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Fuel Supply System (coupe) Audi TT 8J

Fuel System 83 illustrations ~12285 words

CLEAN WORKING CONDITIONS

Even a little contamination can lead to faults. When working on the fuel supply and 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. Seal the open lines and connections immediately with clean plugs, for example, from the engine bung set VAS 6122.
  3. Place removed parts on a clean surface and cover them. Use lint-free cloths.
  4. Carefully cover or plug unpacked components if repairs cannot be performed immediately.
  5. Only install clean components: Remove the replacement parts from their packaging just prior to installing them. 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 the disconnected connectors from dirt and moisture and only connect when they are dry.

CONTACT CORROSION

Contact corrosion can occur if incorrect fasteners (bolts, nuts, washers, etc.) are used.

For this reason, only connecting elements with a special surface coating are installed.

In addition, rubber or plastic parts and adhesive are made of materials that do not conduct electricity.

If you are not sure about the suitability of parts, install new parts.

Note. Only original replacement parts are recommended, they are checked and compatible with aluminum. It is recommended to use Audi accessories. Damage resulting from contact corrosion is not covered by the warranty.

LEAK DETECTION SYSTEM

Function

The leak detection system recognizes leaks in the complete fuel system, including the fuel tank, EVAP canister and Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80-.

On the mechanical side, the leak detection system consists mainly of a vacuum-driven diaphragm pump, that is equipped with a reed contact on the actuation rod of the pump diaphragm. The pump is supplied with vacuum via the mechanical vacuum pump or the engine intake stroke.

  1. When the leak detection is activated, the diaphragm pump pumps the fuel system up to 20 to 30 mbar. The pump diaphragm is then moved out so that the reed contact at the operating rod remains in the "open" position.
  2. During leak diagnosis, the reed contact is monitored to check if it remains open within 15 seconds. This indicates the fuel system is sealed.
  3. If pressure falls (indicating a leak), the diaphragm moves back and the reed contact closes.
  4. If reed contact closes within 15 seconds of leak detection time, a further test is performed: In this case the diaphragm pump pumps 4 times again. The Engine Control Module (ECM) measures the time for each of the 4 pumps until the reed contact is closed again. From that, the control module can recognize a "small leak" (smaller than 1 mm in diameter) or a "large leak".

The leak detection is activated automatically, shortly after each cold engine start (under 35 °C (95 °F)) and a continual drive faster than 10 km/h. In case a fault is detected, a Diagnostic Trouble Code (DTC) will be stored to memory. The Malfunction Indicator Lamp (MIL) in the instrument cluster lights up if the malfunction is recognized for 2 subsequent starts. Leak diagnosis can also be activated using the vehicle diagnosis, testing and information System VAS 5051B. Refer to LEAK DETECTION TEST, PERFORMING .

Note. After the cold start, the leak detection can be repeated up to 10 times within the first 20 minutes. It can be determined if an automatic leak diagnosis was recently performed by using the VAS 5051B in measured value block 071. Refer to LEAK DETECTION TEST, PERFORMING .

FUEL SYSTEM

Note the following when working on the fuel system

WARNINGThe very high fuel pressure on vehicles with an FSI engine can cause serious personal injury. Let the fuel pressure come down before opening any high pressure components in the fuel injection system. To reduce any remaining pressure, place a clean cloth over the connections and carefully loosen the connections.

Procedures before opening high pressure fuel injection system. Refer to [For engine(s) CETA, CCTA] General Information or to [For engine(s) CEPB] General Information or to [For engine(s) CBRA] General Information or to [For engine(s) BPY, CDMA] General Information .

Carry out the following measures before starting work on the fuel supply

WARNINGRisk of explosion due to cell phones. Keep cell phones out of reach in the work space area.
CAUTIONRisk of destroying electronic components when disconnecting the battery. Observe measures for disconnecting battery. Only disconnect the battery with ignition switched off.
  1. Disconnect the battery. Refer to «[For transmission(s) 02E] Removal and Installation»(/audi/tt/8j-2006-2010/remont/charging-system/#battery-starter-generator-cruise-control-coupe) .
  2. Open the fuel filler flap briefly and then close it again.

FOR TEST DRIVES WITH THE USE OF TEST AND MEASURING DEVICES

If testing equipment must be used during a road test, observe the following

Scheme 168

Scheme 168: FOR TEST DRIVES WITH THE USE OF TEST AND MEASURING DEVICES
Scheme 168: FOR TEST DRIVES WITH THE USE OF TEST AND MEASURING DEVICES
WARNINGDistraction and testing equipment that is not secured properly can cause accidents. The passenger airbag could pose a risk if it deploys in a collision. Operating testing equipment while driving causes it to shift position. There is an increased risk of injury due to unsecured testing equipment. TT Coupe: Always secure testing equipment on the rear seat using a strap and have a second person in the rear seat to operate it. TT Roadster: Position passenger's seat as far back as possible. Only use the vehicle diagnosis and service information System VAS 5052 A or diagnostic System VAS 5053. Testing and measuring instruments -1- must lay flat on the passenger's thighs and be operated by him or her, as shown in the illustration.

FULL OR PARTIALLY FULL FUEL TANKS, REMOVING AND INSTALLING

Note the following when removing and installing fuel tank components which are completely or partially filled

  1. The fuel tank may only be partially full. How much fuel can remain in the fuel tank may be read in the respective work description. Empty fuel tank if necessary. Refer to vehicles with front wheel drive «FUEL TANK, DRAINING»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) , for vehicles with all wheel drive «FUEL TANK, DRAINING»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__fuel-tank-draining) .
  2. Before starting work, switch on exhaust extraction system and place an extraction hose close to the installation opening of fuel tank to extract escaping fuel fumes. If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displacement greater than 15 m 3 /h can be used.
  3. Prevent fuel from contacting skin! Wear fuel-resistant gloves!

Note the following when removing and installing the fuel tank

  1. Fuel tank must be empty for weight reasons. Empty fuel tank if necessary. Refer to front-wheel drive «FUEL TANK, DRAINING»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) , all-wheel drive «FUEL TANK, DRAINING»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__fuel-tank-draining) .

TEST CONDITIONS

  1. Battery voltage at least 12.5 V.
  2. Fuel pump fuse OK, refer to the appropriate SYSTEM WIRING DIAGRAMS information.
  3. Fuel pump control module -J538- OK; check in "Guided Fault Finding" using a vehicle diagnostic tester operating mode.
  4. Fuel pump relay -J17- OK, refer to the appropriate SYSTEM WIRING DIAGRAMS information.
  5. Fuel tank minimum 1 / 4 full.
  6. Fuel filter OK.
  7. Fuel lines OK (not plugged, not kinked).
  8. Ignition switched off

FUEL TANK, DRAINING

Special tools and workshop equipment required

  1. Wrench T10202
  2. Fuel Extracting Device VAS 5190

Procedure

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Open the fuel filler door.

CAUTIONRisk of destroying electronic components when disconnecting the battery. Observe measures for disconnecting battery.

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

WARNINGRisk of explosion due to electrostatic charge. Secure the VAS 5190 Ground (GND) wire to a bare area of the chassis.

Remove the cone piece -2- from the shaft piece -1- on the VAS 5190.

Scheme 169

Scheme 169
Scheme 169

Using insulating tape, apply a mark -arrow- on hose at length -a- = 1370 mm from the end of suction hose.

Remove the fuel cap from the fuel filler tube.

Scheme 170

Scheme 170
Scheme 170

Install the VAS 5190 shaft piece on the fuel tank filler tube.

Slide suction hose as far into the fuel tank until the mark applied earlier -arrow- stands on shaft piece.

Note. If using a fuel siphoning device without shaft piece, proceed principally in the same manner. In this case, apply a mark -arrow- using insulating tape on hose at length -a- = 1305 mm from end of suction hose. The suction hose is inserted correctly when the marking applied earlier aligns with the lip of the fuel filler neck. If the hose can only be inserted with difficulty, coat it thinly with engine oil. Never use lubricants containing silicon.

Empty fuel tank as much as possible via fuel filler tube.

Carefully pull out the suction hose.

TT Coupe

Remove rear seat bench. Refer to Removal and Installation .

TT Roadster

Remove the left side rear panel trim panel. Refer to Removal and Installation .

All Vehicles

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

Scheme 171

Scheme 171
Scheme 171

Disconnect electrical harness connector -1- at locking flange.

Scheme 172

Scheme 172
Scheme 172

Disengage electrical harness connector -2- and lay it aside.

Remove locking ring with T10202.

Scheme 173

Scheme 173
Scheme 173

Carefully pull the fuel level sensor 2 -G169- -1- and suction jet pump partially out of the fuel tank opening.

Scheme 174

Scheme 174
Scheme 174

Note. When removing, be sure not to bend the floater arm of fuel level sensor 2.

Extract the fuel in the left half of the fuel tank through the opening using the VAS 5190.

Push the hose into the right chamber and extract any fuel still there.

Reinstall fuel level sensor 2 Fuel Level Sensor 2 -G169 , observing notes for connecting the battery.

SUCTION JET PUMP

The fuel tank in a vehicle with all-wheel drive is divided into a left and right chamber. To move the volume of fuel from the left fuel tank chamber -3- to the right baffle housing of the fuel delivery unit -2-, a suction jet pump -1- is utilized.

Scheme 175

Scheme 175: SUCTION JET PUMP
Scheme 175: SUCTION JET PUMP

Function of Suction Jet Pump

Function of the suction jet pump is based on a simple physical principle: A suction jet from the electrical fuel pump is compressed by a nozzle in the suction jet pump and is thereby accelerated. This acceleration causes the surrounding fuel to be drawn in and be forced to the baffle housing of the fuel delivery unit.

Malfunctions of Faulty Suction Jet Pump

CAUTIONTow-in due to faulty suction jet pump. If suction jet pump is faulty, the vehicle can stop running due to lack of fuel, though the fuel tank is up to 1 / 4 filled.

If the suction jet pump does not function, up to 15 liters of fuel (up to approximately 1 / 4 tank) remain in left chamber of fuel tank, because it can not be extracted by the fuel delivery unit.

If the vehicle stops running, although the fuel tank is approximately 1 / 4 filled, proceed as follows

Check fuel pump. Refer to FUEL PUMP ELECTRICAL, CHECKING .

If the fuel pump is OK, but no fuel is supplied

Fill fuel tank with approximately 5 liters of fuel.

Start the engine.

If the engine starts now

Replace suction jet pump. Refer to SUCTION JET PUMP .

Special tools and workshop equipment required

  1. Fuel Extracting Device VAS 5190

Procedure

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Open the fuel filler door.

CAUTIONRisk of destroying electronic components when disconnecting the battery. Observe measures for disconnecting battery.

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

WARNINGRisk of explosion due to electrostatic charge. Secure the VAS 5190 Ground (GND) wire to a bare area of the chassis.

