How to Diagnosis the Maintenance (Maintenance Procedures (coupe)) Audi TT 8J

ENGINE OVERVIEW

TYPE PLATE AND VIN

A - Type plate

It is secured on the right suspension strut tower.

B - Vehicle Identification Number

It is stamped in the upper wheel housing right longitudinal member near the reservoir.

Vehicle Data Label

The vehicle data label is in the customer's Maintenance booklet and in the vehicle in the spare wheel recess or on the floor panel.

The label contains the following vehicle data

Scheme 1

1 - Vehicle Identification Number (VIN)

2 - Model identification number/Production control number

3 - Model explanation

4 - Engine output/Emissions standard/Transmission

5 - Engine and transmission codes (no information for certain countries)

6 - Paint number/interior equipment identification number

7 - Optional equipment identification numbers

8 - Curb weight/Consumption/CO 2 emissions (no information for certain countries)

Engine Code and Engine Identification

Note. The "engine code" is on the vehicle data label in the Maintenance booklet and in the spare wheel recess or on the floor panel.

A label with engine code and engine number is also applied to the toothed belt guard.

4-Cylinder Engines

Scheme 2

Engine number ("engine code" and "serial number") is located at front of engine/transmission connecting point.

6-Cylinder Engines

Scheme 3

The engine number and engine code -arrow- are stamped on the cylinder block near the vibration damper.

RAISING VEHICLE

Floor Jack

Always use a suitable rubber or wooden block between the jack and the vehicle.

A floor jack must be attached only at the mounting points depicted in the illustration.

Do not lift the vehicle at the engine oil pan, transmission, or on front or rear axles as serious damage may result.

Hoist and Floor Jack Lifting Points

Front

Scheme 4

On the floor longitudinal reinforcement in the area of the marking.

Rear

Scheme 5

On aluminum case part in front of rear axle mounting point

TOW STARTING/TOWING

Attach tow rope or bar only at following eyes

Front Towing Eyes

Scheme 6

Open cover.

Screw towing eye in by hand and tighten counter-clockwise using wheel bolt wrench.

Rear Towing Eye

Scheme 7

The rear towing eye is located under the bumper cover on the rear right.

Screw towing eye in by hand and tighten counter-clockwise using wheel bolt wrench.

Tow starting or towing vehicle

Note. Tow-ropes or bars should be attached at above mentioned points only. The tow-rope should be able to stretch to reduce the risk of damage to both vehicles. Therefore only ropes of synthetic material or rope from similarly flexible material should be used. However it is safer to use a tow bar! Avoid excessive towing effort and do not jerk. During towing operations on unsurfaced roads there is always a danger that the attachment points will be overstressed and damaged. Vehicle towing should only be done if it is not possible to start the engine with the starting assist cable.

If the vehicle must ever tow or be towed, observe the following

1. Legal regulations concerning towing must be observed.
2. Both drivers must be familiar with towing procedures. Inexperienced drivers should not attempt to tow start or tow.
3. When using a tow rope the driver of the towing vehicle must engage the clutch very gently when moving off and changing gear.
4. The driver of the vehicle being towed must ensure that the tow rope is always taut.
5. Both vehicles must have the emergency flasher switched on - if necessary observe any other regulations.
6. The ignition must be switched on, so that the steering wheel is not locked and the turn signals, horn, windshield wipers, and windshield washer system can be operated.
7. Since the brake booster only works with the engine running, the brake pedal must be stepped on with substantially more force when the engine is switched off.
8. With the engine switched off, the power steering also does not work, increasing the amount of steering effort.
9. Without lubricants in the manual transmission and/or automatic transmissions the car may only be towed with raised drive wheels.

Important notes concerning tow starting a vehicle

It is generally recommended not to tow start vehicles. Instead, jumper cables should be used.

There are several reasons to not tow start

1. During tow starting, the risk of an accident occurring is high, e.g. driving into vehicle towing.
2. Vehicles with gasoline engines can be damaged by unburned fuel entering the catalytic converter.
3. Tow starting of vehicles with automatic transmission is not possible for technical reasons.

If a vehicle should be tow started at any time, observe the following

Before tow starting, push in clutch pedal and hold, and select gear 2 or 3.

Switch ignition on.

When both vehicles are in motion, release the clutch pedal.

As soon as the engine is started, push in the clutch and take the car out of gear to avoid running into the towing vehicle.

Note. Vehicles with catalytic converter (gasoline engine only) must not be started when the catalytic converter is at operating temperature and pulling the vehicle over a longer distance of more than 50 m. Otherwise, the vehicle could be damaged by unburned fuel entering the catalytic converter.

When towing a vehicle with automatic transmission the following additional points must be observed

1. Selector lever must be in the "N" position.
2. Do not tow at speeds greater than 30 mph (50 km/h).
3. The maximum towing distance is 30 miles (50 km).

For longer distances, the front end of the vehicle must be raised.

Reason: With engine switched off, the transmission oil pump does not work. Therefore the transmission is not sufficiently lubricated at higher speeds and longer distances.

When towing with a tow truck, the vehicle may only be towed with raised front wheels.

Reason: With car raised in the back, the driveshafts turn backwards. This would cause the planetary gears in the automatic transmission to achieve such high RPM that the transmission would be heavily damaged within a very short time.

Note. If normal towing of the vehicle is not possible, the vehicle must be transported with a special transporter or trailer. This also applies to towing distances of over 30 miles (50 km)

VEHICLE CHECKS DURING INSPECTION AND MAINTENANCE

For vehicle checks, we recommend interactive acceptance VAS 5000 and performance test stand V.A.G 1858.

Brakes, Testing

Information for checking brakes on FWD and AWD vehicles is in the corresponding brake system repair information.

Performance Check

Perform performance check on performance test stand recommended by Audi. The corresponding correction factors for automatic transmissions and AWD are provided in these test stands. Vehicles with AWD may only be tested on a four-wheel performance test stand.

Tachometer Check

With the tachometer test, the vehicle wheels are driven. Vehicles with AWD may only be tested on a four-wheel test stand.

Shock Absorber Check

Information on testing shock absorbers can be found in the suspension repair information.

