3.2l - Multiport Fuel Injection - Engine Code(s): Cbra (roadster) Audi TT 8J

SAFETY PRECAUTIONS

To prevent personal injury and damage to the injection and ignition system, observe the following

1. The ignition must be switched off before connecting or disconnecting injection and ignition system wiring or tester cables.
2. Only clean engine with ignition switched off.
3. If electrical connectors were disconnected, faults are saved in ECM

Connect the vehicle diagnosis, testing and information system VAS 5051B while the ignition is switched off.

Start "Guided Functions" operating mode.

Generate readiness code in ECM.

Disconnect battery. Refer to [For transmission(s) 02E] Removal and Installation .

Note the following when working on the fuel system

If it is necessary to use testing and measuring devices on road tests, observe the following

Scheme 450

CLEAN WORKING CONDITIONS

Even a little contamination can lead to faults. When working on the fuel supply and on the fuel injection system, observe the following guidelines for a clean working environment

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. Immediately seal off lines and connections with clean plugs or protective caps.
3. Place parts that have been removed on a clean surface and cover them. Use lint-free cloths.
4. Carefully cover over opened components or seal, if repairs are not performed immediately.
5. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored unpacked (for example in tool boxes etc.).
6. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.
7. Protect disconnected electrical connectors from dirt and moisture and only connect if dry.

Scheme 451

1. 3-Pin Harness Connector For Knock Sensor (KS) 1 -G61- Component location (Scheme 463)
2. Knock Sensor (KS) 1 -G61- Component location (Scheme 463)
3. Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80
4. Heated Oxygen Sensor (HO2S) -G39- before Catalytic Converter with Oxygen Sensor (O2S) Heater -Z19- Component location (Scheme 455)Removal and installation, refer to «OXYGEN SENSORS BEFORE CATALYTIC CONVERTER»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__oxygen-sensors-before-catalytic-converter)
5. Electrical Connectors For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- with Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater -Z29- For Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- with Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater -Z30- Component location (Scheme 456)
6. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- with Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater -Z29- Component location (Scheme 458)Removal and installation, refer to «OXYGEN SENSORS AFTER CATALYTIC CONVERTER»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__oxygen-sensors-after-catalytic-converter)
7. Engine Control Module -J623- Removal and installation, refer to «ENGINE CONTROL MODULE»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__engine-control-module)
8. Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- with Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater -Z30- Component location (Scheme 458)Removal and installation, refer to «OXYGEN SENSORS AFTER CATALYTIC CONVERTER»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__oxygen-sensors-after-catalytic-converter)
9. Heated Oxygen Sensor (HO2S) 2 -G108- before Catalytic Converter with Oxygen Sensor (O2S) 2 Heater -Z28- Component location (Scheme 455)Removal and installation, refer to «OXYGEN SENSORS BEFORE CATALYTIC CONVERTER»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__oxygen-sensors-before-catalytic-converter)
10. Positive Crankcase Ventilation (PCV) Heating Element -N79
11. Ignition Coils with Power Output Stages Cylinder 1 Ignition Coil 1 with Power Output Stage -N70- Cylinder 2 Ignition Coil 2 with Power Output Stage -N127- Cylinder 3 Ignition Coil 3 with Power Output Stage -N291- Cylinder 4 Ignition Coil 4 with Power Output Stage -N292- Cylinder 5 Ignition Coil 5 with Power Output Stage -N323- Cylinder 6 Ignition Coil 6 with Power Output Stage -N324- Removal and installation, refer to «IGNITION COILS»(/audi/tt/8j-2006-2010/remont/ignition-system/#32l-ignitionglow-plug-system-engine-codes-cbra-roadster-as-of-072007__ignition-coils)
12. Throttle Valve Control Module -J338- With Throttle Drive (for Electronic Power Control (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
13. Electrical Connectors For Heated Oxygen Sensor (HO2S) -G39- before catalytic converter with Oxygen Sensor (O2S) Heater -Z19- For Heated Oxygen Sensor (HO2S) 2 -G108- before catalytic converter with Oxygen Sensor (O2S) 2 Heater -Z28- Component location (Scheme 454)
14. Mass Air Flow Sensor -G70- Removal and installation, refer to «MASS AIR FLOW SENSOR»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__mass-air-flow-sensor)
15. Clutch Position Sensor -G476- For vehicles with manual transmission Component location (Scheme 453)
16. Throttle Position (TP) Sensor -G79- and Accelerator Pedal Position Sensor 2 -G185- Component location (Scheme 452)
17. Instrument Cluster With Malfunction Indicator Lamp (MIL) -K83
18. Engine Compartment E-Box With Fuel Pump (FP) Relay -J17- With Motronic Engine Control Module (ECM) Power Supply Relay -J271- With Secondary air injection (AIR) pump relay -J299- Locations (Scheme 459)
19. Secondary Air Injection Sensor 1 -G609- For engine code CBRA only Component location (Scheme 467)
20. Camshaft Position (CMP) Sensor 2 -G163- Component location (Scheme 465)
21. Camshaft Adjustment Valve 1 (exhaust) -N318- Brown harness connector Component location (Scheme 465)
22. Camshaft Adjustment Valve 1 -N205- Black harness connector Component location (Scheme 465)
23. Camshaft Position Sensor -G40- Component location (Scheme 465)
24. Engine Coolant Temperature (ECT) Sensor -G62- Component location (Scheme 462)
25. Vacuum Actuator for Intake Manifold Flaps Checking, refer to «INTAKE MANIFOLD FLAP VACUUM ACTUATOR, CHECKING»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__intake-manifold-flap-vacuum-actuator-checking) Removal and installation, refer to «INTAKE MANIFOLD FLAP VACUUM ACTUATOR»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__intake-manifold-flap-vacuum-actuator)
26. Engine speed (RPM) sensor -G28- Component location (Scheme 460)
27. Intake Manifold Tuning (IMT) Valve -N156- Component location (Scheme 461)
28. Secondary Air Injection (AIR) Pump Motor -V101- Removal and installation, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cbra-roadster-as-of-032009)
29. Secondary Air Injection Solenoid Valve -N112- and Secondary Air Injection Solenoid Valve 2 -N320- For engine code CBRA only Component location (Scheme 466)
30. Knock Sensor (KS) 2 -G66- Component location (Scheme 464)
31. 3-Pin Harness Connector For Engine Speed (RPM) Sensor -G28- Component location (Scheme 460)
32. Fuel Injector Cylinder 1 Cylinder 1 Fuel Injector -N30- Cylinder 2 Cylinder 2 Fuel Injector -N31- Cylinder 3 Cylinder 3 Fuel Injector -N32- Cylinder 4 Cylinder 4 Fuel Injector -N33- Cylinder 5 Cylinder 5 Fuel Injector -N83- Cylinder 6 Cylinder 6 Fuel Injector -N84- Checking injection quantity, leaks and spray pattern of fuel injectors, refer to «FUEL INJECTORS, CHECKING INJECTION QUANTITY, SPRAY PATTERN AND FOR LEAKS»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__fuel-injectors-checking-injection-quantity-spray) Removal and installation, refer to «FUEL INJECTORS»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__fuel-injectors)