Remove the cone piece -2- from the shaft piece -1- on the VAS 5190.

Using insulating tape, apply a mark -arrow- on hose at length -a- = 1370 mm from end of suction hose.

Remove the fuel cap from the fuel filler tube.

Install the VAS 5190 shaft piece on the fuel tank filler tube.

Slide suction hose as far into fuel tank until the mark applied earlier -arrow- stands on shaft piece.

Note. If using a fuel siphoning device without shaft piece, proceed principally in the same manner. In this case, apply a mark -arrow- using insulating tape on hose at length -a- = 1305 mm from end of suction hose. The suction hose is inserted correctly when the marking applied earlier aligns with the lip of the fuel filler neck. If the hose can only be inserted with difficulty, coat it thinly with engine oil. Never use lubricants containing silicon.

Drain fuel tank through fuel filler tube.

Carefully pull out the suction hose.

After completing work, connect battery. Observe safety precautions after connecting battery. Refer to [For transmission(s) 02E] Removal and Installation .

Scheme 176

Scheme 176: EVAP CANISTER AND TANK LEAK DETECTION SYSTEM, HOSE DIAGRAM
Scheme 176: EVAP CANISTER AND TANK LEAK DETECTION SYSTEM, HOSE DIAGRAM
  1. Vacuum Line From the engine to the leak detection pump -V144- Clipped into the bracket on the underbody
  2. Vent Line From EVAP canister to engine Clipped to fuel tank in fuel tank area Separating points at front and rear on fuel tank
  3. Fuel Filler Tube
  4. Vent Line From fuel filler tube to EVAP canister Clipped into the bracket on the underbody
  5. EVAP Canister Installed location: In the bottom of the spare wheel well Removing and Installing, refer to «EVAPORATIVE EMISSION (EVAP) CANISTER»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__evaporative-emission-evap-canister)
  6. Connecting Line From the leak detection pump to the EVAP canister Clipped into the bracket on the underbody
  7. Air Filter Housing For the leak detection pump
  8. Leak Detection Pump -V144- Installed location: Under wheel housing liner in left rear wheel housing Checking: In "Guided Fault Finding" using the vehicle diagnostic tester Removing and Installing, refer to «Leak Detection Pump (LDP) -V144»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__leak-detection-pump-ldp-v144)
  9. Vacuum Hose to Leak Detection Pump
  10. Vacuum Hose to Evaporative Emission (EVAP) Canister

Scheme 177

Scheme 177: EVAP CANISTER AND LEAK DETECTION SYSTEM, HOSE DIAGRAM
Scheme 177: EVAP CANISTER AND LEAK DETECTION SYSTEM, HOSE DIAGRAM
  1. Vacuum Line From the engine to the leak detection pump -V144- Clipped into the bracket on the underbody
  2. Vent Line From the EVAP canister to Evaporative Emission (EVAP) canister purge regulator valve 1 -N80- Clipped to fuel tank in fuel tank area Separating points at front and rear on fuel tank
  3. Fuel Filler Tube
  4. Vent Line From fuel filler tube to EVAP canister Clipped into the bracket on the underbody
  5. EVAP Canister Installed location: In the bottom of the spare wheel well Removing and Installing, refer to «EVAPORATIVE EMISSION (EVAP) CANISTER»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__evaporative-emission-evap-canister)
  6. Connecting Line From the leak detection pump to the EVAP canister Clipped into the bracket on the underbody
  7. Air Filter Housing For the leak detection pump
  8. Leak Detection Pump -V144- Installed location: Under wheel housing liner in left rear wheel housing Checking: In "Guided Fault Finding" using the vehicle diagnostic tester Removing and Installing, refer to «Leak Detection Pump (LDP) -V144»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__leak-detection-pump-ldp-v144)
  9. Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80- Installed location: At front in engine compartment
  10. Vacuum hose to Leak Detection Pump To disconnect, press release button on connection piece
  11. Vacuum hose to EVAP Canister To disconnect, press release button on connection piece

FUEL FILTER OVERVIEW

The fuel system without return flow on the Audi TT, the fuel pressure regulator is located in the fuel filter In this system, only the supply line is routed forward to the engine compartment. If the pressure in the fuel supply line goes above the specified maximum pressure, the fuel pressure regulator opens. Excess fuel is routed into a return line from the fuel filter and back into the fuel tank.

Scheme 178

Scheme 178: FUEL FILTER OVERVIEW
Scheme 178: FUEL FILTER OVERVIEW
  1. Fuel Filter with Pressure Regulator For TFSI engine with fuel pressure regulator 6.4 bar pressure For MPI engine with fuel pressure regulator 4 bar pressure Direction of flow is marked with arrows Do not interchange connections Installed position: Pin on filter housing must engage in recess of guide on filter bracket. Refer to «INSTALLED LOCATION»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) . Removing and Installing, refer to «FUEL FILTER»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__fuel-filter)
  2. Fuel Supply Line From the fuel tank To disconnect, press release button on connection piece
  3. Fuel Return Line To fuel tank To disconnect, press release button on connection piece
  4. Fuel Line To engine To disconnect, press release button on connection piece
  5. Bolt 1. Nm
  6. Fuel Filter Bracket Attached to the fuel tank

Scheme 179

Scheme 179: EVAP CANISTER AND LEAK DETECTION SYSTEM OVERVIEW
Scheme 179: EVAP CANISTER AND LEAK DETECTION SYSTEM OVERVIEW
  1. Vent line To fuel tank filler tube To disconnect, press release button on connection piece
  2. Vent line To Evaporative Emission (EVAP) canister purge regulator valve 1 -N80- To disconnect, press release button on connection piece
  3. Clamp Must be appropriate for the model type.
  4. Connecting Hose
  5. Nut 4 Nm
  6. Vacuum Line To engine
  7. Rubber Bushing
  8. Bracket
  9. Leak Detection Pump -V144- Installed location: Under wheel housing liner in left rear wheel housing Checking: In "Guided Fault Finding" using the vehicle diagnostic tester Removing and Installing, refer to «Leak Detection Pump (LDP) -V144»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__leak-detection-pump-ldp-v144)
  10. Connecting Line To disconnect, press release button on connection piece
  11. Bolt 4 Nm
  12. Bracket
  13. Air Filter Housing For the leak detection pump
  14. Bolt 4 Nm
  15. EVAP Canister Installed location: In the bottom of the spare wheel well Removing and Installing, refer to «EVAPORATIVE EMISSION (EVAP) CANISTER»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__evaporative-emission-evap-canister)
  16. Bushing
  17. Bolt 8 Nm

Scheme 180

Scheme 180: ACCELERATOR PEDAL MODULE OVERVIEW, VERSION 1
Scheme 180: ACCELERATOR PEDAL MODULE OVERVIEW, VERSION 1
  1. Wiring Router Connected to accelerator pedal module
  2. Electrical Harness Connector
  3. Accelerator Pedal Module With accelerator pedal position sensor -G79- and accelerator pedal position sensor 2 -G185- Removing and Installing, refer to «ACCELERATOR PEDAL MODULE, VERSION 1»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__accelerator-pedal-module-version-1)
  4. Cap
  5. Bolt 9 Nm

Scheme 181

Scheme 181: ACCELERATOR PEDAL MODULE OVERVIEW, VERSION 2
Scheme 181: ACCELERATOR PEDAL MODULE OVERVIEW, VERSION 2
  1. Cap
  2. Bolt 9 Nm
  3. Electrical Harness Connector
  4. Accelerator Pedal Module With accelerator pedal position sensor -G79- and accelerator pedal position sensor 2 -G185- Removing and Installing, refer to «ACCELERATOR PEDAL MODULE, VERSION 2»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__accelerator-pedal-module-version-2)

Scheme 182

Scheme 182: FUEL TANK WITH ATTACHMENTS OVERVIEW
Scheme 182: FUEL TANK WITH ATTACHMENTS OVERVIEW
  1. Nut 23 Nm
  2. Fuel Tank Heat Shield With carrier plate
  3. Nut 23 Nm
  4. Fuel Line To engine To disconnect, press release button on connection piece
  5. Vent Line From the EVAP canister to Evaporative Emission (EVAP) canister purge regulator valve 1 -N80- Clipped in on fuel tank
  6. Electrical Harness Connector For transfer fuel pump -G6- and fuel level sensor -G
  7. Protective Plate For fuel delivery connection
  8. Bolt 11 Nm
  9. Cover Attached to the fuel tank insert with a fastening device
  10. Ground Connection For discharging electrostatic charge Installed position (Scheme 185)Make sure the connector is securely seated. After installation, check electrical connection from fuel filler tube protective plate -7- to an empty place on the body using an Ohm meter; specified value: Approximately 0 ohms
  11. Vent Line From gravity valve to EVAP canister Clipped in on bracket in wheel housing To disconnect, press release button on connection piece
  12. Pop Rivet
  13. Fuel Tank Removing and Installing, refer to «FUEL TANK WITH ATTACHMENTS»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__fuel-tank-with-attachments)
  14. Mounting Strap Installed position: Locating point (hole) points in driving direction

Scheme 183

Scheme 183
Scheme 183

Ensure filler tube threaded connections -2 and 4- are free of corrosion so the Ground (GND) connection to the body is not affected.

Route GND connection -1- as shown in illustration.

Ensure GND connection connector -arrows- is seated firmly on protective plate -5- and on filler tube -3-.

WARNINGRisk of explosion due to electrostatic charge. After installing, check electrical connection on fuel filler neck metal ring to an empty spot on the body using an Ohm meter. Specified value: Approximately 0 ohms.

