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
- Before loosening, connections and surrounding areas must be cleaned thoroughly with engine or brake cleaner, and then cleaned area must be dried completely.
- Seal the open lines and connections immediately with clean plugs, for example, from the engine bung setVAS 6122.
- Place removed parts on a clean surface and cover them. Use lint-free cloths.
- Carefully cover or plug unpacked components if repairs cannot be performed immediately.
- 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.).
- When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.
- 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.
- 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.
- During leak diagnosis, the reed contact is monitored to check if it remains open within 15 seconds. This indicates the fuel system is sealed.
- If pressure falls (indicating a leak), the diaphragm moves back and the reed contact closes.
- 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
| WARNING | The 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) CBRA] General Information or refer to [For engine(s) BPY, CDMA] General Information .
Carry out the following measures before starting work on the fuel supply
| WARNING | Risk of explosion due to cell phones. Keep cell phones out of reach in the work space area. |
| CAUTION | Risk of destroying electronic components when disconnecting the battery. Observe measures for disconnecting battery. Only disconnect the battery with ignition switched off. |
- 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-roadster) .
- 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 518
| WARNING | Distraction 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
- 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-roadster) , for vehicles with all wheel drive «FUEL TANK, DRAINING»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster__fuel-tank-draining) .
- 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.
- Prevent fuel from contacting skin! Wear fuel-resistant gloves!
Note the following when removing and installing the fuel tank
- 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-roadster) , all-wheel drive «FUEL TANK, DRAINING»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster__fuel-tank-draining) .
TEST CONDITIONS
- Battery voltage at least 12.5 V.
- Fuel pump fuse OK, refer to the appropriate SYSTEM WIRING DIAGRAMS information.
- Fuel pump control module -J538- OK; check in "Guided Fault Finding" using a vehicle diagnostic tester operating mode.
- Fuel pump relay -J17- OK, refer to the appropriate SYSTEM WIRING DIAGRAMS information.
- Fuel tank minimum 1 / 4 full.
- Fuel filter OK.
- Fuel lines OK (not plugged, not kinked).
- Ignition switched off
FUEL TANK, DRAINING
Special tools and workshop equipment required
- Wrench T10202
- 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.
| CAUTION | Risk 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 .
| WARNING | Risk 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 519
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 520
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 521
Disconnect electrical harness connector -1- at locking flange.
Scheme 522
Disengage electrical harness connector -2- and lay it aside.
Remove locking ring with T10202.
Scheme 523
Carefully pull the fuel level sensor 2 -G169- -1- and suction jet pump partially out of the fuel tank opening.
Scheme 524
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 525
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
| CAUTION | Tow-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
- 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.
| CAUTION | Risk 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 .
| WARNING | Risk 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 526
- Vacuum Line From the engine to the leak detection pump -V144- Clipped into the bracket on the underbody
- Vent Line From EVAP canister to engine Clipped to fuel tank in fuel tank area Separating points at front and rear on fuel tank
- Fuel Filler Tube
- Vent Line From fuel filler tube to EVAP canister Clipped into the bracket on the underbody
- 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-roadster__evaporative-emission-evap-canister)
- Connecting Line From the leak detection pump to the EVAP canister Clipped into the bracket on the underbody
- Air Filter Housing For the leak detection pump
- 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-roadster__leak-detection-pump-ldp-v144)
- Vacuum Hose to Leak Detection Pump
- Vacuum Hose to Evaporative Emission (EVAP) Canister
Scheme 527
- Vacuum Line From the engine to the leak detection pump -V144- Clipped into the bracket on the underbody
- 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
- Fuel Filler Tube
- Vent Line From fuel filler tube to EVAP canister Clipped into the bracket on the underbody
- 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-roadster__evaporative-emission-evap-canister)
- Connecting Line From the leak detection pump to the EVAP canister Clipped into the bracket on the underbody
- Air Filter Housing For the leak detection pump
- 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-roadster__leak-detection-pump-ldp-v144)
- Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80- Installed location: At front in engine compartment
- Vacuum hose to Leak Detection Pump To disconnect, press release button on connection piece
- 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 528
- 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-roadster) . Removing and Installing, refer to «FUEL FILTER»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster__fuel-filter)
- Fuel Supply Line From the fuel tank To disconnect, press release button on connection piece
- Fuel Return Line To fuel tank To disconnect, press release button on connection piece
- Fuel Line To engine To disconnect, press release button on connection piece
- Bolt 1. Nm
- Fuel Filter Bracket Attached to the fuel tank
Scheme 529
- Vent line To fuel tank filler tube To disconnect, press release button on connection piece
- Vent line To Evaporative Emission (EVAP) canister purge regulator valve 1 -N80- To disconnect, press release button on connection piece
- Clamp Must be appropriate for the model type.