STRUT TUBE CAP, LUBRICATING

Special tools and workshop equipment required

Scheme 8

1. Lubricant G 000 405 A2
2. Brush

Scheme 9

Coat the plastic cap on the strut tube on the contact surface -arrow- with lubricant G 000 405 A2.

Note. After removing the spring clip and the spacer and lubricating the strut tube cap, make sure that the boot in the strut bearing is in the correct position as with the shock absorber tube.

MEASURED VALUES BLOCK 32, READING

Note. Applies to certain countries only. Refer to the Maintenance table.

Follow these steps in sequential order.

Scheme 10

1. Connect VAS 5051/5052
2. On Board Diagnostic
3. Engine electronics
4. Measured value blocks
5. Select measured values block 32
6. Display field 2 (4-cylinder engines)
7. Display field 2 and 4 (V6 and V8 engines)

Note. If the values deviate by > 15%, then the Fuel Injector Cleaner G17 must be increased by a factor of 4, refer to FUEL INJECTOR CLEANER G17 .

BATTERY, CHECKING LEVEL USING GUIDED FAULT FINDING

Follow these steps in sequential order.

1. Connect VAS 5051/5052
2. Guided Fault Finding or Guided Functions
3. Select brand and type.
4. Service Work
5. Check the battery -A
6. Continue following the instructions.
7. Send the diagnostic protocol online.

Note. If tester display shows charge or replace battery. Refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation

BATTERY, CHECKING NO LOAD VOLTAGE BEFORE STARTING ENGINE

Note. For delivery inspection only for vehicles without battery monitoring control module -J367- or energy management control module -J644-.

Special tools and workshop equipment required

Scheme 11

1. Portable multimeter V.A.G 1526C

Make sure the following points are observed - otherwise a correct measurement cannot be guaranteed.

Scheme 12

1. Battery must not be loaded by connected electrical components for at least 12 hours before testing.
2. The batter must not be charged for at least 12 hours before measuring.

Remove rear molded insert -3- for tools under luggage compartment floor cover.

Remove battery compartment cover -arrow-.

Scheme 13

Remove molded insert under battery.

Scheme 14

Measure voltage between the battery terminals -2- and -3- with the ignition switched off.

Scheme 15

1. If tester shows 12.5 V or higher, battery is O.K.
2. If the tester shows 12.2 to 12.5 Volts, battery should be charged. Refer to «BATTERY, CHARGING»(/audi/tt/8j-2006-2010/remont/charging-system/#battery-starter-generator-cruise-control-coupe__battery-charging) .
3. If the tester shows a value between 11.6 and 12.2 Volt, the following procedure must be used: Charge battery, refer to «BATTERY, CHARGING»(/audi/tt/8j-2006-2010/remont/charging-system/#battery-starter-generator-cruise-control-coupe__battery-charging) . Let the battery sit for 24 hours after charging it. Perform a battery test/ battery load test after the waiting period. Refer to «DIAGNOSIS AND TESTING»(/audi/tt/8j-2006-2010/remont/charging-system/#battery-starter-generator-cruise-control-coupe) .
4. If measured value is 11.6 Volt or lower, battery must be replaced. Refer to «[For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation»(/audi/tt/8j-2006-2010/remont/charging-system/#battery-starter-generator-cruise-control-coupe) .

GENERAL INFORMATION

Note. Batteries with or without visual indicator must not be opened.

The battery is located at the rear right of the luggage compartment.

Switch ignition off and remove ignition key.

Remove rear molded insert -3- for tools under luggage compartment floor cover.

Note. Ignore -1- and -item 2-.

Remove battery compartment cover -arrow-.

Remove molded insert under battery.

BATTERY WITHOUT VISUAL INDICATOR

1. On batteries with visible min and max markings, electrolyte level only needs to be checked visually.
2. The electrolyte level must be above the MIN marking.
3. Use a flashlight to improve visibility when performing an exterior visual inspection of the min and max markings.

BATTERY WITH VISUAL INDICATOR

1. As the "visual indicator" is only located in a battery cell, only the battery electrolyte level for this battery cell can be checked.
2. The "visual indicator" -arrow- provides information about the fluid levels and the state of charge for the battery being checked.
3. Bubbles can build up under the "visual indicator" when the battery is charging and also while driving, causing the color displayed to be incorrect.

Loosen the bubbles under the "visual indicator" by lightly and carefully hitting the "visual indicator" -arrow- with the handle of a screwdriver.

Scheme 16

Read the battery electrolyte level present in the color display. Two different displays are possible

AGM BATTERY, CHECKING

Note. AGM batteries are marked with "AGM". The AGM battery is closed, needs no maintenance, and must not be opened.

Perform a visual inspection of the battery

1. Corrosion on the battery pole
2. Battery terminal and battery secure
3. Damage to the battery terminals and housing

BATTERY, CHECKING CABLES FOR SECURE SEATING

Check the battery terminals for secure seating and tighten nuts -1- and -4- if necessary.

Scheme 17

Check battery for secure fit, tighten screws -2- on securing bracket -3- if necessary.

Note. Wheels and tires of the same construction and size should be used on the front and back. On vehicles with AWD, tires should also be of the same make and have the same tread.

Delivery Inspection

Check running surfaces and side walls for damage, remove foreign bodies, if necessary.

Inspection Service

Check tire treads for cupping, feathering, one-sided tread wear, porous side walls, cracks, cuts, and rim damage.

Tires, Checking Wear Pattern

The wear pattern of the front wheels can be used to assess whether a check of the track and camber is necessary

1. Feathered edges of the treads may indicate faulty toe adjustment.
2. One-sided tread wear is mostly caused by faulty camber.

Note. If such wear patterns are found, determine the causes by checking the wheel alignment (repair measure).

Tread Depth, Checking

1. Minimum tread depth: 1.6 mm

Note. This value may vary for individual countries due to different legislative regulations. If the tread wear is close to the wear limits, inform customer and note findings on the repair order.

TIRE PRESSURE, CORRECTING

The tire pressure value are on the label on the B-pillar.

Scheme 18

Note. Observe that the inflation pressure specifications on the label refer to the air pressure of cold tires. Do not reduce tire pressure when the tires are warm.

