the intake manifold runner position sensor -G336- must be adapted to the engine control module vehicle diagnosis and service system VAS 5052 "Guided Function". Removing and installing, refer to «INTAKE FLAP MOTOR AND INTAKE MANIFOLD RUNNER POSITION SENSOR»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__intake-flap-motor-and-intake-manifold)
11. Intake Flap Motor -V157- with Intake Manifold Runner Position Sensor -G336- Bolt 7 Nm
12. Intake Manifold Support
13. Intake Manifold Support Bolt 23 Nm
14. Throttle Valve Control Module -J338-, Throttle Drive for Electronic Power Control -G186-, Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) -G187- and Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) -G188- After replacing the throttle valve control module -J338-, it must be adapted to the engine control module -J623- see vehicle diagnosis and service systemVAS 5052 "Guided Function".
15. Throttle Valve Control Module -J338- Bolt 4 pieces 7 Nm
16. Intake Manifold Support Nut 10 Nm
17. Seal Replace
18. Fuel Rail Removing and installing, refer to «INTAKE MANIFOLD WITH FUEL RAIL»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__intake-manifold-with-fuel-rail)
19. Fuel Pressure Sensor -G247- 20 Nm

Scheme 634

1. Radial Adjustment Replace if damaged
2. Fuel Injector With combustion chamber seal (Teflon seal), always replace Replace O-rings Note correct installation position Removing and installing, refer to «FUEL INJECTORS»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__fuel-injectors)
3. Support Ring
4. Fuel Rail Removing and installing, refer to «INTAKE MANIFOLD WITH FUEL RAIL»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__intake-manifold-with-fuel-rail)
5. Fuel Pressure Sensor -G247- 22 Nm Tighten connections to 30 Nm
6. Low Fuel Pressure Sensor -G410
7. Fuel Pressure Regulator Valve -N276
8. Mechanical Single-Piston High-Pressure Pump With Fuel Pressure Regulator Valve -N276- and Low Fuel Pressure Sensor -G410- An electrical fuel pump, located in the fuel tank, supplies fuel to the mechanical high-pressure pump at a pressure of approximately 6 bar. When installing high-pressure pump, make sure that no dirt enters the fuel system. The fuel system must be pressureless to install the high-pressure pump, releasing fuel pressure. Refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__before-opening-high-pressure-fuel-injection) . Do not install fuel lines with tension Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__high-pressure-pump)
9. EVAP Canister Purge Regulator Valve -N80
10. Throttle Valve Control Module -J338-, Throttle Drive for Electronic Power Control -G186-, Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) -G187- and Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) -G188- After replacing the throttle valve control module -J338-, it must be adapted to the engine control module -J623- see vehicle diagnosis and service systemVAS 5052 "Guided Function".
11. Intake Air Temperature Sensor 2 -G299- 5 Nm
12. Intake Manifold Bolts 9 Nm
13. Intake Manifold Removing and installing, refer to «INTAKE MANIFOLD WITH FUEL RAIL»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__intake-manifold-with-fuel-rail)

HIGH PRESSURE PUMP ASSEMBLY OVERVIEW

Scheme 635

1. Air Deflector Plates Removable Check for damages and correct positioning
2. Sleeve remains inserted in cylinder head after removing the high-pressure pump, removable
3. O-Ring Replace
4. Mechanical Single-Piston High-Pressure Pump An electrical fuel pump, located in the fuel tank, supplies fuel to the mechanical high-pressure pump at a pressure of approximately 6 bar. When installing the high-pressure pump, make sure that no dirt enters the fuel system. The fuel system must be pressureless, releasing fuel pressure, refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__before-opening-high-pressure-fuel-injection) Do not install fuel lines with tension Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__high-pressure-pump)
5. Fuel Pressure Regulator Valve -N276
6. Low Fuel Pressure Sensor -G410- 15 Nm
7. High-Pressure Pump Bolts 10 Nm
8. Fuel Return Line to Fuel Tank Connection When replacing threaded supports, always leave old sealing ring in pump. It is pinched during initial assembly by the supplier and cannot be removed. The threaded support has a "biting edge" for sealing for this purpose.
9. Fuel Supply Line to Fuel Rail Connection Replace connecting piece Tighten connections to 30 Nm Do not install fuel line with tension (ensure cleanliness), tightening specifications: 27 Nm
10. Hole In Cylinder Head For High-Pressure Pump
11. Fuel Injector Replace O-rings Note correct installation position Removing and installing, refer to «FUEL INJECTORS»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__fuel-injectors)

TECHNICAL DATA

LOWER FUEL PRESSURE, CHECKING WITH HIGH PRESSURE PUMP

Note. Fuel pump (FP) control module OK Fuel Pump (FP) OK Fuel filter OK Battery voltage at least 11 Volts

Switch on ignition.

Connect Vehicle Diagnosis and Service SystemVAS 5052 and select the engine control module.

Select "engine electronics" in OBD.

Then select "Measured values" read out.

Select measured value block 103.

During ignition, the fuel low pressure is displayed in field 1.

Note. By switching the ignition off and on the Fuel Pump (FP) Control Module -J538- activates the fuel pump for several seconds.