- Connecting Hose
- Nut 4 Nm
- Vacuum Line To engine
- Rubber Bushing
- Bracket
- 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-roadster__leak-detection-pump-ldp-v144)
- Connecting Line To disconnect, press release button on connection piece
- Bolt 4 Nm
- Bracket
- Air Filter Housing For the leak detection pump
- Bolt 4 Nm
- 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-roadster__evaporative-emission-evap-canister)
- Bushing
- Bolt 8 Nm
Scheme 530
- Wiring Router Connected to accelerator pedal module
- Electrical Harness Connector
- 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-roadster__accelerator-pedal-module-version-1)
- Cap
- Bolt 9 Nm
Scheme 531
- Cap
- Bolt 9 Nm
- Electrical Harness Connector
- 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-roadster__accelerator-pedal-module-version-2)
Scheme 532
- Nut 23 Nm
- Fuel Tank Heat Shield With carrier plate
- Nut 23 Nm
- Fuel Line To engine To disconnect, press release button on connection piece
- Vent Line From the EVAP canister to Evaporative Emission (EVAP) canister purge regulator valve 1 -N80- Clipped in on fuel tank
- Electrical Harness Connector For transfer fuel pump -G6- and fuel level sensor -G
- Protective Plate For fuel delivery connection
- Bolt 11 Nm
- Cover Attached to the fuel tank insert with a fastening device
- Ground Connection For discharging electrostatic charge Installed position (Scheme 535)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
- Vent Line From gravity valve to EVAP canister Clipped in on bracket in wheel housing To disconnect, press release button on connection piece
- Pop Rivet
- Fuel Tank Removing and Installing, refer to «FUEL TANK WITH ATTACHMENTS»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster__fuel-tank-with-attachments)
- Mounting Strap Installed position: Locating point (hole) points in driving direction
Scheme 533
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-.
| WARNING | Risk 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 534
- 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-roadster__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-roadster__fuel-level-sensor-g)
- 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-roadster__fuel-pump-electrical-checking) Checking residual pressure, refer to «[For engine(s) CETA, CCTA] Diagnosis and Testing»(ref-505807-S31167778962012100100000) or refer to «[For engine(s) CBRA] Diagnosis and Testing»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster) or refer 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-roadster) Removing and Installing, refer to «FUEL DELIVERY UNIT»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster__fuel-delivery-unit) Fill the fuel tank with at least 5 liters of fuel.
- Seal Replace Install dry
- 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
- 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
- Electrical Harness Connector For transfer fuel pump -G6- and fuel level sensor
- Locking Ring 110 Nm Use Wrench T10202 for removing and installing
- Fuel Delivery Line From the suction jet pump to the fuel delivery unit Clipped to the fuel delivery unit
- Electrical Harness Connector For fuel level sensor 2 -G169
- Locking Ring 110 Nm Use T10202 for removing and installing
- Seal Replace Install dry
- 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-roadster__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-roadster__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-roadster__fuel-level-sensor-2-g169)
- 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-roadster)
- Suction Jet Pipe From fuel pump to suction jet pump To disconnect, press release button on connection piece
Scheme 535
- Nut 20 Nm
- Mounting Strap Installed position: Locating point (hole) points in driving direction
- Fuel Tank Heat Shield
- Nut 20 Nm
- Fuel Line To engine To disconnect, press release button on connection piece
- Vent Line From the EVAP canister to Evaporative Emission (EVAP) canister purge regulator valve 1 -N80- Clipped in on fuel tank
- Electrical Harness Connector For transfer fuel pump -G6- and fuel level sensor -G
- Protective Plate For fuel delivery connection
- Bolt 11 Nm
- Cover Attached to the fuel tank insert with a fastening device
- Bolt 11 Nm
- Ground (GND) Connection For discharging electrostatic charge Installed position (Scheme 537)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
- Vent Line From gravity valve to EVAP canister Clipped in on bracket in wheel housing To disconnect, press release button on connection piece
- Pop Rivet
- Fuel Tank Removing and Installing, refer to «FUEL TANK WITH ATTACHMENTS»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster)
- Nut 20 Nm
- 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-.