Scheme 184

Scheme 184: FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR -G- OVERVIEW
Scheme 184: FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR -G- OVERVIEW
  1. Fuel Level Sensor -G- Check the resistance values. Refer to «Fuel Level Sensor -G-, CHECKING»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__fuel-level-sensor-g-checking) Removing and Installing, refer to «Fuel Level Sensor -G»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__fuel-level-sensor-g)
  2. Fuel Delivery Unit with Locking Flange Fuel pump electrical, checking, refer to «FUEL PUMP ELECTRICAL, CHECKING»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__fuel-pump-electrical-checking) Checking residual pressure, refer to «[For engine(s) CETA, CCTA] Diagnosis and Testing»(ref-505666-S11835783052012100100000) or to «[For engine(s) CEPB] Diagnosis and Testing»(ref-505667-S01972312672012100100000) or to «[For engine(s) CBRA] Diagnosis and Testing»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-coupe) or to «[For engine(s) BPY, CDMA] Diagnosis and Testing»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-coupe) Removing and Installing, refer to «FUEL DELIVERY UNIT»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__fuel-delivery-unit) Fill the fuel tank with at least 5 liters of fuel.
  3. Seal Replace Install dry
  4. Fuel Supply Line To fuel filter Do not kink Attaches to connection with identification "V" at sealing flange To remove from locking flange, press release button
  5. Fuel Return Line From the fuel filter Do not kink Attaches to connection with identification "R" at sealing flange To remove from locking flange, press release button
  6. Electrical Harness Connector For transfer fuel pump -G6- and fuel level sensor
  7. Locking Ring 110 Nm Use Wrench T10202 for removing and installing
  8. Fuel Delivery Line From the suction jet pump to the fuel delivery unit Clipped to the fuel delivery unit
  9. Electrical Harness Connector For fuel level sensor 2 -G169
  10. Locking Ring 110 Nm Use T10202 for removing and installing
  11. Seal Replace Install dry
  12. Fuel Level Sensor 2 -G169- Only available together with -13- Installed position «PRESS LOCKING FLANGE DOWN AGAINST THE SPRING PRESSURE AND BRING IT INTO INSTALLATION POSITION»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__press-locking-flange-down-against-the) Check the resistance values. Refer to «FUEL LEVEL SENSOR 2 -G169-, CHECKING»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__fuel-level-sensor-2-g169-checking) Removing and installing, refer to «FUEL LEVEL SENSOR 2 -G169»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__fuel-level-sensor-2-g169)
  13. Suction Jet Pump With lines Only available together with -12- Removing and installing, refer to «SUCTION JET PUMP»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe)
  14. Suction Jet Pipe From fuel pump to suction jet pump To disconnect, press release button on connection piece

Scheme 185

Scheme 185: FUEL TANK WITH ATTACHMENTS OVERVIEW
Scheme 185: FUEL TANK WITH ATTACHMENTS OVERVIEW
  1. Nut 20 Nm
  2. Mounting Strap Installed position: Locating point (hole) points in driving direction
  3. Fuel Tank Heat Shield
  4. Nut 20 Nm
  5. Fuel Line To engine To disconnect, press release button on connection piece
  6. Vent Line From the EVAP canister to Evaporative Emission (EVAP) canister purge regulator valve 1 -N80- Clipped in on fuel tank
  7. Electrical Harness Connector For transfer fuel pump -G6- and fuel level sensor -G
  8. Protective Plate For fuel delivery connection
  9. Bolt 11 Nm
  10. Cover Attached to the fuel tank insert with a fastening device
  11. Bolt 11 Nm
  12. Ground (GND) Connection For discharging electrostatic charge Installed position (Scheme 187)Ensure connector is seated securely After installation, check electrical connection from fuel filler tube protective plate -7- to an empty place on the body using an Ohm meter; specified value: Approximately 0 ohms
  13. Vent Line From gravity valve to EVAP canister Clipped in on bracket in wheel housing To disconnect, press release button on connection piece
  14. Pop Rivet
  15. Fuel Tank Removing and Installing, refer to «FUEL TANK WITH ATTACHMENTS»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe)
  16. Nut 20 Nm
  17. Lock Washer 3 Nm Turn toward left to remove

Ensure filler tube threaded connections -2 and 4- are free of corrosion so the Ground (GND) connection to the body is not affected.

Route GND connection -1- as shown in illustration.

Ensure GND connection connector -arrows- is seated firmly on protective plate -5- and on filler tube -3-.

WARNINGRisk of explosion due to electrostatic charge. After installing, check electrical connection on fuel filler neck metal ring to an empty spot on the body using an Ohm meter. Specified value: Approximately 0 ohms.

Scheme 186

Scheme 186: FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR -G- OVERVIEW
Scheme 186: FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR -G- OVERVIEW
  1. Fuel Delivery Unit Different version. Fuel pump, vehicles with TFSI engine, checking electrically, refer to «FUEL PUMP, TESTING ELECTRICALLY»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__fuel-pump-testing-electrically) Checking residual pressure, refer to «[For engine(s) CETA, CCTA] Diagnosis and Testing»(ref-505666-S11835783052012100100000) or to «[For engine(s) CEPB] Diagnosis and Testing»(ref-505667-S01972312672012100100000) or to «[For engine(s) CBRA] Diagnosis and Testing»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-coupe) or to «[For engine(s) BPY, CDMA] Diagnosis and Testing»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-coupe) Removing and installing, refer to «FUEL DELIVERY UNIT»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) Fill the fuel tank with at least 5 liters of fuel.
  2. Seal Replace Install dry
  3. Fuel Supply Line To fuel filter Do not kink Attaches to connection with identification "V" at sealing flange To remove from locking flange, press release button
  4. Fuel Return Line Do not kink Attaches to connection with identification "R" at sealing flange To remove from locking flange, press release button
  5. Electrical Harness Connector For transfer fuel pump -G6- and fuel level sensor -G
  6. Locking Ring 110 Nm Use Wrench T10202 for removing and installing
  7. Fuel Level Sensor -G- Different versions. Check the resistance values. Refer to «Fuel Level Sensor -G-, CHECKING»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) Removing and installing, refer to «Fuel Level Sensor -G»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe)

FASTENER TIGHTENING SPECIFICATIONS

ComponentFastener SizeNm
Accelerator Pedal Module to Body Bolt9
Air Filter Housing to Bracket Bolt4
Bracket to Body Nut4
Bracket to Leak Detection Pump Bolt4
EVAP Canister to Underbody Bolt8
Fuel Filter Bracket Bolt1
Front Wheel Drive Vehicles
Fuel Tank Filler Tube to Underbody Bolt11
Fuel Tank to Underbody Nut20
Heat Shield to Fuel Tank Lock Washer3
Locking Ring to Fuel Tank110
Securing Strap to Underbody Nut20
All Wheel Drive Vehicles
Fuel Tank Filler Tube to Underbody Bolt11
Heat Shield to Underbody Nut23
Locking Ring to Fuel Tank110
Securing Strap to Underbody Nut23

LEAK DETECTION TEST, PERFORMING

Special tools and workshop equipment required

  1. Hose Clamps Up to 25 mm Dia. 3094

Diagnostic leak test occurs in "Guided Fault Finding" using the vehicle diagnostic tester.

Checking Fuel Supply and Tank Ventilation Systems for Leaks

Note. The following describes individual areas in the fuel supply and ventilation systems where leaks are possible. After repairing a possible leak, perform a leak test to ensure that leak was successfully repaired.

Turn off ignition.

Check whether the fuel filler cap of the fuel tank was completely sealed for the test.

Check whether seal of fuel filler cap was damaged or crimped. Replace if necessary.

Remove rear seat bench. Refer to Removal and Installation .

Unclip catches -arrows- of right connector flange cover.

Scheme 187

Scheme 187
Scheme 187

Note. Observe installation notes for locking flanges FUEL DELIVERY UNIT and FUEL DELIVERY UNIT .

AWD Vehicles

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

Note. Follow the installation instructions for the locking flange Fuel Level Sensor 2 -G169 .

All Vehicles

Check sealing rings seals under locking flanges are OK and lock rings are properly tightened on fuel tank. Also check the fuel line connections.

Visually check all wires and hose connections of fuel supply system and replace leaking lines, for example

  1. Line from EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80
  2. Lines from EVAP canister to Leak Detection Pump (LDP) -V144-.
  3. Line from fuel tank to EVAP canister (below heat shield for EVAP canister).
  4. Lines for tank ventilation (beneath right rear wheel housing liner).
  5. Fuel lines to engine.

Note. Leaks at lines and components of the tank system can sometimes be located using a nonflammable, environmentally compliant leak detection spray. For this, initiate leak diagnostic several times in sequence to build up pressure in the system. At leaking areas, bubbles will form.

Perform a visual inspection on the fuel system components and tank ventilation system

  1. Fuel tank
  2. EVAP canister
  3. Leak detection pump
  4. EVAP canister purge regulator valve 1

Note. Due to the form or function of the components, leaking areas may not always be localized by spraying on leak detection spray. It may be necessary to clamp off the relevant component using 3094 and initiate tank leak detection diagnostic. If the leak is no longer indicated, the component that was clamped off is faulty. If clamped off directly at the leak detection pump and a leak is still indicated, the leak detection pump itself is leaking.

FUEL LEVEL SENSOR -G-, CHECKING

Special tools and workshop equipment required

  1. Multimeter V.A.G 1526D
  2. Connector Test Set V.A.G 1594C

Procedure

TT Coupe

Remove rear seat bench. Refer to Removal and Installation .

TT Roadster

Remove the right side rear panel trim panel. Refer to Removal and Installation .

All Vehicles

Unclip catches -arrows- of right connector flange cover.

Disconnect the connector -arrow- from the locking flange.

Scheme 188

Scheme 188
Scheme 188

Connect multimeter between terminals -2 and 3- to measure resistance.

Scheme 189

Scheme 189
Scheme 189

Fuel level sensor installed

  1. Sensor at lower stop: Approximately 270 ohms.
  2. Sensor at upper stop: Approximately 70 ohms.

Note. To check resistance values "tank full" or "tank empty", the fuel delivery unit must be removed and the sensor floater must be placed in upper or lower end position. Refer to FUEL DELIVERY UNIT . If measured value is 0 ohms there is a short circuit. If measured value is there, there is an open circuit in the wiring. With fuel level sensor removed, the following values are obtained because of the greater deflection of the floater arm

Fuel level sensor removed

  1. Sensor at lower stop: Approximately 290 ohms.
  2. Sensor at upper stop: Approximately 60 ohms.

Connect multimeter between terminals -3 and 4- to measure resistance.

Fuel level sensor installed or removed

  1. Any sensor position: Approximately 340 ohms.

Assemble in reverse order of disassembling. Note the following

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

TT Roadster

Install the right side rear panel trim panel. Refer to Removal and Installation .

FUEL LEVEL SENSOR 2 -G169-, CHECKING

Special tools and workshop equipment required

  1. Multimeter V.A.G 1526D
  2. Connector Test Set V.A.G 1594C

Procedure

TT Coupe

Remove rear seat bench. Refer to Removal and Installation .

TT Roadster

Remove the left side rear panel trim panel. Refer to Removal and Installation .

All Vehicles

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

Disconnect electrical harness connector -1- at locking flange.

Note. Ignore -2-.

Connect multimeter between terminals -1 and 2- to measure resistance.

Scheme 190

Scheme 190
Scheme 190

Fuel level sensor 2 installed

  1. Sensor at lower stop: Approximately 270 ohms.
  2. Sensor at upper stop: Approximately 70 ohms.

Note. To check resistance values "tank full" or "tank empty", the fuel level sensor 2 must be removed and the sensor floater must be placed in upper or lower end position. Refer to Fuel Level Sensor 2 -G169 . If measured value is 0 ohms there is a short circuit. If measured value is there, there is an open circuit in the wiring. With fuel level sensor 2 removed, the following values are obtained because of the greater deflection of the floater arm

Fuel level sensor 2 removed

  1. Sensor at lower stop: Approximately 286 ohms.
  2. Sensor at upper stop: Approximately 50 ohms.

Connect multimeter between terminals -2 and 3- to measure resistance.