SPARE TIRE

1. Spare wheel with standard tire

Maintain the highest specified tire pressure for the tire size according to the tire pressure label.

1. Mini spare tire

The tire pressure is on the sidewall.

1. Break-down kit

Tire Repair Kit, Checking Expiration Date

Note. Tire valves must be sealed with valve caps. Otherwise, dirt can enter valve needle which becomes jammed and can no seal shut.

BRAKE SYSTEM, INSPECTING FOR LEAKS AND DAMAGE

Check the following components for leaks and damage

1. Brake Master Cylinder
2. Brake Booster
3. ABS Hydraulic unit
4. Calipers

Make sure the brake hoses are not twisted.

Make sure the brake hoses do not come in contact with any vehicle components when steering is at full lock.

Check brake hoses for porosity, bubbles and cracks.

Check brake hoses for chafing.

Check the brake line connections for leaks or corrosion and make sure they are attached securely.

BRAKE PADS, CHECKING THICKNESS

Special tools and workshop equipment required

1. Test pin T40139

Scheme 19

To determine brake pad thickness, the sliding ring must be slid as far as stop in the direction of the measure point.

then bring measuring point of test pin through rim and into contact with brake pad and slide test pin evenly in direction of brake pad until the test pin touches the brake pad backing plate.

Then remove test pin and read out value on scale marked with brake symbol

Note. Make sure the sliding ring does not move, otherwise the measurement will be incorrect. The second scale on the test pin (tire symbol) can be used to determine the tire tread depth.

Scheme 20

a - Brake pad thickness including backing plate

Wear limit: 7

Scheme 21

a - Brake pad thickness including backing plate

Wear limit: 7

Note. On some vehicles, due to the shape of the rims (accessory rims), it may not be possible to bring the test pin through the rim and into contact with the brake disc or pad. If this is the case, use the following procedure: Determine thickness of outer pads by checking visually (using a flashlight through a hole in wheel). Determine thickness of the inner pad by visual check (using a flashlight through a hole in the wheel).

BRAKE FLUID, CHECKING DEPENDING ON BRAKE PAD WEAR

Note. Use only new Original VW / Audi brake fluid.

Please observe the following

Scheme 22

1. Fluid level must be at MAX mark

Note. To prevent the brake fluid from overflowing from the reservoir, the level must not be over the MAX mark.

Note. Use only new Original VW / Audi brake fluid.

Change brake fluid with brake charger/bleeder unit VAS 5234

BRAKE FLUID, CHANGING USING BRAKE CHARGER/BLEEDER UNIT VAS 5234

Special tools and workshop equipment required

Scheme 23

Scheme 24

1. Brake charger/bleeder unit VAS 5234
2. Reservoir

Note. The brake fluid level in the reservoir must be high enough so that air cannot get into the brake system. Do not remove the strainer inside the brake fluid reservoir. Follow VAS 5234 operating instructions!

Remove brake fluid reservoir cap -1-.

Scheme 25

Use the hose from the VAS 5234 to extract as much brake fluid as possible.

Scheme 26

Install adapter -1- to brake fluid reservoir.

Scheme 27

Connect filler hose -2- on VAS 5234 to adapter.

Manual Transmission

Pull cover cap off clutch slave cylinder bleed screw.

Place extractor bleeder hose -1- on clutch slave cylinder bleeder screw, open bleeder screw, and let about 100 ml drain out. Close bleeder screw and install cover cap.

Operate clutch pedal several times.

All Vehicles

Remove caps from the bleeder screws.

Connect extractor bleeder hose -1- to front left bleeder screw, open bleeder screw and allow about 200 ml to flow out. Close bleeder screw.

Repeat work sequence on other side of vehicle at front.

Connect extractor bleeder hose -1- to rear left bleeder screw, open bleeder screw and allow about 200 ml to flow out. Close bleeder screw.

Repeat procedure on opposite rear.

Install cover caps on brake caliper bleeder screws.

Move filler lever on VAS 5234 to position -B- (see operating instructions).

Remove the filler hose from the adapter.

Remove the adapter from the brake fluid reservoir.

Install the brake fluid reservoir cap.

Check brake fluid level and fill if necessary.

Check pedal pressure and brake pedal free play. Free play: max 1 / 3 of pedal travel

SEQUENCE AND BRAKE FLUID CAPACITY TABLE

FUEL INJECTOR CLEANER G17

Note. Applies to certain countries only. Refer to the Maintenance table.

1. Add Fuel Injector Cleaner G17 into the fuel tank in a ratio of 10ml of additive for every 10 liters of fuel.
2. The following table shows the required quantities for each fuel level shown in the fuel gauge.

Mixture Ratio

Note. The values in the table are based on an 60 liter fuel tank. If there are other fuel capacities in the fuel tank which are not mentioned in the table, then add 10 ml of additive for every 10 liters of fuel.

KEY, CHECK FUNCTIONALITY

Separate keys so that the function of each key can be checked individually.

Insert each key into the ignition and start the engine.

If engine switches off by itself after about 3 seconds and "save" appears in the odometer display, the key has not been programmed to the immobilizer.

Repair measure: Guided Fault Finding (Programming vehicle keys).

Note in the delivery check list the number of keys checked and given to the owner.

DTC MEMORY, CHECKING

Follow these steps in sequential order.

1. Connect VAS 5051/5052
2. Vehicle Self-Diagnosis (OBD)
3. Gateway device list
4. Read the control module with the fault stored in the DTC memory.
5. Correct relevant malfunctions with customer's approval.

ENGINE COMPARTMENT FRONT NOISE INSULATION COVER, REMOVING AND INSTALLING

Remove noise insulation -mounting pieces 1 through 4-.

Scheme 28

COOLANT SYSTEM, CHECKING

Note. The additional coolant portion of the mixture must amount to at least 40% (freeze protection to -13°F [-25°C]) and should not exceed 60% (freeze protection to -40°F [-40°C]). Otherwise the freeze protection will be reduced and the cooling efficiency will be worsened. The freeze protection must be ensured to approximately -13°F (-25 °C). Freeze protection.