Scheme 452

1. To disconnect electrical harness connector -2-, press release button and pull off wiring -1-.
2. Removal and installation, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) .

Scheme 453

1. On clutch master cylinder -arrow-.
2. Removal and installation, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/clutches-manual-hydraulic/#clutch-manual-transmission-02q-awd-roadster) .

Scheme 454

1. Heated Oxygen Sensor (HO2S) 2 -G108- before catalytic converter with Oxygen Sensor (O2S) 2 Heater -Z28
2. Heated Oxygen Sensor (HO2S) -G39- before catalytic converter with Oxygen Sensor (O2S) Heater -Z19

Note. Ignore -3-.

Scheme 455

1. In front exhaust pipe.

1. Heated Oxygen Sensor (HO2S) 2 -G108- before catalytic converter with Oxygen Sensor (O2S) 2 Heater -Z28
2. Heated Oxygen Sensor (HO2S) -G39- before catalytic converter with Oxygen Sensor (O2S) Heater -Z19

Tighten the heated oxygen sensors (HO2S) to 55 Nm.

Scheme 456

1. At right beneath vehicle floor.

Remove nuts -1- and -2- on electrical connector bracket.

Note. Ignore -3-.

Remove cover.

Scheme 457

1. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- with Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater -Z29
2. Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- with Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater -Z30

Scheme 458

1. In the catalytic converters.

1. Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- with Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater -Z30
2. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- with Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater -Z29

Tighten the heated oxygen sensors (HO2S) to 55 Nm.

Scheme 459

2.1 - Fuel Pump (FP) 2 Relay -J49

2.2 - Coolant Circulation Pump Relay -J151

3 - Secondary Air Injection (AIR) Pump Relay -J299

4 - Motronic engine control module (ECM) power supply relay -J271

5 - Fuel pump (FP) relay -J17

Scheme 460

1. At front on engine.

1. 3-pin harness connector
2. Engine speed (RPM) sensor -G28

Scheme 461

1. On vacuum reservoir at front on engine -arrow-.

Scheme 462

1. At front left of cylinder head -arrow-.
2. Removal and installation, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/cooling-fan/#32l-cooling-system-engine-codes-cbra-roadster) .