Measure fuel pressure.

1. Specified value: Approximately 6 bar (5 to 7 bar) positive pressure

If specified value is not attained, check the delivery rate of the electrical fuel pump. Refer to Diagnosis and Testing

Check fuel pressure and residual pressure with Fuel Inj. Pressure Gauge-CIS V.A.G 1318. Refer to FUEL PRESSURE AND RESIDUAL PRESSURE BEFORE HIGH PRESSURE PUMP, CHECKING .

FUEL PRESSURE AND RESIDUAL PRESSURE BEFORE HIGH PRESSURE PUMP, CHECKING

Special tools and workshop equipment required

1. Pressure gauge K-Jetronic V.A.G 1318
2. Adapter V.A.G 1318/11
3. Adapter V.A.G 1318/17-1 from adapter kit V.A.G 1318/17
4. Double connection V.A.G 1318/23
5. Remote control V.A.G 1348/3 A with adapter cable V.A.G 1348/3-3
6. Connector test kit V.A.G 1594 C or V.A.G 1594 A
7. Measuring container, fuel-resistant

Test Conditions

1. Battery voltage at least 12.5 Volts.
2. Fuel filter OK.
3. Fuel tank at least 1 / 4 full.
4. Fuel Pump (FP) Control Module -J538- OK; checking
5. Ignition switched off.

Test Sequence

Remove rear seat bench. Refer to Removal and Installation .

Unclip retainers -arrows- of the cover for sealing flange.

Scheme 636

Disconnect electrical harness connector -arrow- at locking flange.

Scheme 637

Connect remote control V.A.G 1348/3 A with connection V.A.G 1348/3-3 to contact -1- using an adapter cable from the connector test set V.A.G 1594 C.

Scheme 638

Using insulating tape, tape over the second contact of connection V.A.G 1348/3-3 to prevent a short circuit -arrow-.

Connect contact -5- to vehicle Ground (GND) using a jumper cable from the connector test set V.A.G 1594 C.

Connect alligator clip to vehicle battery (+).

Remove fuel filler cap from fuel filler tube.

Disconnect fuel supply line -arrow-.

Scheme 639

Attach Fuel Line Feed Adapter V.A.G 1318/23 and Adapter V.A.G 1318/17-1 to Fuel Inj. Pressure Gauge-CIS V.A.G 1318.

Scheme 640

Push adapter V.A.G 1318/17-1 onto the disconnected fuel supply line.

Attach Adapter V.A.G 1318/11 to Fuel Inj. Pressure Gauge-CIS V.A.G 1318.

Push an assisting hose -arrow- onto it and hold it into a measuring container.

Open shut-off valve on Fuel Inj. Pressure Gauge-CIS V.A.G 1318. The lever points in the direction of flow.

Bleed fuel system by pressing remote control briefly.

Close shut-off valve on Fuel Inj. Pressure Gauge-CIS V.A.G 1318. Lever stands perpendicular to direction of flow -arrow-.

Scheme 641

Press remote control switch until pressure increase is no longer observed on Fuel Inj. Pressure Gauge-CIS V.A.G 1318.

1. Specified value: Approximately 6 bar (4 to 8 bar) positive pressure

If specification is not obtained

Check delivery rate of fuel pump. Refer to Diagnosis and Testing .

Residual Pressure, Checking

Check for leaks and residual pressure by observing pressure drop on Fuel Inj. Pressure Gauge-CIS K-Jetronic V.A.G 1318.

1. After 10 minutes there must be a residual pressure of at least 3 bar.

If residual pressure drops below 3 bar

1. Check connection between Fuel Inj. Pressure Gauge-CIS K-Jetronic V.A.G 1318 and fuel supply line for leaks.
2. Check Fuel Inj. Pressure Gauge-CIS V.A.G 1318 for leaks.
3. Check fuel lines and their connections for leaks.
4. Replace fuel filter with integrated fuel pressure regulator. Refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) . Then repeat test.
5. If fuel filter is OK, replace fuel pump. Refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) .

Assembly is in reverse order of removal, note the following

Ignition must be switched off.

Note. Before disconnecting pressure gauge, release pressure by opening shut-off valve. Hold assisting hose in a container when doing so.

Reconnect fuel supply line (pay attention to cleanliness and leaks).

WIRING AND COMPONENTS, CHECKING WITH TEST BOX VAG 1598/42

Special tools and workshop equipment required

1. Adapter cable -V.A.G 1598/39-1
2. Adapter cable -V.A.G 1598/39-2
3. Test box -V.A.G 1598/42

Note. The test box is designed with 105 pins. The connection cable can be separated from the test box. This means that as new engine control module connectors are introduced in the future, only a new cable must be designed and no longer the entire test box. The smaller of the two connectors on the engine control module is assigned with terminals 1 to 60. The larger of the two connectors is assigned with terminals 1 to 94. For testing at the 60-pin harness connection, the adapter cable -V.A.G 1598/39-1- is connected to the test box with connector -A-. Components of the 60-pin harness connection. For testing at the 94-pin harness connection, the adapter cable -V.A.G 1598/39-2- is connected to the test box with connectors -A- and -B-. Components of the 94-pin harness connection. The test box V.A.G 1598/42 is designed so that it can be connected simultaneously to the engine control module harness and the engine control module itself. This is advantageous because electronic engine control remains fully functional (e.g. measurement of signals with engine running) when the test box is attached. The procedures will indicate whether the engine control module is to remain connected to the test box or not. Always use connector test set V.A.G 1594 C to connect measuring equipment (e.g. voltage tester V.A.G 1527 B, portable multimeter V.A.G 1526 C, etc.)