Fuel level sensor 2 installed or removed

  1. Any sensor position: Approximately 340 ohms.

Assemble in reverse order of disassembling. Note the following

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

TT Roadster

Install the left side rear panel trim panel. Refer to Removal and Installation .

FUEL PUMP CONTROL MODULE, CHECKING

  1. On vehicles with the TFSI engine, the fuel pump is supplied with voltage via the fuel pump control module -J538-.
  2. Fuel Pump (FP) Control Module -J538- testing occurs in "Guided Fault Finding" operating mode using the vehicle diagnostic tester.

FUEL PUMP DELIVERY RATE, CHECKING

Special tools and workshop equipment required

  1. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
  2. Adapter V.A.G 1318/11
  3. Adapter V.A.G 1318/17-1A
  4. Fuel Line Feed Adapter V.A.G 1318/23
  5. Remote Control V.A.G 1348/3A with Remote Control V.A.G 1348/3-3
  6. Connector Test Set V.A.G 1594C
  7. Measuring container, fuel-resistant

Procedure

Observe test conditions, refer to TEST CONDITIONS .

TT Coupe

Remove rear seat bench. Refer to Removal and Installation .

TT Roadster

Remove the right side rear panel trim panel. Refer to Removal and Installation .

All Vehicles

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

Disconnect the connector -arrow- from the locking flange.

Scheme 191

Scheme 191
Scheme 191

Connect V.A.G 1348/3A with V.A.G 1348/3-3 with an adapter cable from V.A.G 1594C at terminal -1-.

Scheme 192

Scheme 192
Scheme 192

Cover the second connector terminal of V.A.G 1348/3-3 with insulating tape to prevent short circuit -arrow-.

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

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

Remove the fuel cap from the fuel filler tube.

Vehicles with Toothed Belt Drive

Disengage fuel line on bracket and remove heat shield -1- on fuel line separating point.

Scheme 193

Scheme 193
Scheme 193
WARNINGThere is a risk of injury because the fuel is under high pressure. To reduce pressure in the fuel system, lay a clean cloth around the connector and carefully loosen connector.

Disconnect fuel line -arrow- by pulling release ring.

Vehicles with Timing Chain Drive

Disconnect the fuel line by first stretching the boot -1- downward.

Scheme 194

Scheme 194
Scheme 194

First push the hose coupling -2- downward -arrow A-, then press the release buttons -arrow B-.

Remove the hose coupling with the release buttons pressed.

All Vehicles

Attach the V.A.G 1318/23 and V.A.G 1318/17-1A to V.A.G 1318.

Scheme 195

Scheme 195
Scheme 195

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

Attach V.A.G 1318/11 to V.A.G 1318.

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

Open shut-off valve of pressure gauge set.

  1. The lever points in the direction of flow.

Generate pressure in the fuel system by pressing the switch of the remote control and slowly closing the shut-off valve of the pressure gauge.

  1. Specified value: 4 bar positive pressure.

From this point on do not move position of shut-off valve.

Empty the measuring container.

Press the switch on the remote control for 15 seconds.

Compare quantity of the fuel delivered with minimum delivery rate in diagram (cm 3 /15s).

Scheme 196

Scheme 196
Scheme 196

Note. Voltage at fuel pump with engine stopped and pump running is approximately 2 volts less than battery voltage.

If minimum delivery quantity is not obtained, the following malfunctions may be present

  1. Fuel lines pinched.
  2. Fuel filter clogged.
  3. Fuel pump faulty.

Assemble in reverse order of disassembling. Note the following

TT Roadster

Install the right side rear panel trim panel. Refer to Removal and Installation .

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

Special tools and workshop equipment required

  1. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
  2. Adapter V.A.G 1318/11
  3. Adapter V.A.G 1318/17-1A
  4. Fuel Line Feed Adapter V.A.G 1318/23
  5. Remote Control V.A.G 1348/3A with Remote Control V.A.G 1348/3-3
  6. Connector Test Set V.A.G 1594C
  7. Measuring container, fuel-resistant

Procedure

Observe test conditions, refer to TEST CONDITIONS .

TT Coupe

Remove rear seat bench. Refer to Removal and Installation .

TT Roadster

Remove the right side rear panel trim panel. Refer to Removal and Installation .

All Vehicles

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

Disconnect the connector -arrow- from the locking flange.

Connect V.A.G 1348/3A with V.A.G 1348/3-3 with an adapter cable from V.A.G 1594C at terminal -1-.

Cover the second connector terminal of V.A.G 1348/3-3 with insulating tape to prevent short circuit -arrow-.

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

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

Remove the fuel cap from the fuel filler tube.

Disengage fuel line on bracket and remove heat shield -1- on fuel line separating point.

Scheme 197

Scheme 197
Scheme 197
WARNINGThere is a risk of injury because the fuel is under high pressure. To reduce pressure in the fuel system, lay a clean cloth around the connector and carefully loosen connector.

Disconnect the fuel line -3- by pulling release ring -2-.

Attach the V.A.G 1318/23 and V.A.G 1318/17-1A to V.A.G 1318.

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

Attach the V.A.G 1318/11 to V.A.G 1318.

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

Open shut-off valve of pressure gauge set.

  1. The lever points in the direction of flow.

Generate pressure in the fuel system by pressing the switch of the remote control and slowly closing the shut-off valve of the pressure gauge.

  1. Specified value: 4 bar positive pressure.

From this point on do not move position of shut-off valve.

Empty the measuring container.

Press the switch on the remote control for 15 seconds.

Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15s).

Scheme 198

Scheme 198
Scheme 198

Note. Voltage at fuel pump with engine stopped and pump running is approximately 2 volts less than battery voltage.

If minimum delivery quantity is not obtained, the following malfunctions may be present

  1. Fuel lines pinched.
  2. Fuel filter clogged.
  3. Fuel pump faulty.

Assemble in reverse order of disassembling. Note the following

TT Roadster

Install the right side rear panel trim panel. Refer to Removal and Installation .

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

Special tools and workshop equipment required

  1. Adapter V.A.G 1318/17-1 from Adapter for VAG 1318 V.A.G 1318/17
  2. Remote Control V.A.G 1348/3A with Remote Control V.A.G 1348/3-3
  3. Connector Test Set V.A.G 1594C
  4. Measuring container, fuel-resistant

Procedure

Observe test conditions, refer to TEST CONDITIONS .

Remove the fuel cap from the fuel filler tube.

TT Coupe

Remove rear seat bench. Refer to Removal and Installation .

TT Roadster

Remove the right side rear panel trim panel. Refer to Removal and Installation .

All Vehicles

Unclip catches -arrows- of right connector flange cover.

Disconnect the connector -arrow- from the locking flange.

Connect V.A.G 1348/3A with V.A.G 1348/3-3 with an adapter cable from V.A.G 1594C at terminal -1-.

Cover the second connector terminal of V.A.G 1348/3-3 with insulating tape to prevent short circuit -arrow-.

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

Connect alligator clip to battery positive.

WARNINGThere is a risk of injury because the fuel is under high pressure. To reduce pressure in the fuel system, lay a clean cloth around the connector and carefully loosen connector.

Press the release button and disconnect the fuel return line -arrow-.

Scheme 199

Scheme 199
Scheme 199

Connect V.A.G 1318/17-1 to disconnected fuel return line and hold it in a measuring container.

Scheme 200

Scheme 200
Scheme 200

Press the switch on the remote control for 15 seconds.

Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15s).

Note. Voltage at fuel pump with engine stopped and pump running is approximately 2 volts less than battery voltage.

If minimum delivery quantity is not obtained, the following malfunctions may be present

  1. Fuel lines pinched.
  2. Fuel filter clogged.
  3. Fuel pump faulty.

Assemble in reverse order of disassembling. Note the following

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

TT Roadster

Install the right side rear panel trim panel. Refer to Removal and Installation .

FUEL PUMP ELECTRICAL, CHECKING

Special tools and workshop equipment required

  1. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-2
  2. Multimeter V.A.G 1526D
  3. Connector Test Set V.A.G 1594C

Procedure

Observe test conditions, refer to TEST CONDITIONS .

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

Scheme 201

Scheme 201
Scheme 201

Remove fuse -arrow- at position 1 from "fuse carrier ST2" (brown) -2-.

Scheme 202

Scheme 202
Scheme 202

Connect V.A.G 1348/3A with V.A.G 1348/3-2 to terminal on fuse to fuel pump and battery positive.

Scheme 203

Scheme 203
Scheme 203

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

  1. Running noise of pump must be audible.

Note. The fuel pump runs quietly. Avoid surrounding noises while testing the fuel pump.

If no operating noise can be heard

TT Coupe

Remove rear seat bench. Refer to Removal and Installation .

TT Roadster

Remove the right side rear panel trim panel. Refer to Removal and Installation .

All Vehicles

Unclip catches -arrows- of the right connector flange cover.

Disconnect the connector -arrow- from the locking flange.

Connect multimeter between terminal -1 and 5- of harness connector for voltage measurement.

Scheme 204

Scheme 204
Scheme 204

Press the switch on the remote control.

  1. Specified value: approximately battery voltage.

If the specification is not obtained

Repair open circuit in wiring according to wiring diagram.

If specified value is obtained, although no running-noise can be heard at pump

Install the fuel delivery unit. Refer to FUEL DELIVERY UNIT .

Check if the electrical wiring between the flange and fuel pump is connected and has continuity.

Scheme 205

Scheme 205
Scheme 205

If no fault is detected in the wiring

Fuel pump faulty. Replace the fuel delivery unit.

Assemble in reverse order of disassembling. Note the following

Install the fuel delivery unit. Refer to FUEL DELIVERY UNIT .

TOOTHED BELT DRIVE, PERFORMING A FUEL PUMP ADAPTATION AFTER REPLACING FUEL DELIVERY UNIT

Note. On vehicles with the TFSI engine with toothed belt drive, the Engine Control Module (ECM) must be adapted after replacing the fuel delivery unit. This is not necessary on vehicle equipped with a TFSI engine with timing chain drive.

Special tools and workshop equipment required

  1. Vehicle Diagnostic, Testing, and Information System VAS 5051B

Procedure

  1. No faults in Diagnostic Trouble Code (DTC) memory.

Connect the VAS 5051B to the Data Link Connector (DLC) -arrow- and start the engine.

Scheme 206

Scheme 206
Scheme 206

Select the following menu entries

  1. "OBD"
  2. "01- Engine electronics"
  3. "Basic setting display group 103"
  4. "Activate"

Check reading in display field "4".

Scan tool display: "ADP in progress". After the fuel pump adaptation is completed, the display shows "ADP OK".

Note. If "ADP not OK" is displayed: Check the DTC memory.

End the "OBD".

Turn the ignition off and disconnect the DLC.

FUEL PUMP, TESTING ELECTRICALLY

Special tools and workshop equipment required

  1. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-2
  2. Multimeter V.A.G 1526D
  3. Connector Test Set V.A.G 1594C
  4. Remote Control V.A.G 1348/3-3

Procedure

Observe test conditions, refer to TEST CONDITIONS .