Scheme 463

1. At right rear on cylinder block.

1. Knock Sensor (KS) 1 -G61
2. 3-pin harness connector

Scheme 464

1. Front at cylinder head -arrow-.

Scheme 465

1. Left on cylinder head.

1. Camshaft position sensor -G40
2. Camshaft position (CMP) sensor 2 -G163
3. Camshaft Adjustment Valve 1 -N205
4. Camshaft Adjustment Valve 1 (exhaust) -N318

Scheme 466

1. On vacuum reservoir at front on engine.

1. Secondary air injection (AIR) solenoid valve -N112
2. Secondary Air Injection (AIR) Solenoid Valve 2 -N320

1. Removal and installation, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cbra-roadster-as-of-032009) .

Scheme 467

1. Near the throttle valve control module -J338

1. Secondary Air Injection Sensor 1 -G609

1. Removal and installation, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cbra-roadster-as-of-032009) .

Note. Ignore -arrows-.

Scheme 468

1. Gasket Secured in bottom section of air filter housing
2. Front Air Guide Clean off dirt, leaves and salt residue
3. Bolt 2 Nm
4. Lower Section for Air Duct 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- Removal and installation, refer to «MASS AIR FLOW SENSOR»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__mass-air-flow-sensor)
10. Seal Replace if damaged
11. Upper Section of Air Filter Housing Removal and installation, refer to «AIR FILTER»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__air-filter)
12. Air Filter Removal and installation, refer to «AIR FILTER»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__air-filter) Always use an Original air filter Observe change intervals.
13. Lower Section of Air Filter Housing Removal and installation, refer to «AIR FILTER HOUSING»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__air-filter-housing) Clean off dirt, leaves and salt residue
14. Bolt 10 Nm
15. Rubber Grommet Permanent
16. Bolt 10 Nm
17. Air Filter Housing Bracket
18. Retaining Pin 10 Nm
19. Rubber Grommet

Scheme 469

1. Change-Over Roller
2. Bearing Bushing
3. O-ring Replace
4. Bolt
5. Bearing Cap
6. Intake Manifold
7. Bolt 20 Nm
8. Bolt 20 Nm
9. Seal
10. Connection for Crankcase Ventilation With Positive Crankcase Ventilation (PCV) Heating Element -N79
11. O-ring
12. Throttle Valve Control Module -J338- Removal and installation, refer to «THROTTLE VALVE CONTROL MODULE»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__throttle-valve-control-module)
13. Bolt 10 Nm
14. Bolt 20 Nm
15. Heat Shield for Exhaust Manifold With intake manifold support
16. Gasket Replace Insert in intake manifold
17. Bolt 13 Nm
18. Bolt 10 Nm
19. Vacuum Actuator For intake manifold flaps Checking, refer to «INTAKE MANIFOLD FLAP VACUUM ACTUATOR, CHECKING»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__intake-manifold-flap-vacuum-actuator-checking) Removal and installation, refer to «INTAKE MANIFOLD FLAP VACUUM ACTUATOR»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__intake-manifold-flap-vacuum-actuator)
20. Low Pressure Connection To Intake Manifold Tuning (IMT) Valve -N156
21. O-ring Replace
22. Bearing Bushing

Scheme 470

Tighten bolts -arrows- to 20 Nm.

Scheme 471

Tight the bolts -3- and -4- to 5 Nm.

Scheme 472

1. Fuel Rail
2. Secure the fuel line from the connector flange of the fuel tank using hose clamps appropriate for the model type WARNING: Remove fuel pump (FP) 2 relay -J49- before removing fuel hose «REMOVE FUEL PUMP (FP) 2 RELAY -J49- -2.1»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__remove-fuel-pump-fp-2-relay) .
3. Bolt 10 Nm
4. O-ring Removal and installation, refer to «FUEL INJECTORS»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__fuel-injectors) Replace Coat with clean engine oil
5. Retaining Clip After installing, check fuel injector is securely fastened
6. Fuel Injector
7. O-ring Removal and installation, refer to «FUEL INJECTORS»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__fuel-injectors) Replace Coat with clean engine oil

TEST DATA

FASTENER TIGHTENING SPECIFICATIONS

Oil Dipstick and Vacuum Reservoir - Tightening Specifications

Tight the bolts -3- and -4- to 5 Nm.

Engine Lifting Eye on the Cylinder Head - Tightening Specification

Tighten bolts -arrows- to 20 Nm.