| WARNING | Risk 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 536
- 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-roadster__fuel-pump-testing-electrically) Checking residual pressure, refer to «[For engine(s) CETA, CCTA] Diagnosis and Testing»(ref-505807-S31167778962012100100000) or refer to «[For engine(s) CBRA] Diagnosis and Testing»(/audi/tt/8j-2006-2010/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cbra-roadster) or refer 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-roadster) Removing and installing, refer to «FUEL DELIVERY UNIT»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) Fill the fuel tank with at least 5 liters of fuel.
- Seal Replace Install dry
- 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
- Fuel Return Line Do not kink Attaches to connection with identification "R" at sealing flange To remove from locking flange, press release button
- Electrical Harness Connector For transfer fuel pump -G6- and fuel level sensor -G
- Locking Ring 110 Nm Use Wrench T10202 for removing and installing
- 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-roadster) Removing and installing, refer to «Fuel Level Sensor -G»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster)
FASTENER TIGHTENING SPECIFICATIONS
| Component | Fastener Size | Nm |
|---|---|---|
| Accelerator Pedal Module to Body Bolt | 9 | |
| Air Filter Housing to Bracket Bolt | 4 | |
| Bracket to Body Nut | 4 | |
| Bracket to Leak Detection Pump Bolt | 4 | |
| EVAP Canister to Underbody Bolt | 8 | |
| Fuel Filter Bracket Bolt | 1 | |
| Front Wheel Drive Vehicles | ||
| Fuel Tank Filler Tube to Underbody Bolt | 11 | |
| Fuel Tank to Underbody Nut | 20 | |
| Heat Shield to Fuel Tank Lock Washer | 3 | |
| Locking Ring to Fuel Tank | 110 | |
| Securing Strap to Underbody Nut | 20 | |
| All Wheel Drive Vehicles | ||
| Fuel Tank Filler Tube to Underbody Bolt | 11 | |
| Heat Shield to Underbody Nut | 23 | |
| Locking Ring to Fuel Tank | 110 | |
| Securing Strap to Underbody Nut | 23 | |
LEAK DETECTION TEST, PERFORMING
Special tools and workshop equipment required
- 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 537
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
- Line from EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80
- Lines from EVAP canister to Leak Detection Pump (LDP) -V144-.
- Line from fuel tank to EVAP canister (below heat shield for EVAP canister).
- Lines for tank ventilation (beneath right rear wheel housing liner).
- 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
- Fuel tank
- EVAP canister
- Leak detection pump
- 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
- Multimeter V.A.G 1526D
- 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 538
Connect multimeter between terminals -2 and 3- to measure resistance.
Scheme 539
Fuel level sensor installed
- Sensor at lower stop: Approximately 270 ohms.
- 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
- Sensor at lower stop: Approximately 290 ohms.
- Sensor at upper stop: Approximately 60 ohms.
Connect multimeter between terminals -3 and 4- to measure resistance.
Fuel level sensor installed or removed
- 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
- Multimeter V.A.G 1526D
- 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 540
Fuel level sensor 2 installed
- Sensor at lower stop: Approximately 270 ohms.
- 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
- Sensor at lower stop: Approximately 286 ohms.
- Sensor at upper stop: Approximately 50 ohms.
Connect multimeter between terminals -2 and 3- to measure resistance.
Fuel level sensor 2 installed or removed
- 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
- On vehicles with the TFSI engine, the fuel pump is supplied with voltage via the fuel pump control module -J538-.
