Fuel

2006 Audi TT
ENGINE Fuel Supply System
ENGINE
Fuel Supply System
20 FUEL SUPPLY
FUEL SUPPLY SYSTEM, GENERAL INFORMATION
General repair notes
Observe safety precautions. Refer to Safety rules when working on fuel

supply system.
Observe rules for cleanliness. Refer to Rules of cleanliness.
Fuel Pump (FP) relay and activation, checking:
Refer to
24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V
TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU
TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC
TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP
TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA
24 MULTIPORT FUEL INJECTION (MFI) for 3.2 LITER V6 4V FUEL
INJECTION & IGNITION, ENGINE CODE(S): BHE
Safety rules when working on fuel supply system
WARNING: Fuel supply lines are under pressure! Before

removing from hose connection wrap a cloth around
the connection. Then release pressure by carefully
pulling hose off connection.
The following steps should be taken before beginning work on the fuel supply:
me
Friday, April 17, 2009 5:34:25
5:34:20 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
2006 Audi TT
Switch ignition off and disconnect battery Ground (GND) strap.

Open fuel filler cap briefly and then close again.
When removing and installing components from full or partially full fuel tanks, the
following must be observed:
Fuel tank may be only a maximum of 1/3 full.

If necessary, remove fuel from tank as described - vehicles with Front Wheel
Drive (FWD). Refer to Fuel supply system components, servicing (vehicles
with Front Wheel Drive), vehicles with All Wheel Drive (AWD), refer to
Fuel supply system components, servicing (vehicles with All Wheel Drive).
Before starting work, switch on exhaust extraction system and place an
extraction hose close to the sensor opening in 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 m3/h can be used.
Prevent gasoline from contacting skin! Wear fuel-resistant gloves!
Before removal of complete fuel tank, tank must be emptied for weight
considerations.
If necessary, remove fuel from tank as described - vehicles with Front Wheel
Drive (FWD). Refer to Fuel supply system components, servicing (vehicles
with Front Wheel Drive), vehicles with All Wheel Drive (AWD), refer to
Fuel supply system components, servicing (vehicles with All Wheel Drive).
Rules of cleanliness
When working on the fuel supply and/or injection system, pay careful attention to
the following points:
Thoroughly clean all connections and the surrounding area before

disconnecting.
Place parts that have been removed on a clean surface and cover. Do not use
fluffy cloths!
Carefully cover opened compartments or seal, if the repair cannot be carried
out immediately.
me
Friday, April 17, 2009 5:34:20 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.
2006 Audi TT
Only install clean components: Only unpack replacement parts immediately

prior to installation. Do not use parts that have been stored loose (in tool boxes
etc.)
When the system is open: Do not work with compressed air if it can be
avoided. Do not move vehicle unless absolutely necessary.
FUEL SUPPLY SYSTEM COMPONENTS, SERVICING (VEHICLES WITH FRONT WHEEL
DRIVE)
Fuel supply system components, servicing (vehicles with Front Wheel Drive)
NOTE: Secure all hose connections using same type of clips

as originally installed:
VAG1921 Pliers are recommended for installing spring clips.

Always replace seals and gaskets.
Line up arrows on hose and tube connections.
Fuel tank with attachments, component overview
me
2006 Audi TT
Fig. 1: Identifying Special Tools - Fuel Tank With Attachments, Component

Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.
1 - Mounting straps
Removing and installing. Refer to Fuel tank with attachments, removing

and installing
Note varying lengths
2 - Fuel filter
Note installation position

me
2006 Audi TT
Installed position: arrow points in direction of flow
3 - Supply line
Black
To fuel rail
To remove fuel filter, press release button at connection piece
4 - Screw clip
For fuel filter

Installed position. See Fig. 3
5 - Vent line
White
From Evaporative Emission (EVAP) canister
To EVAP canister purge regulator valve -N80-
6 - Supply line
Black
To fuel filter
Attaches to connection with "V.marking at connector flange
Press release button on connector piece to remove from flange or from filter.
7 - Return line
Blue
From fuel rail
Attaches to connection with "R" marking at connector flange
To remove connector flange, press release button on connecting piece.
8 - 4-pin harness connector
me
2006 Audi TT
9 - 11 Nm
10 - Cap nut, 10 Nm
11 - Ground (GND) connection
Installed position/test requirements. See Fig. 2

Check for tight fit of connector at metal ring of filler tube.
Securely tighten screw eyelet of electrical wire using cap nut item 14 under
Fuel tank with attachments, component overview.
After installing, check electrical connection of metal ring at fuel filler tube to a
blank portion of chassis using multimeter:
Specified value: approx. 0 ohms
12 - Nut, 10 Nm
13 - Bracket
For fuel filler tube
14 - Sealing cap
With seal
15 - Tensioning ring
Large diameter
Small diameter
17 - Rubber cup
With overflow hose