Oil Dipstick and Vacuum Reservoir - Tightening Specifications

Tight the bolts -3- and -4- to 5 Nm.

INTAKE MANIFOLD FLAP VACUUM ACTUATOR, CHECKING

The test should only be done if there were complaints about reduced torque, elasticity or engine power.

Special tools and workshop equipment required

1. Hand Vacuum Pump VAS 6213

Procedure

Start engine.

Accelerate abruptly and observe linkage on back side of vacuum actuator when doing so.

Scheme 473

1. Linkage must move -arrow-.

If the linkage on the vacuum actuator does not move, check

1. the vacuum system for leaks.
2. the change-over mechanism linkage for ease of movement.
3. the vacuum lines for correct connection.
4. the vacuum hoses.

If no malfunction can be found

Remove air filter housing. Refer to AIR FILTER HOUSING .

Disconnect vacuum hose -3- on vacuum actuator.

Scheme 474

Note. Ignore -1 and 2- and -arrows-.

Connect Hand Vacuum Pump VAS 6213 to vacuum actuator connector as shown in illustration.

Scheme 475

Generate vacuum using hand vacuum pump.

Observe linkage on vacuum actuator when doing so

1. Linkage must move -arrow-.

Vent the hand vacuum pump.

1. Linkage must move back into output position.

Note. Check linkage movement sequence over entire adjustment range: it must move continuously without jerking.

If the linkage on the vacuum actuator does not move or moves with a jerk

Replace vacuum actuator. Refer to INTAKE MANIFOLD FLAP VACUUM ACTUATOR .

FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING

Note. Fuel pressure regulator is integrated in fuel filter and cannot be replaced individually.

Special tools and workshop equipment required

1. Hose Clamps Up to 25 mm Dia. 3094
2. Fuel Inj. Pressure Gauge-Cis V.A.G 1318 with Adapters V.A.G 1318/11, V.A.G 1318/17 and V.A.G 1318/23

Procedure

1. Fuel Pump (FP) Relay OK.
2. Fuel Pump (FP) OK, checking. Refer to «Diagnosis and Testing»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) .
3. Fuel filter OK.
4. Battery voltage min. 12.5 V.

Measuring fuel pressure

Scheme 476

Press both latches in direction of -arrow- and remove engine compartment E-box cover.

Remove Fuel Pump (FP) 2 Relay -J49- -2.1-.

Note. Removing the fuel pump (FP) 2 relay -J49- prevents the fuel pump from starting when the driver's door is opened.

Disconnect fuel supply line -arrow- by pulling release ring.

Scheme 477

Disconnect fuel supply line -arrow- from fuel rail.

Scheme 478

Connect V.A.G 1318 with V.A.G 1318/11, V.A.G 1318/17 and V.A.G 1318/23.

Scheme 479

Connect pressure gauge to fuel supply line.

Install a fuel-resistant auxiliary hose on fuel rail and on pressure gauge.

Note. Use hose clamps -arrows- to secure assisting hose.

Open shut-off valve of pressure gauge set.

1. The lever points in the direction of flow.

Start engine and let run at idle.

Measure fuel pressure.

1. Specified value: approximately 4.0 bar positive pressure

Switch off ignition.

If the specification is not obtained

Check delivery quantity of Fuel Pump (FP). Refer to Diagnosis and Testing .

Checking seal and residual pressure

Check for leaks and for residual pressure by observing the pressure loss on the pressure gauge.

1. After 10 minutes there must be a residual pressure of at least 3.0 bar.

If the residual pressure drops below 3.0 bar

Start engine and let run at idle.

Wait until pressure has built-up, and then switch off ignition. Simultaneously close shut-off valve of V.A.G 1318.

Scheme 480

1. Lever stands perpendicular to direction of flow -arrow-.

Observe pressure drop on pressure gauge.

If the pressure drops again

Check line connections, o-rings on fuel rail and injectors for leaks.

Check pressure gauge for leaks.

If the pressure does not drop

Open shut-off valve of pressure gauge (lever in direction of flow).

Remove rear seat bench. Refer to Removal and Installation .

Unclip catches -arrows- of right connector flange cover.

Scheme 481

Disconnect fuel return line -arrow- by pressing release button.

Scheme 482

Connect 1318/17-1 to fuel return line.

Scheme 483

Clamp off adapter piece using a 3094.

Note. 3094 must not be placed directly on fuel line, otherwise it may be damaged.

Cover return line connection with a cloth.

Start engine and let run briefly at idle.

Wait until pressure has built-up, and then switch off ignition.

Observe pressure drop on pressure gauge.

If pressure does not drop now, check-valve of fuel pump is malfunctioning.

Replace fuel pump. Refer to Removal and Installation .