The engine control module must be removed to disconnect the ECM multi-pin connectors. Refer to ENGINE CONTROL MODULE .

Connect test box V.A.G 1598/42 to wiring harness connector. Ground (GND) clip at test box must be clipped to battery minus. The procedures will indicate whether the engine control module is to be connected to the test box.

Perform test as described in relevant repair sequences.

Installing engine control module

Install in reverse order of removal.

Thereafter, the engine control module must be equipped with the metal retainer.

Clean threaded holes for shear bolts of locking compound residue. Cleaning can be performed with a thread cutter (tap).

Always use new shear bolts.

Perform the following work after the engine control module is reconnected

Check DTC memory and, if necessary, erase.

REMOVAL AND INSTALLATION

Engine Codes BWA and BPY

Engine Code CDMA

All

ENGINE COVER WITH AIR FILTER

The air filter element is integrated into the engine cover.

Engine Cover, Removing

Disconnect electrical harness connector -3- at Mass Air Flow (MAF) Sensor -G70-.

Scheme 642

Open clips -1 and 2- and remove air guide hose from mass air flow sensor.

Remove front air intake connector on lock carrier -5-.

Open spring-type clip -4- and remove air intake hose from the engine cover.

Carefully remove the engine cover from locations -1 - 2 - 3 - 4-.

Scheme 643

Cover open intake hose with a clean rag.

Air filter element, removing

Remove all bolts -arrows-.

Scheme 644

Remove heat shield.

Separate engine cover, paying attention to the retainer -arrows-.

Scheme 645

Pull air filter element out of the engine cover.

Scheme 646

Air filter element, installing

Note. Always use an original equipment air filter element. Hose connections and charge air system hoses must be free of oil and grease before installing. When installing, do not use any lubricants containing silicone. The air filter housing must be clean. Secure all hose connections using hose clamps appropriate for the model type. Note the following when blowing out the air filter housing with pressurized air: To prevent malfunctions, cover the critical air flow components, such as Mass Air Flow Sensor, air intake tubes, etc., with a clean rag. Observe disposal regulations!

Check the MAF sensor and intake hose (intake air side) for salt residue, dirt, and leaves.

Check air intake hose from the air duct for dirt.

Make sure that air filter element is properly centered when placed into the mounting of the lower section of air filter housing.

Set the upper section of air filter housing onto lower section of air filter housing, without using much force. When doing this, make sure that the upper section of air filter housing is not placed crooked onto the air filter element (observe sealing lip of air filter element).

Make sure the intake hose is securely seated on Mass Air Flow (MAF) Sensor -G70-.

Further installation is performed in reverse order.

MASS AIR FLOW SENSOR

Disconnect electrical connector -3- on Mass Air Flow (MAF) Sensor -G70-.

Scheme 647

Remove both bolts from the Mass Air Flow (MAF) Sensor -G70- and carefully remove the Mass Air Flow (MAF) Sensor -G70- from the air filter housing guide.

Installing

For problem-free operation of the mass air flow (MAF) sensor -G70- it is very important to observe the following notes and procedures.

Note. If the air filter element is very dirty or soaked, dirt particles or moisture may have contaminated the Mass Air Flow (MAF) Sensor -G70- and may be causing false mass air flow values. This results in a reduction of power, since a lower injection quantity is calculated. Always use an original equipment air filter element. Use a lubricant (silicone-free) for installing the intake hose. Secure all hose connections using hose clamps appropriate for the model type.

Check the MAF sensor and intake hose (intake air side) for salt residue, dirt, and leaves.

Check the intake ducting up to the air filter element for dirt. If any contaminants are discovered, clean air filter housing (upper and lower sections) of salt residue, dirt and leaves (if necessary, clean by washing or vacuuming). Air filter, removing and installing. Refer to ENGINE COVER WITH AIR FILTER .

Further installation is performed in reverse order.

INTAKE FLAP MOTOR AND INTAKE MANIFOLD RUNNER POSITION SENSOR

For the installation location of the intake flap motor -V157-. Refer to INTAKE MANIFOLD ASSEMBLY OVERVIEW .

Special tools and workshop equipment required

1. Commercial 1 / 4 ratchet
2. Torx 30

Removing

Remove engine cover.

Disconnect vacuum lines -arrows-.

Scheme 648

Remove bracket -arrow- for the harness.

Scheme 649

Disconnect connectors attached to the wiring harness and move the cable harness to the side as needed.

Remove bracket for cable connector -arrows- from coolant pipe.

Scheme 650

Note. Open the nut with the left -arrow- just enough so that the bracket can moved to the side.