Installed position. Refer to Installing
me
2006 Audi TT
18 - Vent line
To EVAP canister
Only remove together with tank protection valve and gravity valve
19 - Vent line
White
From EVAP canister
To Evaporative Emission (EVAP) canister purge regulator valve -N80-
20 - Fuel tank

and installing
21 - Heat shield
For fuel tank
22 - Clamping washer
Removing: turn to left
Installing: tighten to 2 Nm
23 - 26 Nm
24 - 26 Nm
Installation position of Ground (GND) connection
me
2006 Audi TT
Fig. 2: Installation Position Of Ground (GND) Connection

Route Ground (GND) connection as shown in Fig. 2.
Ensure connector -2- of Ground (GND) connection fits securely at metal ring -
1- of fuel filler tube.
Disconnect Ground (GND) connection at both retaining clips (arrow).
NOTE: Depending on construction version, a cable binder may be

implemented in place of a clip.
Work sequence
Tighten eyelet of electrical wire -1- at chassis using cap nut -2- (10 Nm).
After installing, check electrical Ground connection using an ohmmeter
between metal ring of fuel filler tube and chassis.
Specified value 0 ohms

Installation position of screw clip for fuel filter
me
2006 Audi TT
Fig. 3: Installation Position Of Screw Clip For Fuel Filter

Install screw clip (arrow) as shown.
NOTE: Illustration depicts fuel filter from front.

Fuel filler tube, component overview
me
2006 Audi TT
Fig. 4: Fuel Filler Tube, Component Overview

1 - Pressure retention valve

Clipped to fuel filler unit
Closes vent line when vacuum from intake manifold is present
Only remove together with vent line and gravity valve
2 - Change-over valve
Removing and installing, checking. See Fig. 5.
me
2006 Audi TT
3 - O-rings
Different sizes
Always replace
4 - Seal
Installed position: sealing lip faces fuel filler unit

5 - O-ring
Always replace
6 - Gravity valve
Only remove together with vent line and pressure retention valve
Checking. See Removing, installing, and checking gravity valve, Removing,
installing, and checking gravity valve
To remove, unclip valve upward and lift out.

Installed position/check requirements. See Fig. 7
Ensure secure fit of connector at metal ring of fuel filler unit
Securely tighten eyelet of electrical wire with cap nut. Refer to item 8 under
Fuel filler tube, component overview.
blank portion of chassis using multimeter: Specified value: approx. 0 ohms
8 - Cap nut, 10 Nm
9 - Vent line
To EVAP canister
Removing, installing, and checking change-over valve
me
2006 Audi TT
Fig. 5: Removing, Installing, And Checking Change-Over Valve

Removing
Remove fuel tank. Refer to Fuel tank with attachments, removing and
installing.
Remove valve by unclipping sideways and remove from delivery unit.
Remove hose by pressing release button.
Checking
Blow into hose -2-.
Button -1- at rest: it must not be possible to blow through hose.

Button -1- pressed in direction of arrow: it must be possible to blow through
hose.
Removing, installing, and checking gravity valve
me
2006 Audi TT
Fig. 6: Removing, Installing, And Checking Gravity Valve

Removing
NOTE: Gravity valve -1- can only be replaced together with

pressure retention valve and vent line -3-.
installing.
Unclip pressure retention valve.
To remove, unclip gravity valve upward and lift out.
Checking
Hold valve in installation position.
It must be possible to blow through hose.
Tilt valve 45°.
It must not be possible to blow through hose.
NOTE: O-ring -2- must not be damaged; replace if necessary.

me
2006 Audi TT

Disconnect Ground (GND) connection at both retaining clips (arrow).

Work sequence
Fig. 8: Tightening Eyelet Of Electrical Wire At Chassis Using Cap Nut

me
2006 Audi TT


Fuel tank, emptying
A - Procedure for emptying fuel tank more than 3/4 full. Refer to A - Procedure
for fuel tank more than 3/4 full.
B - Procedure for emptying fuel tank less than 3/4 full. Refer to B - Procedure for
fuel tank less than 3/4 full.
Special tools and equipment
Fig. 9: Identifying Fuel Siphoning Unit VAS 5190

VAS 5190
or
me
2006 Audi TT
Fig. 10: Fuel Siphon Device VAG1433A

VAG 1433 A
Work sequence
Observe safety precautions. Refer to Safety rules when working on fuel supply
system.
Note radio code (for vehicles with coded anti-theft radio). Obtain if necessary.
Vehicles with 4-cylinder engine
Fig. 11: Removing Cover Above Battery

If installed, remove cover above battery.

me
2006 Audi TT
Open battery protective casing (Velcro).
Fig. 12: Disconnecting Battery Ground (GND) Strap

Switch ignition off and disconnect battery Ground (GND) strap (arrow).