TT Coupe

Remove rear seat bench. Refer to Removal and Installation .

TT Roadster

Remove the right side rear panel trim panel. Refer to Removal and Installation .

All Vehicles

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

Disconnect the connector -arrow- from the locking flange.

Connect the V.A.G 1348/3A with V.A.G 1348/3-3 with an adapter cable from V.A.G 1594C at terminal -1-.

Cover the second connector terminal of V.A.G 1348/3-3 with insulating tape to prevent short circuit -arrow-.

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

Connect alligator clip to battery positive.

Press the switch on the remote control.

  1. Running noise of pump must be audible.

Note. The fuel pump runs quietly. Avoid surrounding noises while testing the fuel pump.

If no operating noise can be heard

Install the fuel delivery unit. Refer to FUEL DELIVERY UNIT .

Check if the electrical wiring between the flange and fuel pump is connected and has continuity.

If no fault is detected in the wiring

Fuel pump faulty. Replace the fuel delivery unit.

Assemble in reverse order of disassembling. Note the following

TT Roadster

Install the right side rear panel trim panel. Refer to Removal and Installation .

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

  1. On vehicles with the TFSI engine, the fuel pump is supplied with voltage via the Fuel Pump (FP) control module -J538-.
  2. FP control module testing occurs in "Guided Fault Finding" operating mode using the vehicle diagnostic tester.

Special tools and workshop equipment required

  1. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
  2. Adapter V.A.G 1318/11
  3. Adapter V.A.G 1318/17-1A
  4. Fuel Line Feed Adapter V.A.G 1318/23
  5. Remote Control V.A.G 1348/3A with Remote Control V.A.G 1348/3-3
  6. Connector Test Set V.A.G 1594C
  7. Measuring container, fuel-resistant

Procedure

Observe test conditions, refer to TEST CONDITIONS .

TT Coupe

Remove rear seat bench. Refer to Removal and Installation .

TT Roadster

Remove the right side rear panel trim panel. Refer to Removal and Installation .

All Vehicles

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

Disconnect the connector -arrow- from the locking flange.

Connect the V.A.G 1348/3A with V.A.G 1348/3-3 with an adapter cable from V.A.G 1594C at terminal -1-.

Cover the second connector terminal of V.A.G 1348/3-3 with insulating tape to prevent short circuit -arrow-.

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

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

Remove the fuel cap from the fuel filler tube.

Vehicles with Toothed Belt Drive

Disengage fuel line on bracket and remove heat shield -1- on fuel line separating point.

WARNINGThere is a risk of injury because the fuel is under high pressure. To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

Disconnect fuel line -arrow- by pulling release ring.

Vehicles with Timing Chain Drive

Disconnect the fuel line by first stretching the boot -1- downward.

First push the hose coupling -2- downward -arrow A-, then press the release buttons -arrow B-.

Remove the hose coupling with the release buttons pressed.

All Vehicles

Attach V.A.G 1318/23 and V.A.G 1318/17-1A to V.A.G 1318.

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

Attach the V.A.G 1318/11 to V.A.G 1318.

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

Open shut-off valve of pressure gauge set.

  1. The lever points in the direction of flow.

Generate pressure in the fuel system by pressing the switch of the remote control and slowly closing the shut-off valve of the pressure gauge.

  1. Specified value: 4 bar positive pressure.

From this point on do not move position of shut-off valve.

Empty the measuring container.

Press the switch on the remote control for 15 seconds.

Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15s).

Note. Voltage at fuel pump with engine stopped and pump running is approximately 2 volts less than battery voltage.

If minimum delivery quantity is not obtained, the following malfunctions may be present

  1. Fuel lines pinched.
  2. Fuel filter clogged.
  3. Fuel pump faulty.

Assemble in reverse order of disassembling. Note the following

TT Roadster

Install the right side rear panel trim panel. Refer to Removal and Installation .

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

Note. On vehicles with the TFSI engine with toothed belt drive, the Engine Control Module (ECM) must be adapted after replacing the fuel delivery unit. This is not necessary on vehicle equipped with a TFSI engine with timing chain drive.

Special tools and workshop equipment required

  1. Vehicle Diagnostic, Testing, and Information System VAS 5051B

Procedure

  1. No faults in DTC memory.

Connect the VAS 5051B to the Data Link Connector (DLC) -arrow- and start the engine.

Select the following menu entries

  1. "OBD"
  2. "01- Engine electronics"
  3. "Basic setting display group 103"
  4. "Activate"

Check reading in display field "4".

Scan tool display: "ADP in progress". After the fuel pump adaptation is completed, the display shows "ADP OK".

Note. If "ADP not OK" is displayed: Check the DTC memory.

End the "OBD".

Turn the ignition off and disconnect the DLC.

Special tools and workshop equipment required

  1. Multimeter V.A.G 1526D
  2. Connector Test Set V.A.G 1594C

Procedure

TT Coupe

Remove rear seat bench. Refer to Removal and Installation .

TT Roadster

Remove the right side rear panel trim panel. Refer to Removal and Installation .

All Vehicles

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

Disconnect the connector -arrow- from the locking flange.

Connect multimeter between terminals -2 and 3- to measure resistance.

Fuel level sensor installed

  1. Sensor at lower stop: Approximately 270 ohms.
  2. Sensor at upper stop: Approximately 70 ohms.

Note. To check resistance values "tank full" or "tank empty", the fuel delivery unit must be removed and the sensor floater must be placed in upper or lower end position. Refer to FUEL DELIVERY UNIT . If measured value is 0 ohms there is a short circuit. If measured value is there, there is an open circuit in the wiring. With fuel level sensor removed, the following values are obtained because of the greater deflection of the floater arm

Fuel level sensor removed

  1. Sensor at lower stop: Approximately 290 ohms.
  2. Sensor at upper stop: Approximately 50 ohms.

Connect multimeter between terminals -3 and 4- to measure resistance.

Fuel level sensor installed or removed

  1. Any sensor position: Approximately 340 ohms.

Assemble in reverse order of disassembling. Note the following

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

TT Roadster

Install the right side rear panel trim panel. Refer to Removal and Installation .

ACCELERATOR PEDAL MODULE, VERSION 1

Special tools and workshop equipment required

  1. Release Tool T10238

Removing

Remove cover for steering column -arrows-.

Scheme 207

Scheme 207
Scheme 207

Disconnect electrical harness connector -2-, by pressing release button to the stop -arrow-.

Scheme 208

Scheme 208
Scheme 208

Where necessary, pull the wiring router -1- off from the accelerator pedal module.

Pry off the cover using a screwdriver.

Remove the bolt.

Push the T10238 into the intended openings -arrow- as far as the stop, as shown, and remove the accelerator pedal module.

Scheme 209

Scheme 209
Scheme 209

Installing

  1. Tightening specification, refer to «ACCELERATOR PEDAL MODULE OVERVIEW, VERSION 1»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) .

Install in reverse order, paying attention to the following

Connect the wiring router -1- and the electrical connector -2- to the accelerator pedal module -5-.

Scheme 210

Scheme 210
Scheme 210
  1. The connector must engage audibly.

Push the accelerator pedal module onto the securing studs -6-.

Insert centering pin -7- into hole on the underbody.

Secure the accelerator pedal module with the bolt -3- and install the cap -4-.

Vehicles with Dual Clutch Transmission

Perform after the first kick-down adaptation in "Guided Functions" using the vehicle diagnostic tester.

ACCELERATOR PEDAL MODULE, VERSION 2

Special tools and workshop equipment required

  1. Release Tool T10238

Removing

Remove cover for steering column -arrows-.

Disconnect the connector -1- on the accelerator pedal module -3- by pulling the release -2- all the way up -arrow-.

Scheme 211

Scheme 211
Scheme 211

Pry off the cap -4- using a screwdriver.

Remove the bolt -5-.

Push the T10238 into the intended openings -arrow- as far as the stop, as shown, and remove the accelerator pedal module.

Installing

  1. Tightening specification, refer to «ACCELERATOR PEDAL MODULE OVERVIEW, VERSION 2»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) .

Install in reverse order, paying attention to the following

Connect the connector -2- on the accelerator pedal module -5-.

  1. The connector must engage audibly.

Push the accelerator pedal module onto the securing studs -6-.

Insert centering pin -7- into hole on the underbody.

Secure the accelerator pedal module with the bolt -3- and install the cap -4-.

Note. Ignore -1-.

Vehicles with Dual Clutch Transmission

Perform after the first kick-down adaptation in "Guided Functions" using the vehicle diagnostic tester.

EVAPORATIVE EMISSION (EVAP) CANISTER

Removing

Note. Checking for leaks, refer to LEAK DETECTION TEST, PERFORMING .

Remove rear section of the exhaust system. Refer to [For engine(s) CEPB] Description and Operation or to [For engine(s) CETA, CCTA] Description and Operation or to [For engine(s) CDMA] Description and Operation or to [For engine(s) CBRA] Description and Operation or to [For engine(s) BPY] Description and Operation .

Remove the heat shield from the rear muffler. Refer to Removal and Installation .

Disconnect the vent lines and connecting lines -3, 4 and 5- by pressing the release button.

Scheme 212

Scheme 212: EVAPORATIVE EMISSION (EVAP) CANISTER
Scheme 212: EVAPORATIVE EMISSION (EVAP) CANISTER

Remove bolts -1, 2 and 6-.

Release the retaining tabs in direction of -arrow- with a screwdriver and remove the EVAP canister.

Installing

  1. Tightening specification, refer to «EVAP CANISTER AND LEAK DETECTION SYSTEM OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) .

Installation is carried out in the reverse order while noting the following

Press on the vent and connecting lines until they engage audibly.

Install the heat shield on the rear muffler. Refer to Removal and Installation .

Install exhaust system. Refer to [For engine(s) CEPB] Removal and Installation or to [For engine(s) CETA, CCTA] Removal and Installation or to [For engine(s) CDMA] Removal and Installation or to [For engine(s) CBRA] Removal and Installation or to [For engine(s) BPY] Removal and Installation .

FUEL FILTER

Special tools and workshop equipment required

  1. Reservoir

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

TT Coupe

Remove rear seat bench. Refer to Removal and Installation .

TT Roadster

Remove the right side rear panel trim panel. Refer to Removal and Installation .

Vehicles with a 2.0L TFSI Engine

WARNINGRisk of escaping fuel. To prevent the fuel pump from running when the driver's door is opened, Fuel Pump (FP) control module -J538- must not be receiving any current.

Remove FP control module from locking flange cover and disconnect electrical connector -arrow-.

Scheme 213

Scheme 213
Scheme 213

Vehicles with MPI Engine

WARNINGRisk of escaping fuel. To prevent the fuel pump from running when the driver's door is opened, the fuel pump must not be receiving any current.