Special tools and workshop equipment required

Scheme 29

1. Refractometer T10007

Note. Read the bright/ark boundary to obtain an accurate reading for the following tests. Place a drop of water on the glass to improve the readability of the bright/dark boundary. The bright/dark boundary can be clearly recognized on the "WATERLINE".

Check the concentration of the coolant additive using T10007 (operating instructions).

The scale -1- of the refractometer is designed for coolant additives G 12, G12 Plus, G12 Plus and G11.

Scheme 30

Scale -2- refers only to coolant additive G 13. (begins L80)

Note. The freeze protection must be ensured to approximately -13°F [-25°C]. If climate conditions make greater freeze protection necessary, the amount of can be increased up to 60% (Freeze protection to approximately -40°F [-40°C]). Adding more coolant reduces the freeze protection and reduces the cooling efficiency.

Coolant Level, Checking and Filling

Check the coolant level in the reservoir when the engine is cold.

Scheme 31

1. Delivery inspection: Coolant level above the "MIN marking" -arrow-.
2. Inspection service: Coolant level above the "MIN marking" -arrow-.

If coolant level is too low, fill with coolant mixture.

Note. Determine cause of fluid loss, which cannot be attributed to normal use and repair.

Mixture ratio

Note. Coolant additive prevents freeze and corrosion damage, scaling, and raises the boiling point. For these reasons the cooling system must have coolant additive the whole year. Especially in countries with tropical climates or when vehicle is driven under heavy load, the coolant improves the engine reliability by its increased boiling point. The coolant concentration must not be reduced by adding water, even during the warmer season. The coolant additive ratio must be at least 40%.

INSTRUMENT CLUSTER, SELECTING LANGUAGE

Follow these steps in sequential order.

1. Connect VAS 5051/5052
2. Guided Fault Finding or Guided Functions
3. Go to - function/component selection
4. Service Work
5. Language adaptation
6. Now follow guided program

Note. If the air filter insert is heavily soiled or soaked, dirt particles or moisture can reach the mass airflow sensor -G70- and cause an incorrect airflow reading. This causes lack of performance because a lower injection amount is calculated. Always use an original air filter insert. Use a lubricant (silicone-free) when installing intake hose. Secure all hose connections with hose clamps that match current standard production. Check drain hose in bottom side of air filter or dirt and adhesion (clean, if necessary). Clean air filter housing (upper and lower parts) of salt residue, dirt or leaves (clean with vacuum, if necessary). Check mass airflow sensor and intake hose (clean air side) for salt residue, dirt and leaves. Check the intake canal up to the filter insert for dirt. When installing air filter insert, ensure it is centered in mount on bottom of air filter. Carefully and gently place upper part of air filter on lower part. When doing so, ensure upper part of air filter is not crooked on air filter insert. Pay attention to the seal lip on the air filter insert (air leak). Finally, screw upper part of air filter onto lower part.

6-CYLINDER 3.2L MPI

Open hose clamps -2- with Hose Clip Pliers V.A.G 1921 and remove intake hose -1-.

Scheme 32

Release the connector -3- from the mass airflow sensor and remove.

Remove fastening bolts -arrows-.

Lift and remove the air filter housing upper section.

Remove old air filter -arrow-.

Scheme 33

Clean filter housing and insert new air filter.

Install the air filter housing upper section and tighten the screws.

Connect the connector -3- for the mass airflow sensor and secure.

Attach the air intake tube -1- to the filter housing and secure with hose clamp -2-.

4-CYLINDER 2.0 TFSI

Special tools and workshop equipment required

Scheme 34

1. Spring Type Clip Pliers -VAS 5024A

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

Open the clamps -1 and 2- and disconnect the air guide hose from the mass airflow sensor.

Scheme 35

Disconnect the intake hose -arrows-.

Open the spring clamps -4- and disconnect the air intake hose from the engine cover.

Carefully pull the engine cover off positions -1 - 2 - 3 - 4- one after the other.

Scheme 36

Cover the open intake hose with a clean cloth.

Removing Air Filter Insert

Remove all the screws -arrows-.

Scheme 37

Remove the engine cover from the retainers -arrows-.

Scheme 38

Remove the air filter from the engine cover.

Scheme 39

Clean filter housing and insert new air filter.

Note. Self-locking bolts are equipped for fastening the air filter upper section to the air filter housing lower section. If these bolts are loosened of tightened with a drill motor, the threads in the air filter housing upper section can be damaged. For this reason, a drill motor may only be used when the following prerequisites are met: The drill motor RPM is max. 200 / min. The torque must be adjustable to max. 3 Nm. When installing, place engine compartment cover on four mounting points and press them down at the same time with the hand held flat. When installing, ensure rubber grommets are seated cleanly between air filter housing and intake tube.

Assembly is done in reverse order

Removing

Remove the air guide hose -1- from the mass airflow sensor -G70-.

Scheme 40

Disconnect electrical connector -2- from Mass Air Flow Sensor -G70-.

Remove the air filter housing upper section -arrows- and remove the air filter.

Installing

Installation is reverse of removal, but note the following

For proper mass airflow sensor function, it is important to observe the following notes and perform the procedure exactly.

Note. If the air filter insert is heavily soiled or soaked, dirt particles or moisture can reach the Mass Air Flow Sensor and cause an incorrect airflow reading. This causes lack of performance because a lower injection amount is calculated. Always use an original air filter insert. The air filter housing must be clean. Secure all hose connections with hose clamps that match current standard production When cleaning the air filter housing using compressed air, note the following: to avoid malfunctions, cover the critical air distribution components such as the mass airflow sensor, air guide tubes etc. with a clean cloth. Follow all waste disposal regulations!

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

Scheme 41

Clean air filter housing (upper and lower parts) of salt residue, dirt or leaves (clean with vacuum, if necessary).

Check mass airflow sensor and air guide hose (clean air side) for salt residue, dirt and leaves.

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

When installing air filter insert, ensure it is centered in mount on bottom of air filter.

Carefully and gently place upper part of air filter on lower part. Make sure the air filter housing upper section is not sitting crooked on air filter (pay attention to the air filter sealing lip).

Make sure the air guide hose is seated firmly on mass airflow sensor.