Carefully pry off linkage from Intake Flap Motor -V157- -4-.

Scheme 651

Remove Intake Flap Motor -V157- -5-.

Note. The illustration shows the intake manifold removed.

Installing

Installation is in reverse order.

1. Tightening Specifications. Refer to «INTAKE MANIFOLD ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster) .

ENGINE COVER

Removing

Carefully remove the engine cover -arrows-. Do not pull the engine cover to one side or jerk it when removing it.

Scheme 652

Installing

Carefully press the engine cover into the catch.

To prevent damages, do not hit engine cover with fist or tools.

AIR FILTER

Removing

Disconnect air guide hose -1- at Mass Air Flow (MAF) Sensor -G70-.

Separate the electrical connector -2- from Mass Air Flow (MAF) Sensor -G70-.

Remove upper section of air filter housing -arrows- and remove air filter insert.

Installing

Installation is in reverse order of removal, note the following

For trouble-free function of the Mass Air Flow sensor, it is important to observe the following notes and perform the work procedures exactly.

Note. In the event the air filter element is severely contaminated or completely saturated, dirt particles or moisture may penetrate the MAF sensor and falsify the measured air mass value. This results in a reduction of power, since a lower injection quantity is calculated. Always use an original equipment air filter element. Air filter housing must always be clean. Secure all hose connections with hose clamps appropriate for the model. Note the following when blowing out air filter housing with compressed air: To prevent malfunctions, cover critical air-flow engine components such as Mass Air Flow (MAF) sensor, air duct pipes etc. with a clean cloth. Observe disposal regulations!

Blow out the water drain (small hole in lower section of air filter housing) with compressed air.

Scheme 653

Clean air filter housing (upper and lower sections) of salt residue, dirt or leaves (use vacuum cleaner if necessary).

Check Mass Air Flow sensor and air duct hose (clean air side) for salt residue, dirt and leaves.

Check air duct from lock carrier to air filter housing for dirt and leaves.

When installing air filter element, make sure it is put on centered in mount in lower section of air filter housing.

Place upper section of air filter housing on to lower section or air filter housing carefully and without using excessive force. When doing this, make sure that upper section of air filter housing is not placed tilted on the air filter element (pay attention to sealing lip of air filter element).

Make sure that air duct hose is connected securely to Mass Air Flow sensor.

1. Tightening Specifications. Refer to «AIR FILTER ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster) .

AIR FILTER HOUSING

Removing

Remove air filter element. Refer to AIR FILTER .

Remove bolts -arrows- and remove air duct.

Scheme 654

Remove lower section of air filter housing -arrows-.

Scheme 655

Installing

Installation is in reverse order of removal, note the following.

Note. Air filter housing must always be clean. Secure all hose connections with hose clamps appropriate for the model. Note the following when blowing out air filter housing with compressed air: To prevent malfunctions, cover critical air-flow engine components such as Mass Air Flow sensor, air duct pipes etc. with a clean cloth.

Blow out water drain (small hole in lower section of air filter housing) with compressed air.

Clean air filter housing (upper and lower sections) of salt residue, dirt or leaves (use vacuum cleaner if necessary).

Check Mass Air Flow sensor and air duct hose (clean air side) for salt residue, dirt and leaves.

Check the air duct from lock carrier to air filter housing for dirt and leaves.

Place upper section of air filter housing on to lower section or air filter housing carefully and without using excessive force. When doing this, make sure that upper section of air filter housing is not placed tilted on the air filter element (pay attention to sealing lip of air filter element).

1. Tightening Specifications. Refer to «AIR FILTER ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster) .

Removing

Separate the electrical connector -2- for mass air flow (MAF) sensor -G70-.

Note. Ignore arrows.

Remove air guide hose by opening the hose clamp -1-.

Remove bolts -arrows-.

Scheme 656

Carefully pull Mass Air Flow (MAF) Sensor -G70- out of guide at upper section of air filter housing.

Installing

1. Tightening specifications. Refer to «AIR FILTER ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster) .

Installation is in reverse order of removal, note the following.

For trouble-free function of the Mass Air Flow sensor, it is important to observe the following notes and perform the work procedures exactly.

Note. Replace O-ring. In the event the air filter element is severely contaminated or completely saturated, dirt particles or moisture may penetrate the MAF sensor and falsify the measured air mass value. This results in a reduction of power, since a lower injection quantity is calculated. Always use an original equipment air filter element. Use a silicon-free lubricant to install the air duct hose. Secure all hose connections with hose clamps appropriate for the model.

For installation location of the intake flap motor -V157-. Refer to INTAKE MANIFOLD ASSEMBLY OVERVIEW .

Special tools and workshop equipment required

1. Commercial 1 / 4 ratchet
2. Torx 30

Removing

Remove engine cover.

Disconnect vacuum lines -arrows-.

Disconnect connector on the turbocharger recirculating valve -N249- -1-.

Scheme 657

Remove bolt -2-.

Open hose clamp -3- and remove the turbocharger recirculating valve -N249-.

Note. Cover the opening on the intake hose.

Remove bracket -arrow- for the harness.