Unclip catches -arrows- of the right connector flange cover.

Disconnect the connector -arrow- from the locking flange.

Note. Remove the fuel pump connector, this prevents the fuel pump from running when the driver's door is opened.

All Vehicles

Place the drip tray under the fuel filter.

WARNINGThere is a risk of injury because the fuel is under high pressure. To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

Remove fuel lines -1, 2, 3- by pressing release button.

Scheme 214

Scheme 214
Scheme 214

Remove the bolt -4-.

Remove fuel filter.

Installing

  1. Tightening specification, refer to «FUEL FILTER OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe__fuel-filter-overview) .

Install in reverse order, paying attention to the following

Scheme 215

Scheme 215: INSTALLED LOCATION
Scheme 215: INSTALLED LOCATION
  1. The direction of flow is marked on filter housing with arrows.
  2. Pin -2- on filter housing must engage in recess of guide -1- on filter bracket.

LEAK DETECTION PUMP (LDP) -V144

Removing

Remove rear left wheel housing liner. Refer to Removal and Installation .

Disconnect the bleed line -2- from the diagnosis pump and disengage it from the bracket -arrow-.

Scheme 216

Scheme 216: LEAK DETECTION PUMP (LDP) -V144
Scheme 216: LEAK DETECTION PUMP (LDP) -V144

Disconnect electrical connector -3-.

Disconnect vent line -5- by pressing release button.

Remove nuts -1 and 4-.

Disengage diagnostic pump with bracket.

Installing

  1. Tightening specification, refer to «EVAP CANISTER AND LEAK DETECTION SYSTEM OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) .

Installation is carried out in the reverse order while noting the following

  1. Vent line -5- must engage audibly.

Install left rear wheel housing liner. Refer to Removal and Installation .

FUEL TANK WITH ATTACHMENTS

Special tools and workshop equipment required

  1. Engine/Transmission Jack V.A.G 1383 A
  2. Hooks 3004

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Open the fuel filler door.

CAUTIONRisk of destroying electronic components when disconnecting the battery. Observe measures for disconnecting battery.

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

WARNINGRisk of accident due to weight of fuel tank. The fuel tank must be empty when removing it.

Drain the fuel tank. Refer to FUEL TANK, DRAINING .

Clean the area around the fuel filler tube.

Remove fuel filler cap -arrow- from fuel filler tube.

Scheme 217

Scheme 217
Scheme 217

Close off the opening of the fuel filler tube with a clean piece of foam to prevent dirt from falling in.

Remove the right rear wheel housing liner. Refer to Removal and Installation .

Scheme 218

Scheme 218
Scheme 218

Remove the bolts -3 and 4- from the fuel filler tube.

Remove the ventilation line -2- from the EVAP canister.

Remove the electrical wiring -1- for the ABS speed sensor from the fuel filler tube bracket.

Free up overflow hose -5- on fuel filler tube.

Remove diagonal braces. Refer to Removal and Installation .

Scheme 219

Scheme 219
Scheme 219

Disconnect the vent line -arrow- to EVAP canister by pressing release button.

CAUTIONThe decoupling elements in the front exhaust pipe could get damaged. Flex joints in front exhaust pipe must not be bent more than 10°. Secure front section of the exhaust system on the underbody with a chain before loosening clamping sleeve bolts.

Separate exhaust system at clamping sleeve -1-.

Scheme 220

Scheme 220
Scheme 220

Tie up the front section of the exhaust system with a chain. To do this, engage 3004 in openings on underbody (remove plugs if necessary).

Scheme 221

Scheme 221
Scheme 221

Push the clamping sleeve rearward to separate the exhaust system.

Note. A second technician is needed to help remove the rear section of the exhaust system.

Unhook the rear muffler from the retaining loops and remove rear portion of exhaust system.

Remove the driveshaft. Refer to Removal and Installation .

Disconnect the right front vent line -2- on the fuel tank by pressing release button.

Scheme 222

Scheme 222
Scheme 222
WARNINGThere is a risk of injury because the fuel is under high pressure. To reduce the pressure in the fuel system, lay a clean cloth around the connector and carefully loosen connector.

Disconnect right front fuel line from the fuel tank.

WARNINGRisk of accident due to fuel tank weight. The fuel tank must be empty when removing it.

First remove bolts -2, 5 and 6-.

Scheme 223

Scheme 223
Scheme 223

Detach and free up the wiring harness -arrows-.

Place the V.A.G 1383 A under the fuel tank for support.

Remove bolts -1, 3, 4 and 7-.

CAUTIONDanger of twisting the electric wires too much. Do not pull on the electric wires when lowering the fuel tank.

Lower the fuel tank with the V.A.G 1383 A until the connectors on the locking flanges are accessible.

Scheme 224

Scheme 224
Scheme 224

Note. Both illustrations show the connectors installed on the locking flanges.

Disconnect electrical harness connector -1- at left locking flange.

Disengage the connector -2- from the Haldex clutch.

Disconnect electrical harness connector -arrow- at right locking flange.

Lower the fuel tank with the V.A.G 1383 A, thereby guiding it by hand.

By turning it accordingly, lower the fuel tank sideways and remove it.

A second technician is required to guide out the fuel filler tube by hand at the longitudinal member.

Installing

  1. For the correct tightening specifications, refer to «FUEL TANK WITH ATTACHMENTS OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) .

Install in reverse order, paying attention to the following

Position the fuel tank with mounting straps to underbody using the V.A.G 1383 A.

Attach wiring harness at top of the fuel tank.

Make sure the fuel tank is positioned so that the filler tube can be correctly guided into the opening of the body.

First tighten fuel tank at securing points -1, 3, 4 and 7- and then at -2, 5 and 6-.

Ensure filler tube threaded connections -2 and 4- are free of corrosion so the Ground (GND) connection to the body is not affected.

Tighten fuel filler tube bolts -4- and -5-.

Check if the GND wiring on both connections show signs of oxidation, remove if necessary.

Route GND connection -1- as shown in illustration.

Ensure GND connection connector -arrows- is seated firmly on protective plate -5- and on filler tube -3-.

WARNINGRisk of explosion due to electrostatic charge. After installing, check electrical connection on fuel filler neck metal ring to an empty spot on the body using an Ohm meter. Specified value: Approximately 0 ohms.

Attach the electrical wiring for the ABS speed sensor to the fuel filler tube bracket.

Install ventilation line to EVAP canister on filler tube.

Install rear right wheel housing liner. Refer to Removal and Installation .

Install the driveshaft. Refer to Removal and Installation .

Install the rear section of the exhaust system. Refer to [For engine(s) CEPB] Removal and Installation or to [For engine(s) CETA, CCTA] Removal and Installation or to [For engine(s) CDMA] Removal and Installation or to [For engine(s) CBRA] Removal and Installation or to [For engine(s) BPY] Removal and Installation .

TT Roadster

Install diagonal braces. Refer to Removal and Installation .

All Vehicles

Connect the battery. Observe safety precautions after connecting battery. Refer to [For transmission(s) 02E] Removal and Installation .

FUEL PUMP (FP) CONTROL MODULE

Removing

TT Coupe

Remove rear seat bench. Refer to Removal and Installation .

TT Roadster

Remove the right side rear panel trim panel. Refer to Removal and Installation .

All Vehicles

Remove Fuel Pump (FP) control module -J538- from locking flange cover and disconnect electrical connector -arrow-.

Unclip catches -arrows- of right connector flange cover.

Disconnect the connector -arrow- from the locking flange.

Installing

Install in reverse order, paying attention to the following

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

TT Roadster

Install the right side rear panel trim panel. Refer to Removal and Installation .

Special tools and workshop equipment required

  1. Engine/Transmission Jack V.A.G 1383 A

Removing

TT Coupe

Remove rear seat bench. Refer to Removal and Installation .

TT Roadster

Remove the right side rear panel trim panel. Refer to Removal and Installation .

All Vehicles

Disconnect the connector -3- from the locking flange cover.

Scheme 225

Scheme 225
Scheme 225

Remove the grommet -1- from the locking flange cover -2-.

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

Remove the locking flange cover.

Disconnect the connector -arrow- from the locking flange.

Disengage the parking brake cable -1- from the bracket.

Scheme 226

Scheme 226
Scheme 226

Remove the bolts -4-.

CAUTIONDanger of twisting the electric wires too much. Lower the fuel tank maximum 20 mm using the V.A.G 1383 A so that is it possible to remove the Fuel Pump (FP) control module with the wiring harness and connector.

Remove the bolts -3, 4 and 5-.

Lower the fuel tank maximum 20 mm using the V.A.G 1383 A.

Remove the bracket -3- and control module -2-.

Installing

Install in reverse order, paying attention to the following

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

TT Roadster

Install the right side rear panel trim panel. Refer to Removal and Installation .

FUEL DELIVERY UNIT

Special tools and workshop equipment required

  1. Wrench T10202

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

CAUTIONRisk of destroying electronic components when disconnecting the battery. Observe measures for disconnecting battery.

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

TT Roadster

CAUTIONIt is necessary to remove the fuel tank first in order to be able to remove the fuel delivery unit on the Audi TT Roadster.

Removing fuel tank, refer to FUEL TANK WITH ATTACHMENTS .

TT Coupe

WARNINGDanger due to escaping fuel. To prevent large quantities of fuel from coming out of fuel delivery unit when removing, fuel tank may only be a maximum of 1 / 3 full.

Empty fuel tank if necessary, refer to FUEL TANK, DRAINING .

Remove rear seat bench. Refer to Removal and Installation .

Unclip catches -arrows- of right connector flange cover.

Disconnect the connector -arrow- from the locking flange.

Mark the fuel supply line -1- and fuel return line -2-.

Scheme 227

Scheme 227
Scheme 227
WARNINGThere is a risk of injury because the fuel is under high pressure. To reduce the pressure in the fuel system, lay a clean cloth around the connector and carefully loosen connector.

Pull both lines from locking flange, by pressing the release buttons.

TT Roadster

Mark the fuel supply -1- and the fuel return -2- lines on the removed fuel tank.

Pull both lines from locking flange, by pressing the release buttons.

TT Coupe

WARNINGDanger due to escaping fuel. To prevent large quantities of fuel from coming out of fuel delivery unit when removing, fuel tank may only be a maximum of 1 / 3 full.

All Vehicles

Remove locking ring with T10202.

Pull the right sealing flange and seal of the fuel delivery unit out from the opening in the fuel tank and lay aside with lines still attached.

Through the fuel tank opening, separate the suction jet pipe -2- from suction jet pump, by pressing release button.

Scheme 228

Scheme 228
Scheme 228

Disconnect fuel delivery line -1- by pressing the release -arrow-.

Remove the fuel delivery unit.

Note. When removing fuel delivery unit, be sure not to bend floater arm on the fuel level sensor -G-. Be sure there is still some fuel inside the fuel delivery unit.