If the pressure drops again

Replace fuel filter with integrated fuel pressure regulator. Refer to Removal and Installation .

Note. Before disconnecting pressure gauge, release pressure by opening shut-off valve. Hold a container in front of connection for this.

Assembly is in reverse order of removal, note the following

Note. Secure all hose connections with hose clamps appropriate for the model.

Reconnect fuel pump (FP) 2 relay -J49- -2.1- to relay and fuse holder.

Install rear seat bench. Refer to Removal and Installation .

FUEL INJECTORS, CHECKING INJECTION QUANTITY, SPRAY PATTERN AND FOR LEAKS

Special tools and workshop equipment required

1. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-2
2. Connector Test Set V.A.G 1594C
3. Adapter Cable, 121-Pin V.A.G 1598/31 (test box)
4. Injection Rate Tester V.A.G 1602

Procedure

1. Fuel pressure OK, checking, refer to «FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster__fuel-pressure-regulator-and-residual-pressure) .

Remove the intake manifold. Refer to INTAKE MANIFOLD .

Remove fuel rail with fuel injectors installed. Refer to FUEL RAIL WITH FUEL INJECTORS ASSEMBLY OVERVIEW . Fuel line remains connected.

Checking for Leaks

Press both latches in direction of -arrow- and remove engine compartment E-box cover.

Remove fuse in "position 1" -arrow- from "fuse holder 2" (brown) -2-.

Scheme 484

Connect V.A.G 1348/3A to V.A.G 1348/3-2 as follows

Scheme 485

1. On terminal on removed fuse to fuel pump
2. To "+" wire at front of engine compartment E-box.

Connect battery Ground (GND) cable.

Press switch on the V.A.G 1348/3 A.

1. Fuel Pump (FP) must run.

Check seal of fuel injectors via visual inspection.

1. With fuel pump running, only 1 to 2 drops per minute should escape from each fuel injector.

If the fuel loss is greater

Replace faulty fuel injector, Refer to FUEL INJECTORS .

Injection Quantity, Checking

Disconnect electrical harness connectors for fuel injectors.

Place a fuel injector into a graduated measuring glass of V.A.G 1602.

Connect one terminal of fuel injector to plus wire and an alligator clip from V.A.G 1594C to Ground (GND).

Scheme 486

Connect the second terminal of fuel injector to V.A.G 1348/3 A using V.A.G 1348/3-2.

Connect alligator clip to battery positive (positive terminal pick-off in engine compartment).

Connect auxiliary hose from V.A.G 1594C with fuse -arrow- to terminal on removed fused to fuel pump.

Scheme 487

Connect auxiliary hose with positive wire at front of engine compartment E-box.

1. Fuel Pump (FP) must run.

Press switch on remote control for 30 seconds V.A.G 1348/3 A.

Perform measurement at all fuel injectors using a new measuring glass for each.

Note. Also check spray pattern when testing injection quantity. Spray pattern must be the same for all injectors.

After all 6 fuel injectors were activated

Stop fuel pump by clamping off adapter cable.

Place measuring glasses on an even surface.

1. Specified value of injection quantity for each fuel injector: 128 to 140 ml.

If measured value of one or more fuel injectors is not within tolerance range

Replace faulty fuel injector. Refer to FUEL INJECTORS .

If the measured values of all fuel injectors are outside the specified range

Check fuel pressure. Refer to FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING .

Install fuel injectors together with fuel rail. Refer to INSTALLATION IS IN REVERSE ORDER OF REMOVAL, NOTE THE FOLLOWING .

Install intake manifold. Refer to INTAKE MANIFOLD .

Reinstall fuse in "position 1" -arrow- in "fuse holder 2" (brown) -2-.

WIRING AND COMPONENTS, CHECKING WITH TEST BOX

Special tools and workshop equipment required

1. Adapter Cable, 121-Pin V.A.G 1598/31 (test box)

Note. The V.A.G 1598/31 (test box) is designed so that it can be connected to ECM wiring harness and ECM itself at the same time. This is advantageous because electronic engine control remains fully functional (for example measurement of signals with engine running) when the test box is attached. Respective test procedures note whether Engine Control Module (ECM) must also be connected to the test box. To connect measuring instruments (for example voltage tester V.A.G 1527B, multimeter V.A.G 1526C etc.) always use connector test set V.A.G 1594C.

Procedure

Remove Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE .

Connect V.A.G 1598/31 (test box) to multi-pin harness connectors of wiring harness.

Scheme 488

Clamp test box Ground (GND) clip to Ground (GND).

The procedures will indicate whether the engine control module is to be connected to the test box.