Disconnect the connectors attached to the wiring harness and move the cable harness to the side as needed.

Disconnect the cable connector bracket from the water pipe.

Carefully pry off linkage from Intake Flap Motor -V157- -4-.

Remove Intake Flap Motor -V157- -5-.

Note. The illustration shows the intake manifold removed.

Installing

Installation is in reverse order.

1. Tightening Specifications. Refer to «INTAKE MANIFOLD ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster) .

INTAKE MANIFOLD WITH FUEL RAIL

The intake manifold runner position sensor -G336- must be adapted to the engine control module -J623- after removing or replacing the fuel rail vehicle diagnosis, testing and information systemVAS 5052 "Guided Function".

Note. To access the fuel injectors, the intake manifold and the fuel rail with intake manifold runner control valve must be removed. (Depending on version, more or fewer work steps may be required). The combustion chamber seal (Teflon) and the O-ring must always be replaced. Intake manifold. Refer to INTAKE MANIFOLD ASSEMBLY OVERVIEW . Fuel Rail. Refer to FUEL RAIL ASSEMBLY OVERVIEW .

Removing

Remove engine cover.

Disconnect all electrical harness connectors necessary.

Disconnect vacuum hose between intake manifold and vacuum pump from intake manifold.

Note. This vacuum hose and the vacuum pump (attached to rear of cylinder head) are only installed on vehicles with automatic transmission. Disregard items 1 and 2 in the illustration.

Disconnect hose connections -arrows- from valve cover.

Disconnect vacuum line -2- to EVAP canister.

Scheme 658

Disconnect fuel supply line -arrow-.

Note. The fuel system must have no pressure.

Open both fuel lines -2 and 3- to high pressure pump.

Scheme 659

Remove bolt and nut -arrows-, then push the right front coolant pipe to the side with the coolant hoses still connected.

Scheme 660

Remove nit -arrow- for the oil dipstick guide tube.

Scheme 661

This step only for engine code CDMA

Disconnect electrical connector -3-.

Scheme 662

Remove bolt -arrow-.

Remove hose -2-.

Loosen hose clamp -1- and lay the air guide pipe Turbocharger Recirculating Valve -N249- to the side with the hose -4- still connected.

All engine codes

Loosen hose clamp -2- and remove the air guide pipe from the throttle valve control module -J338-.

Scheme 663

Note. Ignore items -1, 3 and 4-.

Disconnect connector -1- on the intake air temperature sensor -G42-.

Scheme 664

Note. Disregard -arrow-.

Disconnect electrical connectors

Scheme 665

2 - For injector valves, remove the connectors from the bracket

3 - For evaporative emission (EVAP) canister purge regulator valve -N80

4 - Intake Flap Motor -V157

5 - Fuel pressure sensor -G247- and Camshaft Position (CMP) Sensor -G40-, remove the connectors from the bracket

Disconnect electrical connector -1-.

Scheme 666

Remove bolts -arrows- and remove Throttle Valve Control Module -J338-.

Remove nut -2- and bolt -1- and remove intake manifold support.

Scheme 667

Disconnect electrical connector -1- from Fuel Pressure Sensor -G247-.

Scheme 668

Remove all bolts from intake manifold.

Carefully pull off intake manifold with fuel rail from cylinder head.

Note. The fuel injectors could remain stuck in the fuel rail.

Fuel rail, removing and installing. Refer to FUEL RAIL .

Installing

Installation is in reverse order of removal.

1. Tightening Specifications, Intake Manifold. Refer to «INTAKE MANIFOLD ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster) .
2. Tightening specifications, Fuel rail. Refer to «FUEL RAIL ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster) .

FUEL RAIL

If the fuel filter is being replaced, then the intake manifold runner position sensor -G336- must be adapted to the engine control module -J623- Vehicle Diagnosis and Service SystemVAS 5052 "Guided Functions"

Note. Intake manifold must be removed. Refer to INTAKE MANIFOLD WITH FUEL RAIL .

Remove hoses from EVAP canister.

To do so, open hose clamp -1-.

Loosen two bolts -arrows- of fuel rail.

Scheme 669

Pull hose connection -1- off from intake manifold and remove both bolts -arrows-.

Open both fuel lines -2 and 3-.

Carefully pry off linkage from Intake Flap Motor -V157- -4-.

Remove Intake Flap Motor -V157- -5-.

Pry fuel rail off from the intake manifold via the retaining tabs -arrows-.

Scheme 670

Remove fuel rail from intake manifold.

Installing

Installation is in reverse order of removal.

Intake manifold, installing. Refer to INTAKE MANIFOLD WITH FUEL RAIL .

FUEL PRESSURE SENSOR

Special tools and workshop equipment required

1. Assembly tool T10118
2. Socket wrench insert 27 mm VAS 5301/7

Removing

Disconnect coolant pipe and oil dipstick guide from intake manifold -arrows- and pull off oil dipstick guide upward from engine.

Scheme 671

Disengage connector from Fuel Pressure Sensor -G247- using assembly tool T10118.

Remove Fuel Pressure Sensor -G247- using socket wrench insert 27 mm VAS 5301/7.