  1. Tightening specification, refer to «FUEL DELIVERY UNIT AND Fuel Level Sensor -G- OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) .

Install in reverse order, paying attention to the following

Note. Replace seal. Do not bend the fuel level sensor when inserting the fuel delivery unit. Make sure the fuel hoses are secure.

Insert the fuel delivery unit into fuel tank with locking flange set aside.

Push the fuel delivery line -1- on until it engages audibly.

Push the suction jet pipe -2- onto the suction jet pump until it engages audibly.

Install the new locking flange seal dry.

Scheme 229

Scheme 229
Scheme 229

Insert guide of locking flange into guide at fuel delivery unit, observing spring while doing so.

CAUTIONRisk of leaking. When inserting sealing flange, sealing ring must not be damaged or crushed.

Press locking flange down against spring pressure and bring it into installation position.

  1. The tab -2- on the locking flange faces toward the arrow marking and must lie between tabs -1 and 3- on the fuel tank.

Note. Arrow- points in direction of travel.

Tighten locking ring.

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

Connect the battery. Observe safety precautions after connecting battery. Refer to [For transmission(s) 02E] Removal and Installation .

TT Roadster

Installing fuel tank: Refer to vehicles with all wheel drive FUEL TANK WITH ATTACHMENTS .

All Vehicles

After installing fuel delivery unit, fill vehicle with at least 5 liters of fuel.

On vehicles with TFSI engine with toothed belt drive, a fuel pump adaptation must be performed after replacing the fuel delivery unit. Refer to TOOTHED BELT DRIVE, PERFORMING A FUEL PUMP ADAPTATION AFTER REPLACING FUEL DELIVERY UNIT .

FUEL LEVEL SENSOR -G

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

TT Roadster

CAUTIONIt is necessary to remove the fuel tank first in order to be able to remove the fuel delivery unit on the Audi TT Roadster.

Removing fuel tank. Refer to FUEL TANK WITH ATTACHMENTS .

All Vehicles

Install the fuel delivery unit. Refer to FUEL DELIVERY UNIT .

CAUTIONRisk of damage. Before disconnecting electrical connectors on the fuel level sensor, first release connector contact retaining tab.

Disconnect the connectors -1 through 3-.

Scheme 230

Scheme 230
Scheme 230

Pry on the retaining tabs -4 and 5- with a screwdriver and pull the fuel level sensor off downward -arrow-.

Installing

Install in reverse order, paying attention to the following

Insert the fuel level sensor in the guides on the fuel delivery unit and push upward until it engages.

Connect the electrical connections and check that they are securely engaged.

Install fuel delivery unit FUEL DELIVERY UNIT . Follow the instructions for connecting the battery.

FUEL LEVEL SENSOR 2 -G169

Special tools and workshop equipment required

  1. Wrench T10202

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

CAUTIONRisk of destroying electronic components when disconnecting the battery. Observe measures for disconnecting battery.

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

TT Roadster

CAUTIONIt is necessary to remove the fuel tank first in order to remove fuel level sensor 2 on the Audi TT Roadster.

Removing fuel tank. Refer to FUEL TANK WITH ATTACHMENTS .

TT Coupe

WARNINGDanger due to escaping fuel. To prevent large quantities of fuel from escaping when removing fuel level sensor 2, fuel tank may only be a maximum of 1 / 3 full.

Empty fuel tank if necessary. Refer to FUEL TANK, DRAINING .

Open the fuel filler flap briefly and then close it again.

Remove rear seat bench. Refer to Removal and Installation .

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

Disconnect electrical harness connector -1- at locking flange.

Disengage electrical harness connector -2- and lay it aside.

WARNINGDanger due to escaping fuel. To prevent large quantities of fuel from escaping when removing fuel level sensor 2, fuel tank may only be a maximum of 1 / 3 full.

All Vehicles

Remove locking ring with T10202.

Carefully pull fuel level sensor 2 - 2- and suction jet pump -1- partially out of the fuel tank opening.

Scheme 231

Scheme 231
Scheme 231

Remove seal.

Unclip suction jet pump from locking flange -arrows-.

Note. When removing, be sure not to bend floater arm of fuel level sensor 2.

  1. Tightening specification, refer to «FUEL DELIVERY UNIT AND Fuel Level Sensor -G- OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) .

Install in reverse order, paying attention to the following

Note. Replace seal. When inserting, be sure not to bend floater arm on fuel level sensor 2.

Carefully insert fuel level sensor 2 in fuel tank opening.

Clip the suction jet pump -1- to the locking flange so that it is audibly engaged.

Install the new locking flange seal dry.

Scheme 232

Scheme 232
Scheme 232
CAUTIONRisk of leaking. When inserting sealing flange, sealing ring must not be damaged or crushed.

Press Locking Flange Down Against The Spring Pressure And Bring It Into Installation Position

  1. The tab -2- on locking flange faces toward the arrow marking and must lie between tabs -1 and 3- on fuel tank.

Note. Arrow- points in direction of travel.

Tighten locking ring.

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

Observe safety precautions after connecting battery. Refer to [For transmission(s) 02E] Removal and Installation .

TT Roadster

Installing fuel tank vehicles with all wheel drive FUEL TANK WITH ATTACHMENTS .

Special tools and workshop equipment required

  1. Wrench T10202

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

CAUTIONRisk of destroying electronic components when disconnecting the battery. Observe measures for disconnecting battery.

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

TT Roadster

CAUTIONIt is necessary to remove the fuel tank first in order to remove the suction jet pump on the Audi TT Roadster.

Removing fuel tank. Refer to FUEL TANK WITH ATTACHMENTS .

TT Coupe

WARNINGDanger due to escaping fuel. To prevent large quantities of fuel from coming out of the suction jet pump when removing, fuel tank may only be a maximum of 1 / 3 full.

Empty fuel tank if necessary. Refer to FUEL TANK, DRAINING .

Remove rear seat bench. Refer to Removal and Installation .

Unclip catches -arrows- of the right connector flange cover.

Disconnect the connector -arrow- from the locking flange.

Mark the fuel supply line -1- and fuel return line -2-.

WARNINGThere is a risk of injury because the fuel is under high pressure. To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

Pull both lines from locking flange, by pressing the release buttons.

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

Disconnect electrical harness connector -1- at locking flange.

Disengage electrical harness connector -2- and lay it aside.

TT Roadster

Mark the fuel supply and return lines on the right locking flange when the fuel tank is removed.

Pull both lines from locking flange, by pressing the release buttons.

TT Coupe

WARNINGDanger due to escaping fuel. To prevent large quantities of fuel from coming out of suction jet pump when removing, fuel tank may only be a maximum of 1 / 3 full.

All Vehicles

Remove right locking ring with T10202.

Pull the sealing flange and seal of fuel delivery unit out from the opening in the fuel tank and lay aside with lines still attached.

Through the fuel tank opening, separate the suction jet pipe -2- from suction jet pump, by pressing release button.

Disconnect fuel delivery line -1- by pressing the release -arrow-.

Remove left locking ring with T10202.

Carefully pull the fuel level sensor 2 -G169- -2- and suction jet pump -1- partially out of the fuel tank opening.

Remove seal.

Unclip the suction jet pump from the locking flange -arrows-.

Note. When removing, be sure not to bend floater arm of fuel level sensor 2.

Reach into the fuel tank opening on left side of the vehicle and pull the suction jet pump with lines out toward the left.

Installing

  1. Tightening specification, refer to «FUEL DELIVERY UNIT AND Fuel Level Sensor -G- OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) .

Install in reverse order, paying attention to the following

Note. Replace seals. When inserting, be sure not to bend floater arm on fuel level sensor 2.

Push suction jet pump with lines at left side of vehicle into fuel tank opening.

Reach into the fuel tank opening on the right side of the vehicle and pull the suction jet pump with lines into installed position.

Push the fuel delivery line -1- on until it engages audibly.

Push the suction jet pipe -2- onto the suction jet pump until it engages audibly.

Install the new locking flange seal dry.

Insert guide of locking flange into guide at fuel delivery unit, observing spring while doing so.

CAUTIONRisk of leaking. When inserting sealing flange, sealing ring must not be damaged or crushed.

Press locking flange down against spring pressure and bring it into installation position.

  1. The tab -2- on locking flange faces toward the arrow marking and must lie between tabs -1 and 3- on the fuel tank.

Note. Arrow- points in direction of travel.

Tighten locking ring.

Carefully insert fuel level sensor 2 in fuel tank opening.

Clip the suction jet pump -1- to the locking flange -2- so that it is audibly engaged.

Install the new locking flange seal dry.

CAUTIONRisk of leaking. When inserting sealing flange, sealing ring must not be damaged or crushed.

Press locking flange down against spring pressure and bring it into installation position.

  1. The tab -2- on locking flange faces toward the arrow marking and must lie between tabs -1 and 3- on fuel tank.

Note. Arrow- points in direction of travel.

Tighten locking ring.

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

Observe safety precautions after connecting battery. Refer to [For transmission(s) 02E] Removal and Installation .

TT Roadster

Installing fuel tank vehicles with all wheel drive FUEL TANK WITH ATTACHMENTS .

All Vehicles

After installing suction jet pump, fill vehicle with at least 5 liters of fuel.

Special tools and workshop equipment required

  1. Engine/Transmission Jack V.A.G 1383 A
  2. Hooks 3004

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Open the fuel filler door.

CAUTIONRisk of destroying electronic components when disconnecting the battery. Observe measures for disconnecting battery.

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

WARNINGRisk of accident due to fuel tank weight. The fuel tank must be empty when removing it.

Drain the fuel tank. Refer to FUEL TANK, DRAINING .

Clean the area around the fuel filler tube.

Remove fuel filler cap -arrow- from fuel filler tube.

Close off the opening of the fuel filler tube with a clean piece of foam to prevent dirt from falling in.

Remove the right rear wheel housing liner. Refer to Removal and Installation .

Remove the bolts -3 and 4- from the fuel filler tube.

Remove the ventilation line -2- from the EVAP canister.

Remove the electrical wiring -1- for the ABS speed sensor from the fuel filler tube bracket.

Free up the overflow hose -5- on the fuel filler tube.

Remove spreader pins -1 and 2-.

Scheme 233

Scheme 233
Scheme 233

Disengage stone impact protection -3- on the right of longitudinal member -arrows- remove it.

TT Roadster

Remove bolts -1 through 4- and remove pendulum support.

Scheme 234

Scheme 234
Scheme 234

All Vehicles

Disconnect the vent line -arrow- to EVAP canister by pressing release button.

Scheme 235

Scheme 235
Scheme 235
CAUTIONThe decoupling elements in the front exhaust pipe could get damaged. Flex joints in front exhaust pipe must not be bent more than 10°. Secure front part of exhaust system on underbody with a chain before loosening clamping sleeve bolts.

Separate exhaust system at clamping sleeve -1-.