- Fuel Pump (FP) Control Module -J538- testing occurs in "Guided Fault Finding" operating mode using the vehicle diagnostic tester.
FUEL PUMP DELIVERY RATE, CHECKING [FOR ENGINE(S): BPY, CCTA, CDMA, CETA, CEPB]
Special tools and workshop equipment required
- Fuel Inj. Pressure Gauge-CIS V.A.G 1318
- Adapter V.A.G 1318/11
- Adapter V.A.G 1318/17-1A
- Fuel Line Feed Adapter V.A.G 1318/23
- Remote Control V.A.G 1348/3A with Remote Control V.A.G 1348/3-3
- Connector Test Set V.A.G 1594C
- 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 541
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 542
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 543
| WARNING | There 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 544
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 545
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.
- 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.
- 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 546
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
- Fuel lines pinched.
- Fuel filter clogged.
- 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 .
FUEL PUMP DELIVERY RATE, CHECKING [FOR ENGINE(S): CEPB]
Special tools and workshop equipment required
- Fuel Inj. Pressure Gauge-CIS V.A.G 1318
- Adapter V.A.G 1318/11
- Adapter V.A.G 1318/17-1A
- Fuel Line Feed Adapter V.A.G 1318/23
- Remote Control V.A.G 1348/3A with Remote Control V.A.G 1348/3-3
- Connector Test Set V.A.G 1594C
- 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 547
| WARNING | There 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.
- 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.
- 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 548
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
- Fuel lines pinched.
- Fuel filter clogged.
- 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 .
FUEL PUMP DELIVERY RATE, CHECKING [FOR ENGINE(S): BUB, CBRA]
Special tools and workshop equipment required
- Adapter V.A.G 1318/17-1 from Adapter for VAG 1318 V.A.G 1318/17
- Remote Control V.A.G 1348/3A with Remote Control V.A.G 1348/3-3
- Connector Test Set V.A.G 1594C
- 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.
| WARNING | There 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 549
Connect V.A.G 1318/17-1 to disconnected fuel return line and hold it in a measuring container.
Scheme 550
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
- Fuel lines pinched.
- Fuel filter clogged.
- 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
- Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-2
- Multimeter V.A.G 1526D
- 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 551
Remove fuse -arrow- at position 1 from "fuse carrier ST2" (brown) -2-.
Scheme 552
Connect V.A.G 1348/3A with V.A.G 1348/3-2 to terminal on fuse to fuel pump and battery positive.
Scheme 553
Press switch on the V.A.G 1348/3 A.
- 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 554
Press the switch on the remote control.
- 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 555
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
- Vehicle Diagnostic, Testing, and Information System VAS 5051B
Procedure
- No faults in Diagnostic Trouble Code (DTC) memory.
Connect the VAS 5051B to the Data Link Connector (DLC) -arrow- and start the engine.
Scheme 556
Select the following menu entries
- "OBD"
- "01- Engine electronics"
- "Basic setting display group 103"
- "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
- Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-2
- Multimeter V.A.G 1526D
- Connector Test Set V.A.G 1594C
- 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.
- 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 .
- On vehicles with the TFSI engine, the fuel pump is supplied with voltage via the Fuel Pump (FP) control module -J538-.
- FP control module testing occurs in "Guided Fault Finding" operating mode using the vehicle diagnostic tester.
FUEL PUMP DELIVERY RATE, CHECKING
Special tools and workshop equipment required
- Fuel Inj. Pressure Gauge-CIS V.A.G 1318
- Adapter V.A.G 1318/11
- Adapter V.A.G 1318/17-1A
- Fuel Line Feed Adapter V.A.G 1318/23
- Remote Control V.A.G 1348/3A with Remote Control V.A.G 1348/3-3
- Connector Test Set V.A.G 1594C
- 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.
| WARNING | There 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.
- 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.
- 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
- Fuel lines pinched.
- Fuel filter clogged.
- 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
- Vehicle Diagnostic, Testing, and Information System VAS 5051B
Procedure
- 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
- "OBD"
- "01- Engine electronics"
- "Basic setting display group 103"
- "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
- Multimeter V.A.G 1526D
- 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
- Sensor at lower stop: Approximately 270 ohms.