Loosen bolts -arrows- and raise cover.

Scheme 42

Remove the old air filter.

Clean the filter housing and insert a new air filter.

Remove the old air filter.

Clean the filter housing and insert a new air filter.

5-CYLINDER 2.5 TFSI

Removing

Scheme 43

Remove the engine cover -1- upwards -arrows-.

Scheme 44

Loosen the hose clamps -1- and -2-.

Remove the screws -arrows- and remove the air filter housing upper section.

Remove air filter insert.

Installing

Installation is reverse of removal, but note the following

For proper mass airflow sensor function, it is important to observe the following notes and perform the procedure exactly.

Note. If the air filter insert is heavily soiled or soaked, dirt particles or moisture can reach the Mass Air Flow Sensor and cause an incorrect airflow reading. This causes lack of performance because a lower injection amount is calculated. Always use an original air filter insert. The air filter housing must be clean. Secure all hose connections with hose clamps that match current standard production. When cleaning the air filter housing using compressed air, note the following: to avoid malfunctions, cover the critical air distribution components such as the mass airflow sensor, air guide tubes etc. with a clean cloth. Follow all waste disposal regulations!

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

Clean air filter housing (upper and lower parts) of salt residue, dirt or leaves (clean with vacuum, if necessary).

Check mass airflow sensor and air guide hose (clean air side) for salt residue, dirt and leaves.

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

When installing air filter insert, ensure it is centered in mount on bottom of air filter.

Carefully and gently place upper part of air filter on lower part. Make sure the air filter housing upper section is not sitting crooked on air filter (pay attention to the air filter sealing lip).

Make sure the air guide hose is seated firmly on mass airflow sensor.

HALDEX CLUTCH OIL, CHANGING

Replace oil. Refer to General Information

HOOD SAFETY CATCH, LUBRICATING

Perform the following steps in the given sequence

Note. Vehicle must be at least at room temperature. Operate the moveable components several times to allow the universal oil to seep in. Remove any excess lubricant with a lint-free cloth.

Scheme 45

Coat the hood safety catches with universal oil-Spray G 000 115 A2 at the marked positions -arrows-.

ENGINE COVER, REMOVING

Special tools and workshop equipment required

Scheme 46

1. Hose Clip Pliers -VAS 6340

4-Cylinder -gasoline engine 2.0L (TFSI)

Relieve load on clamps at Mass Air Flow (MAF) sensor -A- and at air intake connection -B- using pliers for spring type clamps VAS 6340 and slide them back.

Scheme 47

Disconnect the mass airflow sensor -2- and move the connector to the side.

Scheme 48

First pull engine cover forward -3 arrows- and then back -4 arrow-.

To do this, grab under the cover at the sides.

Note. When installing, place engine cover on four mounting points and press them down at the same time with the hand held flat. When installing, ensure rubber grommets are seated cleanly between air filter housing and intake tube.

4-Cylinder -gasoline engine 2.0L TFSI

Removing

Remove the engine cover -arrows-. Do not jerk the engine cover or pull it off from one side.

Scheme 49

Installing

Carefully press the engine cover back into the catches.

To avoid damage, do not hit engine cover with fist or a tool.

4-Cylinder -gasoline engine 1.8 TFSI, 2.0 TFSI

Scheme 50

Remove the engine cover -arrows-.

5-Cylinder -gasoline engine 2.5.0L TFSI

Remove the engine cover -1- upwards -arrows-.

4-Cylinder CR TDI Engine

Scheme 51

Remove the engine cover -arrows-.

ENGINE AND ENGINE COMPARTMENT FROM UNDERNEATH, INSPECTING FOR LEAKS AND DAMAGE

Perform visual check as follows

Check engine and transmission for leaks and damage.

Check the final drive, CV boots and steering for leaks and damage.

Note. Perform oil change at operating temperature.

Special tools and workshop equipment required

Scheme 52

Scheme 53

Scheme 54

1. Oil extractor V.A.G 1782
2. Hazet tension band 2171-1
3. Oil filter wrench 3417
4. Oil drain adapter T 40057

Note. Follow all waste disposal regulations!

4-CYLINDER, GASOLINE ENGINE, 1.8 TFSI, 2.0 TFSI

Remove the noise insulation. Refer to ENGINE COMPARTMENT FRONT NOISE INSULATION COVER, REMOVING AND INSTALLING .

Loosen oil filter with Hazet Tension Band 2171-1 or Oil Filter Wrench 3417 and remove.

Scheme 55

Note. Follow all waste disposal regulations!

Open oil drain plug or extract engine oil.

Clean oil filter sealing surface on engine.

Lubricate rubber seal lightly with oil.

Install new filter and tighten.

Install oil drain plug with new gasket.

Fill with engine oil, specifications, refer to Maintenance, Diagnosis .

4-CYLINDER, GASOLINE ENGINE, 2.0 TFSI, 2.5 TFSI

Remove the noise insulation. Refer to ENGINE COMPARTMENT FRONT NOISE INSULATION COVER, REMOVING AND INSTALLING .

Note. Before removing oil filter, motor oil must be drained from filter so that it does not drain onto engine and attached parts.

Remove bottom valve protective cap -1-.

Scheme 56

Remove ball head hose from Oil Drain Adapter T 40057 and turn threaded bolt in bottom oil filter housing bottom valve -2- under a slight resistance is felt.

Now place ball head hose on threaded bolts and turn Oil Drain Adapter T 40057 to stop - a clear snap of the drain valve will be heard.

Allow oil filter to run empty.

Open oil drain plug or extract engine oil.

Remove Oil Drain Adapter T 40057.

Scheme 57

Check whether bottom valve -1- is flush and not crooked, as in illustration (A02-0423).

Remove protective cap.

Open oil filter housing -2- with Oil Filter Wrench 3417 or with socket AF 36, e.g. Socket AF 36T10125 and remove oil filter.

Replace filter insert -4- and gasket -3-.

Scheme 58

Note. Note the position of the service flag on the seal -arrow-. Follow all waste disposal regulations!

Clean sealing surface on oil filter housing.

Lubricate rubber seal lightly with oil.