Tie up front part of exhaust system with a chain. To do this, engage 3004 in openings on underbody (remove plugs if necessary).

Push the clamping sleeve rearward to separate the exhaust system.

Note. A second technician is needed to help remove the rear section of the exhaust system.

Unhook rear muffler from retaining loops and remove rear portion of exhaust system.

Disconnect the right front vent line -2- on fuel tank by pressing release button.

WARNINGThere is a risk of injury because the fuel is under high pressure. To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

Disconnect right front fuel line -1- on fuel tank by pressing release buttons.

Scheme 236

Scheme 236
Scheme 236
WARNINGRisk of accident due to fuel tank weight. The fuel tank must be empty when removing it.

First remove the bolts -1 and 3-.

Place the V.A.G 1383 A under the fuel tank for support.

Remove the bolts -2 and 4-.

CAUTIONDanger of twisting the electric wires too much. Do not pull on the electric wires when lowering the fuel tank.

Lower the fuel tank with the V.A.G 1383 A until the connector on the locking flange is accessible.

Note. The illustration shows the connectors installed on the locking flange.

Disconnect the connector -arrow- from the locking flange.

By turning it accordingly, lower the fuel tank sideways and remove it.

  1. For the correct tightening specifications, refer to «FUEL TANK WITH ATTACHMENTS OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) .

Install in reverse order, paying attention to the following

Position the fuel tank with mounting strap to underbody using the V.A.G 1383 A.

Make sure the fuel tank is positioned so that the filler tube can be correctly guided into the opening of the body.

Fasten the fuel tank to the fastening points -2 and 4- first, and then to -1 and 3-.

Ensure filler tube threaded connections -2 and 4- are free of corrosion so the Ground (GND) connection to the body is not affected.

Tighten fuel filler tube bolts -4 and 5-.

Check if the GND wiring on both connections show signs of oxidation, remove if necessary.

Route GND connection -1- as shown in illustration.

Ensure GND connection connector -arrows- is seated firmly on protective plate -5- and on filler tube -3-.

WARNINGRisk of explosion due to electrostatic charge. After installing, check electrical connection on fuel filler neck metal ring to an empty spot on the body using an Ohm meter. Specified value: Approximately 0 ohms.

Attach the electrical wiring for the ABS speed sensor to the fuel filler tube bracket.

Install ventilation line to EVAP canister on filler tube.

Install the rear section of the exhaust system. Refer to [For engine(s) CEPB] Removal and Installation or to [For engine(s) CETA, CCTA] Removal and Installation or to [For engine(s) CDMA] Removal and Installation or to [For engine(s) CBRA] Removal and Installation or to [For engine(s) BPY] Removal and Installation .

Install rear right wheel housing liner. Refer to Removal and Installation .

TT Roadster

Install diagonal braces Removal and Installation .

All vehicles

Connect the battery. Observe safety precautions after connecting battery. Refer to [For transmission(s) 02E] Removal and Installation .

FUEL PUMP CONTROL MODULE

Removing

TT Coupe

Remove rear seat bench. Refer to Removal and Installation .

TT Roadster

Remove the right side rear panel trim panel. Refer to Removal and Installation .

All Vehicles

Remove Fuel Pump (FP) control module -J538- from locking flange cover and disconnect electrical connector -arrow-.

Unclip catches -arrows- of right connector flange cover.

Disconnect the connector -arrow- from the locking flange.

Installing

Install in reverse order, paying attention to the following

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

TT Roadster

Install the right side rear panel trim panel. Refer to Removal and Installation .

Special tools and workshop equipment required

  1. Wrench T10202

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

TT Roadster

CAUTIONIt is necessary to remove the fuel tank first in order to be able to remove the fuel delivery unit on the Audi TT Roadster.

Removing fuel tank, refer to FUEL TANK WITH ATTACHMENTS .

TT Coupe

CAUTIONRisk of destroying electronic components when disconnecting the battery. Observe measures for disconnecting battery.

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

WARNINGDanger due to escaping fuel. To prevent large quantities of fuel from coming out of fuel delivery unit when removing, fuel tank may only be a maximum of 3 / 4 full.

Empty fuel tank if necessary. Refer to FUEL TANK, DRAINING .

Remove rear seat bench. Refer to Removal and Installation .

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

Disconnect the connector -arrow- from the locking flange.

Mark the fuel supply line -1- and fuel return line -2-.

Scheme 237

Scheme 237
Scheme 237
WARNINGThere is a risk of injury because the fuel is under high pressure. To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

Pull both lines from locking flange, by pressing the release buttons.

TT Roadster

Mark the fuel supply -1- and the fuel return -2- lines on the removed fuel tank.

Pull both lines from locking flange, by pressing the release buttons.

TT Coupe

WARNINGDanger due to escaping fuel. To prevent large quantities of fuel from coming out of fuel delivery unit when removing, fuel tank may only be a maximum of 3 / 4 full.

All vehicles

Remove locking ring with T10202.

Remove the fuel delivery unit and seal trough the opening in the fuel tank.

Note. When removing fuel delivery unit, be sure not to bend floater arm on the fuel level sensor -G-. Be sure there is still some fuel inside the fuel delivery unit.

Installing

  1. Tightening specification, refer to «FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR -G- OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) .

Install in reverse order, paying attention to the following

Note. Replace seal. When inserting fuel delivery unit, be sure not to bend floater arm on the fuel level sensor -G-.

Install the fuel delivery unit into the fuel tank.

Install the new locking flange seal dry.

Scheme 238

Scheme 238
Scheme 238
CAUTIONRisk of leaking. When inserting sealing flange, sealing ring must not be damaged or crushed.

Press locking flange down against spring pressure and bring it into installation position.

  1. The tab -2- on locking flange must lie between tabs -1 and 3- on fuel tank.

Note. Arrow- points in direction of travel.

Tighten locking ring.

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

Connect the battery. Observe safety precautions after connecting battery. Refer to [For transmission(s) 02E] Removal and Installation .

TT Roadster

Installing fuel tank. Refer to Installing .

All Vehicles

After installing fuel delivery unit, fill vehicle with at least 5 liters of fuel.

On vehicles with TFSI engine, with toothed belt drive, a fuel pump adaptation must be performed after replacing the fuel delivery unit. Refer to TOOTHED BELT DRIVE, PERFORMING A FUEL PUMP ADAPTATION AFTER REPLACING FUEL DELIVERY UNIT .

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

TT Roadster

CAUTIONIt is necessary to remove the fuel tank in order to remove the fuel level sensor -G- on the Audi TT Roadster.

Removing the fuel tank, refer to FUEL TANK WITH ATTACHMENTS .

All Vehicles

Install the fuel delivery unit. Refer to FUEL DELIVERY UNIT .

Version 1

CAUTIONRisk of damage. Before disconnecting electrical connectors on the fuel level sensor, first release the connector contact retaining tab.

Disconnect the connectors -1 through 3-.

Pry on the retaining tabs -4 and 5- with a screwdriver and pull the fuel level sensor off downward -arrow-.

Version 2

Scheme 239

Scheme 239
Scheme 239

Release the retaining tabs -arrows- with a screwdriver and pull the fuel level sensor upward and out.

Scheme 240

Scheme 240
Scheme 240
CAUTIONRisk of damage. Before disconnecting electrical connectors on fuel level sensor, first release connector contact retaining tab.

Disconnect the connectors -1 through 3-.

Installing

Install in reverse order, paying attention to the following

Version 1

Insert the fuel level sensor in the guides on the fuel delivery unit and push upward until it engages.

Connect the electrical connections -1 through 3- and make sure they are securely engaged.

Version 2

Connect the electrical connections -1 through 3- and make sure they are securely engaged.

Insert the fuel level sensor -G- in the guides on the fuel delivery unit and push upward until it engages.

Continuation for All Versions

Install fuel delivery unit. FUEL DELIVERY UNIT , observing notes for connecting battery.

Scheme 241

Scheme 241: SPECIAL TOOLS
Scheme 241: SPECIAL TOOLS

Special tools and workshop equipment required

  1. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
  2. Adapter V.A.G 1318/11
  3. Adapter V.A.G 1318/17-1A
  4. Fuel Line Feed Adapter V.A.G 1318/23
  5. Remote Control V.A.G 1348/3A with Remote Control V.A.G 1348/3-3
  6. Connector Test Set V.A.G 1594C

Special tools and workshop equipment required

Scheme 242

Scheme 242
Scheme 242

Scheme 243

Scheme 243
Scheme 243

Scheme 244

Scheme 244
Scheme 244

Scheme 245

Scheme 245
Scheme 245

Scheme 246

Scheme 246
Scheme 246

Scheme 247

Scheme 247
Scheme 247

Scheme 248

Scheme 248
Scheme 248

Scheme 249

Scheme 249
Scheme 249

Scheme 250

Scheme 250
Scheme 250
  1. Remote Control V.A.G 1348/3A with Remote Control V.A.G 1348/3-3
  2. Wrench T10202
  3. Fuel Extracting Device VAS 5190
  4. Multimeter V.A.G 1526D
  5. Connector Test Set V.A.G 1594C
  6. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-2
  7. Vehicle Diagnostic, Testing, and Information System VAS 5051B
  8. Release Tool T10238
  9. Engine/Transmission Jack V.A.G 1383 A
  10. Hooks 3004
  11. Wrench T10202
  12. Not illustrated
  13. Hose Clamps Up to 25 mm Dia. 3094

See also:
• [For engine(s) CBRA] General Information
• [For engine(s) BPY, CDMA] General Information
• [For transmission(s) 02E] Removal and Installation
• Removal and Installation
• Removal and Installation
• [For engine(s) CBRA] Description and Operation
• [For engine(s) BPY] Description and Operation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• LEAK DETECTION TEST, PERFORMING
• FUEL TANK, DRAINING
• FUEL TANK, DRAINING
• CLEAN WORKING CONDITIONS
• Fuel Level Sensor 2 -G169
• FUEL PUMP ELECTRICAL, CHECKING
• EVAPORATIVE EMISSION (EVAP) CANISTER
• Leak Detection Pump (LDP) -V144
• FUEL FILTER
• ACCELERATOR PEDAL MODULE, VERSION 1
• ACCELERATOR PEDAL MODULE, VERSION 2
• FUEL TANK WITH ATTACHMENTS
• Fuel Level Sensor -G-, CHECKING
• Fuel Level Sensor -G
• FUEL DELIVERY UNIT
• PRESS LOCKING FLANGE DOWN AGAINST THE SPRING PRESSURE AND BRING IT INTO INSTALLATION POSITION
• FUEL LEVEL SENSOR 2 -G169-, CHECKING
• FUEL PUMP, TESTING ELECTRICALLY
• TEST CONDITIONS
• FUEL FILTER OVERVIEW
• TOOTHED BELT DRIVE, PERFORMING A FUEL PUMP ADAPTATION AFTER REPLACING FUEL DELIVERY UNIT

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