Perform test as described in the respective repair procedures.

Install Engine Control Module (ECM) after completing test. Refer to ENGINE CONTROL MODULE .

AIR FILTER

Removing

Remove resonance tube -2- from air guide hose.

Scheme 489

Disconnect air guide hose -1- from throttle valve control module -J338-.

Separate the electrical connector -3- for mass air flow (MAF) sensor -G70-.

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

Installing

1. Tightening specifications, refer to «AIR FILTER ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster) .

Installation is in reverse order of removal, note the following

For trouble-free function of the Mass Air Flow (MAF) 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 air filter. 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.

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

Check Mass Air Flow (MAF) 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.

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 (MAF) sensor.

AIR FILTER HOUSING

Removing

Remove air filter element. Refer to AIR FILTER .

Remove bolts -arrows- and remove air duct.

Scheme 490

Remove lower section of air filter housing -arrows-.

Scheme 491

Installing

1. Tightening specifications, refer to «AIR FILTER ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster) .

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 (MAF) sensor, air duct pipes etc. with a clean cloth.

Blow out the 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 (MAF) 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).

MASS AIR FLOW SENSOR

Removing

Separate the electrical connector -1- for mass air flow (MAF) sensor -G70-.

Scheme 492

Remove air guide hose -arrows-.

Remove the bolts -arrows-.

Scheme 493

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/#32l-multiport-fuel-injection-engine-codes-cbra-roadster) .

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

For trouble-free function of the mass air flow (MAF) 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 air filter. Use a silicon-free lubricant to install the air duct hose. Secure all hose connections with hose clamps appropriate for the model.

INTAKE MANIFOLD

Removing

Note. All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

Clamp off battery Ground (GND) wire with ignition switched off.

Remove air filter element. Refer to AIR FILTER .

Remove air filter housing. Refer to AIR FILTER HOUSING .

Disconnect electrical connectors -1, 2, 3- and free up electrical wires.

Scheme 494

Disconnect crankcase ventilation hose -4-.

Remove ignition coils. Refer to IGNITION COILS .

Remove the Throttle Valve Control Module -J338-. Refer to THROTTLE VALVE CONTROL MODULE .

Remove vacuum hoses -1, 3, 4- back from intake manifold.

Scheme 495

Vehicles with engine code CBRA

Remove the vacuum hose -2- for the leak detection pump -V144-.

All Vehicles

Remove line union from intake manifold -arrows- and place it in the rear with hoses connected.

Remove bolts -arrows- for rear intake manifold mount.

Scheme 496

Disengage harness connector -arrow- for Engine Speed (RPM) Sensor -G28- from bracket on oil dipstick guide tube.

Scheme 497

Remove dipstick.

Remove bolt -3-, remove oil dipstick guide tube -2- and lay it aside.

Remove bolt -4- and remove vacuum reservoir -1- from intake manifold.

Set aside vacuum reservoir with lines still connected.

Release relay lever -arrow- and remove it.

Remove the bolts -1- and -2-.

Remove intake manifold change-over actuator from intake manifold and lay it aside with vacuum hose connected -3-.

Remove bolts -arrows- and remove left engine lifting eye.

Remove bolts -arrows- at front on intake manifold.

Scheme 498

To prevent surface damage to the intake manifold, lay a clean cloth -1- over the lock carrier.

Scheme 499

Tip intake manifold forward -arrow A- and remove it to the left -arrow B-.

Note. Seal intake channels in cylinder head with clean rags or foam pieces so that small pieces cannot fall in.

Installing

1. Tightening specifications, refer to «INTAKE MANIFOLD ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster) .

Installation is in reverse order of removal, note the following

Note. Replace seals.

Install ignition coils. Refer to IGNITION COILS .

Install throttle valve control module -J338-. Refer to THROTTLE VALVE CONTROL MODULE .

Install air filter housing. Refer to AIR FILTER HOUSING .

Install air filter insert. Refer to AIR FILTER .

Connect Ground (GND) cable to battery. Refer to [For transmission(s) 02E] Removal and Installation .

THROTTLE VALVE CONTROL MODULE

Removing

Remove air guide hose -arrows-.

Note. Ignore -1-.

Separate the electrical connector -3-.

Scheme 500

Disconnect crankcase ventilation hose -1-.

Free up oxygen sensor wires on throttle valve control module -J338-.

Note. Ignore -2-.

Remove the bolts -arrows-.

Scheme 501

Remove throttle valve control module -J338- from intake manifold.

Installing

1. Tightening specifications, refer to «INTAKE MANIFOLD ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster) .

Installation is in reverse order of removal.