Smooth side of sealing ring must face toward outside

Screw on filter housing and tighten.

Install oil drain plug with new gasket.

Fill with engine oil, specifications, refer to Maintenance, Diagnosis .

To drain oil, remove noise insulation on drain plug. Refer to ENGINE COMPARTMENT FRONT NOISE INSULATION COVER, REMOVING AND INSTALLING .

Remove oil drain plug -1- and drain oil.

Scheme 59

Note. Follow all waste disposal regulations!

Loosen lower portion of filter housing -3- at the hex -2- or circumference -4- and remove.

Remove the old air filter.

Thoroughly wipe oil filter housing with a shop cloth.

Remove old O-ring.

Take new O-ring and coat with engine oil.

Install new filter element and O-ring.

Tighten the filter housing lower section -3- at the hex bolt -2- to 30 Nm.

Install the oil drain plug -1- with a new seal and tighten to 10 Nm.

Fill with engine oil, specifications, refer to Maintenance, Diagnosis .

HOOD HINGE, LUBRICATING

Lubricate the hood hinge joint with a universal lubricant spray G 000 115 A2.

ENGINE OIL, FILLING

Note. Oil capacities, oil specifications and viscosity class. Refer to Maintenance, Diagnosis .

Engines with a turbocharger

After the engine oil and oil filter have been replaced, observe the following when first starting the engine

1. As long as the oil pressure indicator lamp in the instrument cluster is on, the engine may only run in idle. Do not touch the accelerator pedal! Bumping the accelerator pedal can damage the turbocharger or destroy it completely
2. When the indicator lamp goes out, this means the oil pressure has been reached. Then you may accelerate.

All

Check the oil level. Refer to ENGINE OIL LEVEL, CHECKING .

ENGINE OIL LEVEL, CHECKING

Note. Minimum engine oil temperature 140°F (60°C). Vehicle must be in level position. After stopping engine, wait a few minutes to allow oil to flow back into oil pan. Follow all waste disposal regulations!

Pull out oil dipstick and wipe with clean rag. Replace dipstick and push down to stop.

Scheme 60

Pull out dipstick again and read oil level.

A - Oil must not be topped off.

B - Add oil.

C - Add oil.

1. The oil level should be located in the marked area -arrow-.

NAVIGATION EJECT BUTTON, UNLOCKING

Follow these steps in sequential order.

1. Connect VAS 5051/5052
2. Guided Functions
3. Go to - function/component selection
4. Service Work
5. J401 - Navigation, Eject button, locking/unlocking
6. Now follow guided program

RADIO, ENTERING SECURITY CODE TO ACTIVATE ANTI-THEFT CODING

Radios are supplied having a fixed code. The security code means that every radio with anti-theft coding is programmed with its own code. This code is not active from the factory. To increase anti-theft protection, there is no longer a radio card in the radio and navigation system owner's manual. The entry of the radio code is no longer described in the owner's manual.

The Anti-theft coding on a unit that is ready to play is activated by entering the fixed code.

On chorus II+, concert II+ and symphony II+ radios, enter the radio code as follows

Switch on radio. "Code 1000" appears.

Press the upper left control button "X___" -arrow- until the first digit of the radio code appears in the display.

Enter remaining three radio code digits with other three control buttons

Press the "ENTER" button. The radio is coded.

Dispose of sticker with radio code.

Scheme 61

If the radio code is entered incorrectly two times and "Code Safe 2" appeared in the display, use the following procedure

Leave radio switched on approximately 60 minutes. After 60 minutes, "Code Safe / Code 1000" appears in the display and the radio is switched off.

Enter radio code again.

On navigation system BNS 5.0, enter radio code as follows

Switch on navigation system

Enter PIN using Speller

Confirm entry with "OK".

Dispose of sticker with radio code.

Note. Please inform the customer that he can only learn the anti-theft radio code from the service advisor That way, thieves really cannot use the radio!

ROAD TEST

The following checks depend on the vehicle equipment level and the available testing possibilities (city or rural).

During the road test, check the following

1. Engine: performance, stalling, idle, acceleration
2. Clutch: starting, pedal force, smell
3. Shifting: ease of movement, shift lever position
4. Automatic transmission: selector lever position, shift lock/ignition key interlock, shift behavior, instrument cluster display
5. Foot and parking brake: function, free travel and effectiveness, pulling to one side, rubbing, squeaking
6. ABS function: when braking with activated ABS, the brake pedal must pulse noticeably.
7. Steering: function, steering travel, steering wheel center position when driving straight ahead.
8. Tilt/slide sunroof: function
9. Cruise control system: function
10. Radio: reception, interference
11. Driver information system (DIS): functions
12. A/C system: function
13. Vehicle: pulling to one side while driving straight ahead (level road)
14. Imbalance: wheels, driveshafts
15. Wheel bearing: noises
16. Engine: warm starting behavior
17. Check the horn

WHEEL BOLTS, TIGHTENING SPECIFICATIONS

The adapter to loosen/tighten the anti-theft wheel bolts is located with the vehicle tool kit.

Note. Be sure to tighten wheel bolts in diagonal sequence to the following specified torque

Place the adapter and extractor back in the vehicle tool kit.

TIRE PRESSURE MONITORING DISPLAY, ADAPTING

Note. After each change involving the tires, e.g. tire pressure or replacing or exchanging tires, the system must be programmed.

With ignition on and vehicle standing, press tire pressure monitoring button -arrow- until tire pressure display blinks several times in instrument cluster and a signal is heard.

Scheme 62

Once the signal is heard, the TPMS has been adapted.

WINDSHIELD WASHER SYSTEM, CHECKING AND ADJUSTING SPRAY NOZZLES

Special tools and workshop equipment required

Scheme 63

Scheme 64

1. Setting tool T10127 equipped with Tip 3125/5A
2. or
3. Setting tool T40187 equipped with Tip 3125/5A

Unlock the long cover -1- on the spray nozzle adjusting tool T40187 -arrow A- and push it toward the rear -arrow B-.

Scheme 65

Install the adjusting pin -2- on the spray nozzle -arrow- in the nozzle unit -1- and aim it at the windshield. Adjust it if necessary.