Scheme 672

Installing

Installation is in reverse order of removal.

Tightening specifications of connection "30 Nm" must be checked before installing Fuel Pressure Sensor -G247-.

1. Fuel Pressure Sensor -G247- tightening specifications. Refer to «FUEL RAIL ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster) .

HIGH PRESSURE PUMP

For safety reasons, if the battery is not disconnected, fuse -SF 6- from the Fuel Pump (FP) Control Module -J538- must be removed before opening fuel system. Otherwise, the fuel pump will be activated by the driver's door contact switch.

Note. The fuse is located in the fuse holder in the right of the luggage compartment. By removing fuse -SF 6-, the voltage supply to terminal 30 for the Fuel Pump (FP) Control Module -J538- is interrupted.

Note. The removal and installation of the high-pressure fuel pump can only be performed on a cold engine. When installing the high-pressure fuel pump, make sure that no dirt enters the fuel system. Catch escaping fuel with a rag. The O-ring must always be replaced. The fuel return line banjo fitting must always be replaced. High-pressure fuel lines must always be fastened free of tension.

Removing

Remove engine cover.

Disconnect electrical connectors from Low Fuel Pressure Sensor -G410- -1- and Fuel Pressure Regulator Valve -N276- -2-.

Scheme 673

Open both fuel lines -2 and 3-.

Remove 3 bolts -arrows-.

Carefully pull out the high-pressure fuel pump. The sleeve may remain inserted in the cylinder head.

Installing

Replace O-ring for the high-pressure pump.

Carefully place high pressure pump with sleeve in opening in cylinder head (check sleeve for damage first).

Tighten bolts by hand.

Before installing the fuel lines, check the torque of the connections on the high-pressure pump.

1. Fuel return line connections tightening specifications. Refer to «HIGH PRESSURE PUMP ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__high-pressure-pump-assembly-overview) .
2. Fuel supply line connections tightening specifications. Refer to «HIGH PRESSURE PUMP ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__high-pressure-pump-assembly-overview) .

Always tighten bolts alternating sides with the required torque.

1. High Pressure Pump Tightening Specification. Refer to «HIGH PRESSURE PUMP ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__high-pressure-pump-assembly-overview) .

Firmly place fuel return line hose (with hose clamp) on connection. Align so it is free of stress.

Tighten fuel supply line union nut by hand. Align so it is free of stress.

1. Fuel supply line (union nut) tightening specifications. Refer to «HIGH PRESSURE PUMP ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-roadster__high-pressure-pump-assembly-overview)

Connect electrical connectors on Low Fuel Pressure Sensor -G410- and for Fuel Pressure Regulator Valve -N276-.

Re-insert fuse if it was removed.

Note. Check fuel system for leaks.

FUEL INJECTORS

Removing

Remove intake manifold and fuel rail. Refer to INTAKE MANIFOLD WITH FUEL RAIL .

Removing fuel injectors, in the event that they are stuck in the fuel rail

Carefully pull the fuel injectors out of the fuel rail.

Removing fuel injectors, in the event that they are stuck in the cylinder head

Special tools and workshop equipment required

1. Tool set with puller T10133

Note. The puller T10133/2 was changed and is now called puller T10133/2-A. If the new tool is not available, the old one can be modified.

Modify the puller T10133/2 to create puller T10133/2-A.

Special tools and workshop equipment required

1. Round file approximately 6 mm

File the semi-circle as shown in the illustration. The semi-circle allows the tool to slide farther onto the fuel injector, thus providing the tool with a larger contact surface.

Mark the modified tool with an "A" at the end of the tool number.

Scheme 674

Scheme 675

1 - Radial compensation, replace if damaged

2 - Combustion chamber sealing ring (Teflon sealing ring), replace, the ring must not be greased or handled with any other lubricants when installing.

3 - Groove on fuel injector

4 - Spacer ring, replace if damaged

5 - O-ring (replace, coat lightly with clean engine oil when installing)

6 - Support ring (via this support ring, fuel rail utilizes the force to hold the fuel injector in place in the cylinder head).

Note. With fuel injector installed, the radial adjustment -1- is clipped into the support ring -6-. To remove the fuel injector, the support ring must be separated from the fuel injector in order to install pullerT10133/2 into the indentation on the fuel injector -3-.

Cover open intake channels with a clean rag.

Disconnect electrical harness connector at fuel injector that is to be removed.

Bend retaining tabs of radial compensation to the side using a screwdriver and pull off support ring from fuel injector.

Scheme 676

Position puller T10133/2A in the groove on the fuel injector.

Scheme 677

Then position the trim removal wedge T10133/16 and remove the fuel injector by loosening the bolt -1-.

Note. The combustion chamber seal must always be replaced before re-installing the high-pressure fuel injector. Refer to TEFLON COMBUSTION CHAMBER SEAL .

TEFLON COMBUSTION CHAMBER SEAL

Note. The combustion chamber seal must always be replaced before re-installing the high-pressure fuel injector.

1 - Radial compensation, replace if damaged

2 - Combustion chamber sealing ring (Teflon sealing ring), replace, the ring must not be greased or handled with any other lubricants when installing.