INTAKE MANIFOLD FLAP VACUUM ACTUATOR

Removing

Release relay lever -arrow- and remove it.

Remove the bolts -1- and -2-.

Remove vacuum actuator from intake manifold.

Disconnect vacuum hose -3- on vacuum actuator.

Installing

1. Tightening specifications, refer to «INTAKE MANIFOLD ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster) .

Installation is in reverse order of removal, note the following

Note. Replace O-ring.

FUEL INJECTORS

Removing

Press both latches in direction of -arrow- and remove engine compartment E-box cover.

REMOVE FUEL PUMP (FP) 2 RELAY -J49- -2.1

Note. Removing the fuel pump (FP) 2 relay -J49- prevents the fuel pump from starting when the driver's door is opened.

Remove the intake manifold. Refer to INTAKE MANIFOLD .

Free up electrical wiring harness -1- on fuel rail.

Scheme 502

Remove the bolts -arrows-.

Remove fuel rail -2- with fuel injectors from cylinder head and lay it aside with fuel hose connected.

Pull off retaining clip and remove the relevant fuel injector.

Installing

1. Tightening specifications, refer to «FUEL RAIL WITH FUEL INJECTORS ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster) .

INSTALLATION IS IN REVERSE ORDER OF REMOVAL, NOTE THE FOLLOWING

1. Replace o-rings at all opened connection points. (Never remove plastic cap from valve head to replace front o-ring lift off o-ring over plastic cap).
2. Lubricate o-rings with clean engine oil.
3. Check that fuel injectors are installed in correct position.
4. Check clips for proper seating.
5. Place fuel rail with secured fuel injectors onto intake manifold, and apply uniform pressure to press it in.

Install intake manifold. Refer to INTAKE MANIFOLD .

Reconnect fuel pump (FP) 2 relay -J49- -item 2.1- to relay and fuse holder.

OXYGEN SENSORS BEFORE CATALYTIC CONVERTER

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Remove air filter element. Refer to AIR FILTER .

Remove air filter housing. Refer to AIR FILTER HOUSING .

Disconnect affected electrical connector.

1. heated oxygen sensor (HO2S) 2 -G108- before catalytic converter with oxygen sensor (O2S) 2 heater -Z28
2. heated oxygen sensor (HO2S) -G39- before catalytic converter with oxygen sensor (O2S) heater -Z19

Free up electrical wire to affected oxygen sensor.

Note. Ignore -3-.

Remove affected oxygen sensor with 3337/1.

1. Heated Oxygen Sensor (HO2S) 2 -G108- before catalytic converter with oxygen sensor (O2S) 2 heater -Z28
2. Heated Oxygen Sensor (HO2S) -G39- before catalytic converter with oxygen sensor (O2S) heater -Z19

Installing

1. Tightening specifications. (Scheme 455)

Installation is in reverse order of removal, note the following

Note. Coat new oxygen sensors with an assembly paste. When reinstalling the previously used oxygen sensor, coat thread with hot bolt paste. Assembly paste or hot bolt paste must not get on slits in sensor body. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.

Install air filter housing. Refer to AIR FILTER HOUSING .

Install air filter insert. Refer to AIR FILTER .

OXYGEN SENSORS AFTER CATALYTIC CONVERTER

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Removing

Remove nuts -1- and -2- on right electrical connector bracket under vehicle floor.

Note. Ignore -3-.

Remove cover and disconnect affected electrical connector.

1. Oxygen sensor (O2S) behind three way catalytic converter (TWC) -G130- with oxygen sensor (O2S) 1 (behind Three way catalytic converter (TWC)) heater -Z29
2. Oxygen sensor (O2S) 2 behind three way catalytic converter (TWC) -G131- with oxygen sensor (O2S) 2 (behind Three way catalytic converter (TWC)) heater -Z30

Remove connector from bracket and free up electrical wire to affected oxygen sensor.

Remove affected oxygen sensor with 3337/1.

1. Oxygen sensor (O2S) 2 behind three way catalytic converter (TWC) -G131- with Oxygen Sensor (O2S) 2 (behind three way catalytic converter (TWC)) heater -Z30
2. Oxygen sensor (O2S) behind three way catalytic converter (TWC) -G130- with oxygen sensor (O2S) 1 (behind three way catalytic converter (TWC)) heater -Z29

Installing

1. Tightening specifications (Scheme 458)

Installation is in reverse order of removal, note the following

Note. Coat new oxygen sensors with an assembly paste. When reinstalling the previously used oxygen sensor, coat thread with hot bolt paste. Assembly paste or hot bolt paste must not get on slits in sensor body. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. During installation, all cable ties must be installed at the same location.