Scheme 66

If the spray field does not match the specifications, clean uncleaned washer nozzles.

Note. Never use a needle or a similar object, since it may damage the water hoses in the spray nozzle!

Setting

Scheme 67

Note. The adjustment dimensions give values for a driving vehicle, that is, when parked, the spray pattern will shift slightly.

Mark the 6 points on the windshield with a water-soluble pen

Locate the points of the individual spray jets with the Windshield Washer Aiming Tool T10127.

If the spray field does not match the specifications, clean uncleaned washer jets.

Cleaning washer nozzles

Remove washer nozzle. Refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation

Flush washer jet in the opposite direction of the spray flow with clean water.

To remove the rest of the contaminants, the washer jet may only be cleared with compressed air blowing opposite the direction of the spray.

If the spray field still does not correspond to the specifications, replace the washer jet.

HEADLAMP WASHER SYSTEM, CHECKING SPRAY NOZZLES

Headlamp cleaner spray nozzles are set at the factory and do not need to be adjusted.

WINDSHIELD WIPER BLADES, CHECKING END POSITION AND FOR DAMAGE

Windshield Wiper Blade Park Position

Note. Every second time it is switched off, the wiper motor runs to an over-stroke parked position, that ensures that the lip of the wiper blade is flipped to the other direction. For this to happen, the wiper motor runs downward to the end position and then back up again very slightly. This over-stroke parked position must not be used for aligning/checking the wiper crank. The position where the wiper motor runs directly to end position must be used. Activate mist wipe again, if necessary.

Switch windshield wipers on and off and allow to run to end position.

Turn the ignition off.

Check if the windshield wiper blade tips are positioned with the following distances to the plenum chamber cowl panel grille at the bottom of the windshield

Scheme 68

1. Dimension -a- = 5 mm +10 mm
2. Dimension -b- = 24 mm + 10

Adjust the wiper arm if necessary. Refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation

Note. The dimensions give the distance of the wiper blade point to the black cowl panel on lower edge of windshield. Placement is similar for RHD vehicles.

SERVICE INTERVAL DISPLAY, THROUGH MY 2007, RESETTING

Follow these steps in sequential order.

1. Connect VAS 5051/5052
2. Guided Fault Finding or Guided Functions
3. Go to - function/component selection
4. Service Work
5. Combination Processor, reset WIV
6. Now follow guided program

Note. Please follow guided program function description WIV = Wartungsintervall - Verlαngerung (Maintenance Interval Extension)

SERVICE INTERVAL DISPLAY, FROM MY 2008, RESETTING

Note. From MY 2008, all vehicles are equipped with the new maintenance concept as in the A5

Follow these steps in sequential order.

1. Connect VAS 5051/5052
2. Guided Functions
3. Service Work
4. Now follow guided program

OIL QUALITY, ADAPTING

Follow these steps in sequential order.

1. Connect VAS 5051/5052
2. Use auxiliary K-lead adapter VAS 6017B
3. Guided Fault Finding or Guided Functions
4. Go to - function/component selection
5. Service Work
6. Combination Processor, changing oil quality
7. Now follow guided program

Note. It is necessary to change oil quality if changed between inspection or LongLife Service. Inspection Service = Oil quality 1 LongLife Service = Oil quality 2 WIV = Wartungsintervall - Verlαngerung (Maintenance Interval Extension) Please follow guided program function description

MAXIMUM VALUES, ADAPTING

Note. Applies only through MY 2007

Follow these steps in sequential order.

1. Connect VAS 5051/5052
2. Guided Fault Finding or Guided Functions
3. Go to - function/component selection
4. Service Work
5. Combination Processor, adjusting maximum WIV value
6. Now follow guided program

Maximum values at inspection service

Note. WIV = Wartungsintervall - Verlαngerung (Maintenance Interval Extension) Please follow guided program function description

SERVICE DISPLAY, RESETTING AFTER SERVICE WITHOUT VAS 5051/5052

Note. If the service display is reset manually via the instrument cluster, it automatically sets itself to fixed interval.

Switch the ignition on.

Scheme 69

With button 1 pressed, the message "SERVICE" appears.

Pull the knob one more time within 5 seconds until "SERVICE IN.... KM... DAYS appears."

Service has been reset.

INSTALL FUSE FOR HEADLAMP WASHER SYSTEM

Headlamp washer system fuse: 30 amp fuse is installed in fuse panel 1, location 1 in the E-box in the engine compartment.

Insert it in fuse holder 1 slot number 6 in the engine compartment E-box

Scheme 70

DUST AND POLLEN FILTER, REMOVING AND INSTALLING

Note. The dust and pollen filter is available in different versions without and with a filter inserter in activated charcoal. Audi TT, which have A/C system, a dust and pollen filter with filter insert with activated charcoal is installed at this time. Clean dust and pollen filter area in A/C duct before installing a new filter. On vehicles with driver training equipment, you must remove the driver training pedals if necessary (depending on version, there are service separation points on the training pedals for driver training equipment)

Remove the screws -A- and remove the insulation -B-.

Scheme 71

Cover floor covering in area under dust and pollen filter with paper.

Push cover -B- in direction of arrow -C- and remove cover.

Scheme 72

Note. If the retainers -D- can no longer hold the cover -B-, it can be secured with screws -A-.

Remove dust and pollen filter -A- from A/C unit shaft -B-.

Scheme 73

Clean A/C unit over shaft -B- (e.g. with a vacuum) after removing dust and pollen filter.

TIE RODS, CONTROL ARMS, BALL JOINT AND DRIVESHAFTS, CHECKING PLAY, FIT AND SEALING BOOTS

Note. This test must be performed with vehicle raised (wheels hanging).

Check play by moving tie rods and wheels.

1. There must not be any play.

Scheme 74

Check joint boots -arrow- for damage and proper seating.

Scheme 75

Check joint boots -arrow- for damage and proper seating.

Also check rear side of joint boots with a mirror.

Check the play on the supporting joints -arrow

Check the drive shaft boots.

Scheme 76

Check the sealing boot on the steering gear -arrow 1- for damage.