3 - Groove on fuel injector

4 - Spacer ring, replace if damaged

5 - O-ring (replace, coat lightly with clean engine oil when installing)

6 - Support ring (via this support ring, fuel rail utilizes the force to hold the fuel injector in place in the cylinder head).

Carefully remove the old Teflon seal with the appropriate tool (e.g. with cut the seal open with a razor and spread seal open with a small screwdriver and pull it forward and off.) When doing this, make sure not to damage the groove and circumferential rib in the groove base.

Note. If the groove is damage, the fuel injector must be replaced.

Before installing the new Teflon seal, the seal groove and the shaft of the fuel injector must be cleaned of combustion residue using a clean rag.

Note. A fuel injector with "angled connector" is shown in the illustration. Do not pay attention to this for the remainder of the procedure, because it is unrelated to replacement of the combustion chamber seal.

Place the assembly cone T10133/5 with the new Teflon seal -1- onto the fuel injector -2-.

Scheme 678

Using the assembly sleeve T10133/6, push the Teflon seal further onto the assembly cone T10133/5 until the Teflon seal is engaged in the seal groove. When doing this, do not use any lubricants.

Scheme 679

Note. By pushing the Teflon seal onto the fuel injector, the Teflon seal is expanded. For this reason, the Teflon seal must be contracted again, once it has been pushed on. This is done in two steps. The procedure for this is as follows.

The 1st step of calibrating (adapting) the Teflon seal is performed using the calibration sleeve T10133/7.

Using a rotating motion (approximately 180) and light pressure, push the calibration sleeve T10133/7 over the fuel injector up to the stop. Pull the calibration sleeve T10133/7 off again, rotating it in the opposite direction.

Scheme 680

The 2nd step of calibrating (adapting) the Teflon seal is performed using the calibration sleeve T10133/8.

Using a rotating motion (approximately 180) and light pressure, push the calibration sleeve T10133/8 over the fuel injector up to the stop. Pull the calibration sleeve T10133/8 off again, rotating it in the opposite direction.

Scheme 681

Replace O-ring on fuel injector. Coat the O-ring with clean engine oil before installing.

The Teflon seal must not be oiled.

Using the included nylon brush T10133/4, thoroughly clean the high-pressure fuel injector bores in the cylinder head before installing the fuel injectors.

Scheme 682

Note. Possibly an opened intake valve hinders the cleaning. In this case, engine must be turned further by hand using a wrench on the crankshaft.

Install fuel injector again with support ring -1- and clip in radial compensation -2- on support ring.

Scheme 683

Note. The Teflon sealing ring of fuel injector may not be oiled or greased. When installing the injector valve, make sure there is no cleaning product or oil in the holes in the cylinder head.

Using the assembly drift T10133/9, press the fuel injector into the intended bore in the cylinder head until it stops. Make sure fuel injectors are positioned correctly in cylinder head.

Scheme 684

Further installation is performed in reverse order.

Important: The following points must always be observed

Note. The Teflon sealing ring of fuel injector may not be oiled or greased. When installing the injector valve, make sure there is no cleaning product or oil in the holes in the cylinder head. Coat high pressure fuel injector O-rings with clean engine oil so they are easier to guide into the fuel rail. Replace all seals. The fuel rail should be placed on the fuel injectors and pressed on evenly. Install intake manifold with fuel rail. Refer to INTAKE MANIFOLD WITH FUEL RAIL

HEATED OXYGEN SENSOR AND OXYGEN SENSOR HEATER BEFORE CATALYTIC CONVERTER

Special tools and workshop equipment required

1. Ring spanner 7-piece set for oxygen sensor 3337

Removing the oxygen sensor

Remove engine cover. Refer to ENGINE COVER WITH AIR FILTER .

Disconnect electrical harness connector -1- of the Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19-.

Remove oxygen sensor -arrow- using tool from Ring Spanner 7 piece set 3337 -arrow-.

Installing the oxygen sensor

When installing, note the following

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with sensor slots. Hot bolt paste. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. Tightening specifications: 55 Nm.

OXYGEN SENSOR AFTER CATALYTIC CONVERTER AND OXYGEN SENSOR 1 HEATER

Special tools and workshop equipment required

1. Ring spanner 7-piece set for oxygen sensor 3337

Removing oxygen sensor

Remove nuts -1 and 2- on cover.

Scheme 685

Remove cover and disconnect electrical connector -arrow- on Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) -Z29-.

Remove Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) -Z29- -arrow- using a tool from the Ring Spanner Set3337.

Installing oxygen sensor

When installing, note the following

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with sensor slots. Hot bolt paste. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. Tightening specifications: 55 Nm.

ENGINE CONTROL MODULE

Special tools and workshop equipment required

Scheme 686

1. Heat gun -1- (from the wiring harness repair kit VAS 1978)
2. Nozzle attachment -2- (also from the wiring harness repair kit VAS 1978)
3. Commercially available locking pliers (vise grips) -3
4. Vehicle diagnostic, testing, and information system VAS 5051B

The engine control module -1- is connected with a metal retainer -2 and 5-. To make removing the shear bolts -4- for the retaining tabs -2- more difficult, the threads are coated with locking compound.