ENGINE CONTROL MODULE

The multi-pin harness connectors of Engine Control Module (ECM) are equipped with a protective housing secured by a locking mechanism and shear bolts -arrows-. Also to impede removing of the shear bolts, their threads are coated with locking compound.

Scheme 503

The protective housing must be removed so that multi-pin harness connectors can be disconnected from ECM, for example to connect the test box or to replace the ECM.

Special tools and workshop equipment required

1. Hot Air Gun VAS 1978/14
2. Shrink Tip for Hot Air Gun VAS 1978/15
3. Locking Pliers (commercially available)

Removing

Turn the ignition and remove the ignition key.

Pry cover caps off windshield wiper arms using a screwdriver.

Loosen nuts -arrows- several turns.

Scheme 504

Loosen wiper arms one after another by tilting wiper axles slightly.

Remove nuts completely and remove wiper arms.

Note. If wiper arm cannot be removed in this way, use a standard puller.

Remove rubber seal -1- and remove plenum chamber cover -2- by carefully removing cover from retainers on windshield.

Scheme 505

Free up the rear engine wiring harness at the partition for plenum chamber.

Remove bolt -arrow- and remove engine control module (ECM) from bracket.

Scheme 506

Disconnect electrical connector -arrow- for body wiring harness -1-.

Scheme 507

Adjust settings on hot air gun as depicted in the illustration, this means potentiometer -2- for temperature setting at maximum heat output and two-stage switch -3- for air quantity at position "3".

Scheme 508

Note. Next, the thread of protective housing in which the shear bolts is threaded in is heated using the heat gun. This step decreases the locking effect of the locking compound on the thread of the shear bolts, thus allowing the shear bolts to be removed more easily. Cover all painted parts to prevent damage from the hot air gun or locking pliers.

Perform the following work steps in succession at both shear bolts -arrows-.

Place VAS 1978/15 on VAS 1978/14.

Scheme 509

Guide hot air gun shrink tip onto protective housing shear bolt.

Switch heat gun on and heat bolt for approximately 20 to 25 seconds.

Grip bolt head with pliers and remove shear bolt.

Scheme 510

Slide protective housing -arrow 1-.

Scheme 511

Disconnect electrical multi-pin connector -arrow 2-.

Note. Adaptation values are erased when connectors are disconnected from the Engine Control Module (ECM), DTC memory content remains intact.

Installing

Installation is in reverse order of removal, note the following

Install the engine control module in the housing.

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

Use new shear bolts.

After installing a new Engine Control Module (ECM), the following work steps must be performed

Activate engine control module (ECM) in "Guided Functions" under test sequence/function "Replacing engine control module (ECM)" => .

Scheme 512

Special tools and workshop equipment required

1. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-2
2. Connector Test Set V.A.G 1594C
3. Adapter Cable, 121-Pin V.A.G 1598/31 (test box)
4. Injection Rate Tester V.A.G 1602

Special tools and workshop equipment required

Scheme 513

Scheme 514

Scheme 515

Scheme 516

Scheme 517

1. Hand Vacuum Pump VAS 6213
2. Hose Clamps Up to 25 mm Dia. 3094
3. Fuel Inj. Pressure Gauge-Cis V.A.G 1318 with Adapters V.A.G 1318/11, V.A.G 1318/17 and V.A.G 1318/23
4. Ring Spanner 7-Piece Set 3337
5. Hot Air Gun VAS 1978/14 -item 1
6. Shrink Tip for Hot Air Gun VAS 1978/15 -item 2
7. Locking Pliers -3- (commercially available)

See also:
• [For transmission(s) 02E] Removal and Installation
• IGNITION COILS
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• OXYGEN SENSORS BEFORE CATALYTIC CONVERTER
• OXYGEN SENSORS AFTER CATALYTIC CONVERTER
• ENGINE CONTROL MODULE
• MASS AIR FLOW SENSOR
• INTAKE MANIFOLD FLAP VACUUM ACTUATOR, CHECKING
• INTAKE MANIFOLD FLAP VACUUM ACTUATOR
• FUEL INJECTORS, CHECKING INJECTION QUANTITY, SPRAY PATTERN AND FOR LEAKS
• FUEL INJECTORS
• AIR FILTER
• AIR FILTER HOUSING
• THROTTLE VALVE CONTROL MODULE
• REMOVE FUEL PUMP (FP) 2 RELAY -J49- -2.1
• INTAKE MANIFOLD ASSEMBLY OVERVIEW
• FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING
• INTAKE MANIFOLD
• INSTALLATION IS IN REVERSE ORDER OF REMOVAL, NOTE THE FOLLOWING