Note. Ignore arrows -2- and -3

TRANSPORT MODE, DEACTIVATING USING VAS 5051/5052

Transport mode is for maintaining a vehicle's startability (battery charge). Transport mode limits discharging of battery. If transport mode is activated, many functions are not available or have limited function, for example, CD changer is deactivated, radio is deactivated, etc.

Switch off the transportation mode using Guided Fault Finding or Guided Functions.

Follow these steps in sequential order.

1. Connect VAS 5051/5052
2. Vehicle Self-Diagnosis (OBD)
3. Collected services
4. Energy manager, deactivate transport mode

DOOR ARRESTER, DOOR HINGE AND LOCK CYLINDER, LUBRICATING

Perform the following steps in the given sequence

Note. Vehicle must be at least at room temperature. Operate the moveable components several times to allow the universal oil or spray lubricant to seep in. Remove any excess lubricant with a lint-free cloth.

Scheme 77

Remove the protective cap -1- in the direction of the arrow.

Lubricate the door arrester on the marked positions -arrows-.

1. Use universal oil spray G 000 115 A2.

Scheme 78

Lubricate the door hinge on the marked positions -arrows-.

1. Use universal oil spray G 000 115 A2.

Lock Cylinder

Lubricate the lock cylinder.

1. Use spray lubricant G 052 778 A2.

TRANSPORT PROTECTION, REMOVING FRONT AND REAR SUSPENSION STRUT PROTECTORS

Two versions of protection devices are used. (front spring ridges, rear blocking pieces)

Release coil spring (for example, put vehicle on lift)

Note. It is not necessary to remove the wheels. Be careful not to damage surface of coil springs.

Remove protection devices from springs.

Note. After removing the spring clip and the spacer and lubricating the strut tube cap, make sure that the boot in the strut bearing is in the correct position as with the shock absorber tube.

UNDERBODY PROTECTION, INSPECTING FOR DAMAGE

When inspecting, observe underbody, wheel housings and sills!

PLENUM CHAMBER WATER DRAIN, CHECKING AND CLEANING

Remove the plenum chamber cover.

Note. Visually inspect plenum chamber for contaminants, for example, leaves. If there are contaminants, clean water drain and plenum chamber.

Remove the plenum chamber cover. Refer to Removal and Installation

FACTORY-EQUIPPED WINTER TIRES

Note. On vehicles that were delivered from factory with winter tires, check for correct pressure during delivery inspection. The excessive speed warning label should be placed in driver field of vision.

CLOCK, SETTING

Radio Clock

Note. The clock can function as a radio-controlled quartz clock as well as a normal quartz clock.

If an acceptable radio clock signal is received, clock automatically switches to "radio-controlled quartz clock" operating mode. The radio clock reception symbol (radio tower radiating waves) appears in display. If the clock does not receive a valid signal, it automatically switches to "quartz clock" mode after 3 days and radio clock reception symbol goes out.

Note. Observe waste disposal regulations!

Special tools and workshop equipment required

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

1. Spark plug wrench 3122B
2. Ignition Coil Puller T40039
3. Puller T10095/a
4. Removal/installation tool T10029
5. Removal/installation tool T10118
6. Puller T10094 A

Scheme 85

Turn the ignition off.

Remove connectors for ignition coils with power output stages -arrows-.

Unlock the connector locating device with the assembly tool T10118.

Scheme 86

Place the assembly device T10118 on the connector locating device -arrow-, and carefully pull the connector off.

Push the remover T10095/a from the straight connector side, in the direction of the arrow, on the ignition coil with power output stage

Scheme 87

Pull the ignition coil with power output stage up perpendicularly and out.

Observe the installed locations of the ignition coils with power output stages to the connectors, before they are removed -arrows-.

Scheme 88

The straight side of the connector must fit to the straight side of the ignition coil with power output stage.

Remove spark plugs using spark plug wrench 3122B.

Scheme 89

Install new spark plugs with spark plug wrench 3122B.

Assembly is done in reverse order.

Turn the ignition off.

Disconnect the electrical connectors -arrows- and pull all the connectors evenly from the ignition coils.

Scheme 90

Using the ignition coil puller T40039 remove all the ignition coils from the spark plug shaft.

Scheme 91

Remove spark plugs with 3122 B.

Screw in new spark plugs using 3122 B.

Loosely place all ignition coils in spark plug shaft

Align ignition coils to connectors and place all connectors evenly on ignition coils.

Press ignition coils evenly by hand onto spark plugs (do not use a hammer).

Turn the ignition off.

Remove the engine cover, refer to ENGINE COVER, REMOVING .

Remove both bolts -1-.

Scheme 92

Push connector -2- toward ignition coil, press on catch with hand and remove connector.

Remove ignition coil from spark plug with Ignition Coil Puller T40039.

Remove spark plugs with 3122 B.

Screw in new spark plugs using 3122 B.

Note. Push ignition coils by hand into intended resources in cylinder head cover.

Install ignition coils by rotating slightly - they must engage noticeably.

Turn the ignition off.

Scheme 93

Disconnect the connector -6- on the camshaft position sensor 3 -G300-.

Remove both screws -arrows-.

Release the connectors and at the same time remove them from the ignition coils -1 through 5-.

Scheme 94

Slide the ignition coil puller T40039 onto the ignition coil with power output stage and remove the ignition coil -arrow-.

Remove spark plugs with 3122 B.

Screw in new spark plugs using 3122 B.

Installing

Install all the ignition coils into the spark plug shaft.

Align the ignition coils with the connectors and attach all the connectors at the same time onto the ignition coils.

Press the ignition coils evenly onto the spark plugs by hand. Do not hit them.

Tighten the ignition coil wire guide to the cylinder head cover.

Note. Push ignition coils by hand into intended resources in cylinder head cover.

Install ignition coils by rotating slightly - they must engage noticeably.

See also:
• [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation
• BATTERY, CHARGING
• General Information
• [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation
• Removal and Installation
• FUEL INJECTOR CLEANER G17
• ENGINE COMPARTMENT FRONT NOISE INSULATION COVER, REMOVING AND INSTALLING
• ENGINE OIL LEVEL, CHECKING
• ENGINE COVER, REMOVING