Scheme 687

To disconnect the connectors from the engine control module (e.g. to connect the test box or to replace the ECM), the protective housing must be removed.

Removing

If engine control module was replaced, select diagnostic object "Replacing engine control module (ECM)" in "Guided Functions"

Turn ignition and remove the ignition key.

Pry off the caps on the wiper arms using a screwdriver.

Loosen nuts -arrows- by several turns.

Scheme 688

Loosen wiper arms from the wiper axle by tilting slightly.

Then, remove nuts completely and remove wiper arms from the wiper axles.

Note. If it is not possible to remove the windshield wiper arms this way, use the puller T10369 or a commercially available puller.

Remove rubber seal -1- and remove plenum chamber cover -2-.

Scheme 689

Note. The plenum chamber cover could be damaged. Coat the transition area between the windshield and plenum chamber cover -2- with soapy water and carefully pull the cover vertically up out of the retainers on the windshield, beginning at the edge of the window.

Remove plenum chamber cover -2- by carefully pulling cover out of retainer on windshield.

Free up rear engine wiring harness on plenum chamber partition.

Open clips -arrows- and remove ECM.

Scheme 690

To increase the difficulty with which the ECM connectors can be accessed, the ECM is secured in a metal housing with retaining tabs and shear bolts.

The threads of the shear bolts -4- (that are not installed in ECM) are coated with a locking compound. For this reason, the threads must be heated with the heat gun to remove both bolts.

The threads of both shear bolts -3- (that are installed in ECM) are not coated with a locking compound. The threads in the ECM housing must not be heated and do not require to be heated (unintentional heating of the ECM).

Set the adjustment on the heat gun as shown in the illustration, with the temperature potentiometer -2- set to maximum heat and the two-stage air flow switch -3- set to level 3.

Scheme 691

Warm threads on connector side of shear bolts as shown in illustration.

Switch on heat gun and heat the bolt for approximately 20 to 30 seconds.

Scheme 692

Remove shear bolts with suitable locking pliers (see direction of arrow).

Scheme 693

Both shear bolts that are screwed into the ECM do not require heating to be removed. They can be removed without heat.

Disconnect metal retainers from connectors.

Remove both retainer bolts from ECM.

Disengage connector from ECM and remove connector.

Scheme 694

Remove used ECM and connect new one.

Installing

Install in reverse order of removal.

After that, the ECM must be equipped with the metal retainer.

Clean threaded holes for shear bolts of locking compound residue. Cleaning can be performed with a thread cutter (tap).

Always use new shear bolts.

After installing new Engine Control Module, the following work steps must be performed

Activate the engine control module in the "Guided Functions" operating mode under "Replace engine control module" on the vehicle diagnosis and service systemVAS 5052.

Scheme 695

Special tools and workshop equipment required

1. Pressure gauge K-Jetronic V.A.G 1318
2. Adapter V.A.G 1318/11
3. Adapter V.A.G 1318/17-1 from adapter kit V.A.G 1318/17
4. Double connection V.A.G 1318/23
5. Remote control V.A.G 1348/3 A with adapter cable V.A.G 1348/3-3
6. Connector test kit V.A.G 1594 C or V.A.G 1594 A

Special tools and workshop equipment required

Scheme 696

Scheme 697

Scheme 698

Scheme 699

Scheme 700

1. Adapter cable -V.A.G 1598/39-1
2. Adapter cable -V.A.G 1598/39-2
3. Test box -V.A.G 1598/42
4. Assembly tool T10118
5. Socket wrench insert 27 mm VAS 5301/7
6. Tool set with puller T10133
7. Ring spanner 7-piece set for oxygen sensor 3337
8. Heat gun -1- (from the wiring harness repair kit VAS 1978)

See also:
• IGNITION COILS WITH POWER OUTPUT STAGES
• Removal and Installation
• Diagnosis and Testing
• Removal and Installation
• Removal and Installation
• Removal and Installation
• BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM
• SAFETY PRECAUTIONS
• FUEL INJECTORS
• TEFLON COMBUSTION CHAMBER SEAL
• HEATED OXYGEN SENSOR AND OXYGEN SENSOR HEATER BEFORE CATALYTIC CONVERTER
• ENGINE CONTROL MODULE
• HIGH PRESSURE PUMP
• INTAKE FLAP MOTOR AND INTAKE MANIFOLD RUNNER POSITION SENSOR
• FUEL PRESSURE SENSOR
• MASS AIR FLOW SENSOR
• OXYGEN SENSOR AFTER CATALYTIC CONVERTER AND OXYGEN SENSOR 1 HEATER
• ENGINE COVER WITH AIR FILTER
• MASS AIR FLOW SENSOR
• AIR FILTER
• AIR FILTER HOUSING
• INTAKE MANIFOLD WITH FUEL RAIL
• FUEL PRESSURE AND RESIDUAL PRESSURE BEFORE HIGH PRESSURE PUMP, CHECKING
• FUEL RAIL
• HIGH PRESSURE PUMP ASSEMBLY OVERVIEW