- 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
- Sensor at lower stop: Approximately 290 ohms.
- Sensor at upper stop: Approximately 50 ohms.
Connect multimeter between terminals -3 and 4- to measure resistance.
Fuel level sensor installed or removed
- 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
- Release Tool T10238
Removing
Remove cover for steering column -arrows-.
Scheme 557
Disconnect electrical harness connector -2-, by pressing release button to the stop -arrow-.
Scheme 558
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 559
Installing
- Tightening specification, refer to «ACCELERATOR PEDAL MODULE OVERVIEW, VERSION 1»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) .
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 560
- 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
- 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 561
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
- Tightening specification, refer to «ACCELERATOR PEDAL MODULE OVERVIEW, VERSION 2»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) .
Install in reverse order, paying attention to the following
Connect the connector -2- on the accelerator pedal module -5-.
- 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) CETA, CCTA] Description and Operation or refer to [For engine(s) CDMA] Description and Operation or refer to [For engine(s) CBRA] Description and Operation or refer 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 562
Remove bolts -1, 2 and 6-.
Release the retaining tabs in direction of -arrow- with a screwdriver and remove the EVAP canister.
Installing
- Tightening specification, refer to «EVAP CANISTER AND LEAK DETECTION SYSTEM OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) .
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) CETA, CCTA] Removal and Installation or refer to [For engine(s) CDMA] Removal and Installation or refer to [For engine(s) CBRA] Removal and Installation or refer to [For engine(s) BPY] Removal and Installation .
FUEL FILTER
Special tools and workshop equipment required
- 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
| WARNING | Risk 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 563
Vehicles with MPI Engine
| WARNING | Risk 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.
| WARNING | There 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 564
Remove the bolt -4-.
Remove fuel filter.
Installing
- Tightening specification, refer to «FUEL FILTER OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster__fuel-filter-overview) .
Install in reverse order, paying attention to the following
Scheme 565
- The direction of flow is marked on filter housing with arrows.
- 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 566
Disconnect electrical connector -3-.
Disconnect vent line -5- by pressing release button.
Remove nuts -1 and 4-.
Disengage diagnostic pump with bracket.
Installing
- Tightening specification, refer to «EVAP CANISTER AND LEAK DETECTION SYSTEM OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) .
Installation is carried out in the reverse order while noting the following
- 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
- Engine/Transmission Jack V.A.G 1383 A
- 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.
| CAUTION | Risk 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 .
| WARNING | Risk 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 567
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 568
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 569
Disconnect the vent line -arrow- to EVAP canister by pressing release button.
| CAUTION | The 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 570
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 571
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 or refer to Removal and Installation or refer to [For transmission(s) 02E] Removal and Installation or refer to Removal and Installation or refer to .
Disconnect the right front vent line -2- on the fuel tank by pressing release button.
Scheme 572
| WARNING | There 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.
| WARNING | Risk of accident due to fuel tank weight. The fuel tank must be empty when removing it. |
First remove bolts -2, 5 and 6-.
Scheme 573
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-.
| CAUTION | Danger 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 574
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
- For the correct tightening specifications, refer to «FUEL TANK WITH ATTACHMENTS OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) .
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-.
| WARNING | Risk 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 or refer to Removal and Installation or refer to [For transmission(s) 02E] Removal and Installation or refer to Removal and Installation .
Install the rear section of the exhaust system. Refer to [For engine(s) CETA, CCTA] Removal and Installation or refer to [For engine(s) CDMA] Removal and Installation or refer to [For engine(s) CBRA] Removal and Installation or refer 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 [FOR ENGINE(S): BPY, CCTA, CDMA, CETA]
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 .
FUEL PUMP (FP) CONTROL MODULE [FOR ENGINE(S): CEPB]
Special tools and workshop equipment required
- 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 575
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 576
Remove the bolts -4-.
| CAUTION | Danger 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
- Wrench T10202
Follow all safety precautions. Refer to SAFETY PRECAUTIONS .
Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .
| CAUTION | Risk 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
| CAUTION | It 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
| WARNING | Danger 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 577
| WARNING | There 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
| WARNING | Danger 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 578
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.
- Tightening specification, refer to «FUEL DELIVERY UNIT AND Fuel Level Sensor -G- OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) .
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 579
Insert guide of locking flange into guide at fuel delivery unit, observing spring while doing so.
| CAUTION | Risk 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.
- 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
| CAUTION | It 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 .
| CAUTION | Risk of damage. Before disconnecting electrical connectors on the fuel level sensor, first release connector contact retaining tab. |
Disconnect the connectors -1 through 3-.
Scheme 580
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
- Wrench T10202
Follow all safety precautions. Refer to SAFETY PRECAUTIONS .
Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .
| CAUTION | Risk 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
| CAUTION | It 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
| WARNING | Danger 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.
| WARNING | Danger 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 581
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.
- Tightening specification, refer to «FUEL DELIVERY UNIT AND Fuel Level Sensor -G- OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) .
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 582
| CAUTION | Risk 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
- 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
- Wrench T10202
Removing
Follow all safety precautions. Refer to SAFETY PRECAUTIONS .
Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .
| CAUTION | Risk 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
| CAUTION | It 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
| WARNING | Danger 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-.
| WARNING | There 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
| WARNING | Danger 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
- Tightening specification, refer to «FUEL DELIVERY UNIT AND Fuel Level Sensor -G- OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) .
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.
| CAUTION | Risk 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.
- 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.
| CAUTION | Risk 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.
- 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
- Engine/Transmission Jack V.A.G 1383 A
- 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.
| CAUTION | Risk 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 .
| WARNING | Risk 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 583
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 584
All Vehicles
Disconnect the vent line -arrow- to EVAP canister by pressing release button.
Scheme 585
| CAUTION | The 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.
| WARNING | There 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 586
| WARNING | Risk 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-.
| CAUTION | Danger 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.
- For the correct tightening specifications, refer to «FUEL TANK WITH ATTACHMENTS OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) .
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-.
| WARNING | Risk 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) CETA, CCTA] Removal and Installation or refer to [For engine(s) CDMA] Removal and Installation or refer to [For engine(s) CBRA] Removal and Installation or refer 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
- Wrench T10202
Removing
Follow all safety precautions. Refer to SAFETY PRECAUTIONS .
Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .
TT Roadster
| CAUTION | It 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
| CAUTION | Risk 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 .
| WARNING | Danger 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 587
| WARNING | There 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
| WARNING | Danger 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
- Tightening specification, refer to «FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR -G- OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-roadster) .
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 588
| CAUTION | Risk 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.
- 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
| CAUTION | It 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
| CAUTION | Risk 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 589
Release the retaining tabs -arrows- with a screwdriver and pull the fuel level sensor upward and out.
Scheme 590
| CAUTION | Risk 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 observing notes for connecting battery, refer to FUEL DELIVERY UNIT .
Scheme 591
Special tools and workshop equipment required
- Fuel Inj. Pressure Gauge-CIS V.A.G 1318
- Adapter V.A.G 1318/11
- Adapter V.A.G 1318/17-1A
- Fuel Line Feed Adapter V.A.G 1318/23
- Remote Control V.A.G 1348/3A with Remote Control V.A.G 1348/3-3
- Connector Test Set V.A.G 1594C
Special tools and workshop equipment required
Scheme 592
Scheme 593
Scheme 594
Scheme 595
Scheme 596
Scheme 597
Scheme 598
Scheme 599
Scheme 600
- Remote Control V.A.G 1348/3A with Remote Control V.A.G 1348/3-3
- Wrench T10202
- Fuel Extracting Device VAS 5190
- Multimeter V.A.G 1526D
- Connector Test Set V.A.G 1594C
- Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-2
- Vehicle Diagnostic, Testing, and Information System VAS 5051B
- Release Tool T10238
- Engine/Transmission Jack V.A.G 1383 A
- Hooks 3004
- Wrench T10202
- Not illustrated
- 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
• Removal and Installation
• [For transmission(s) 02E] 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