Switch ignition off and disconnect battery Ground (GND) strap (arrow) under
trunk floor.
Continued for all vehicles
WARNING: Secure VAG 1433 A or VAS 5190 Ground wire to a

bare metal part on the body.
me
2006 Audi TT
A - Procedure for fuel tank more than 3/4 full
Remove filler cap from fuel tank filler neck.
Fig. 14: Disconnecting Tapered Adapter From Shaft End Of VAS 5190
Disconnect tapered adapter -2- from shaft end -1- of VAS 5190.
Make a mark (arrow) on hose at distance a = 1465 mm from end of drain hose
using insulating tape.
Fig. 15: Fitting Shaft End Of Fuel Extractor VAS 5190 Onto Fuel Tank Filler
Neck
me
2006 Audi TT
Fit shaft end -1- of fuel extractor VAS 5190 onto fuel tank filler neck.
Push drain hose into fuel tank until marking on drain hose (arrow) coincides
with shaft end.
NOTE:
Fig. 16: Identifying Spherical Valve, Fuel Tank And

Siphoning Hose & Fuel Extractor VAS 5190
On the lower end of the fuel filler unit, there is a spherical

valve -2- in the fuel tank -1-, which must not be excessively
pressured or damaged via the siphoning hose -3-.
Therefore, the hose should only be inserted to the marking
(arrow).
Remove fuel from tank as much as possible via fuel filler unit.
Carefully remove siphoning hose.
Remove fuel pump. Refer to Fuel pump, removing and installing.
Siphon remaining fuel through opening for fuel pump.
NOTE: The procedure when using a fuel extractor without shaft

me
2006 Audi TT
end is basically the same.
Fig. 17: Identifying Drain Hose Is Fitted Properly

In this case make a mark on drain hose at distance a =

980 mm from end of drain hose using insulating tape.
The drain hose is fitted properly when the marking on
drain hose (arrow) coincides with rim of the filler neck.
If the hose does not go in easily, lubricate lightly with
engine oil. Never use lubricants containing silicone.
B - Procedure for fuel tank less than 3/4 full

Siphon fuel through opening for fuel pump.
Fuel tank with attachments, removing and installing
me
2006 Audi TT
Fig. 18: Identifying Engine/Transmission Jack V.A.G. 1383 A

VAG1383A with VAG1359/2
Removing
system.
NOTE: For weight reasons, fuel tank must be emptied for removal.

me
2006 Audi TT



trunk floor.
TT Coupe
Remove rear seat bench.

me
2006 Audi TT
Refer to 72 - SEAT - FRAMES

TT Roadster
Remove the rear panel side trim.
Refer to 70 - INTERIOR TRIM
Fig. 22: Unscrewing Cover

Unscrew cover-1- at right (arrows).
Fig. 23: Disengaging 4-Pin Electrical Harness Connector

Disengage 4-pin electrical harness connector (arrow) and remove carefully.

me
2006 Audi TT
Open fuel flap.

Clean area surrounding fuel filler unit.
Remove fuel filler cap from fuel filler unit.
Remove rear axle.
Refer to 42 REAR SUSPENSION

Remove center and rear muffler of exhaust system.
Refer to
26 EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL.

5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMU, BEA
5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): ATC, AWP
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL.
5V TURBO GENERIC SCAN TOOL ENGINE CODE(S): AMU, BEA, ATC,
AWP
26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 LITER V6 4V
ENGINE MECHANICAL, ENGINE CODE(S): BHE
me
2006 Audi TT
Fig. 24: Removing Mounts For Rear Muffler & Heat Shield For Rear Muffler
Remove mounts -1- and -2- for rear muffler.

Remove heat shield for rear muffler (arrows).
Remove right rear wheel housing liner.
Refer to 66 EXTERIOR EQUIPMENT
Fig. 25: Unscrewing Ground (GND) Wire And Screws For Fuel Filler Unit
Unscrew Ground (GND) wire -2- and screws -1- for fuel filler unit.

me
2006 Audi TT
Fig. 26: Disconnecting Return Line, Supply Line And Vent Line Front Right
At Fuel Tank
Disconnect return line -1- (blue), supply line -2- (black) and vent line -3-
(white) front right at fuel tank (press release button).
NOTE: Electrical wire to Leak Detection Pump (LDP) -V144- will not
be disconnected.
Fig. 27: Disconnecting Vent Lines And To EVAP Canister

Disconnect vent lines -1- and -2- to EVAP canister.
Place VAG1383A engine/transmission lifter under fuel tank for retrieval.
CAUTION: For weight reasons, the fuel tank must be emptied for
removal.
me
2006 Audi TT
Fig. 28: Removing/Installing Fuel Tank Bolts

Loosen screws (arrows). Begin at retainer strap (lower left arrow).
Lower fuel tank.
Installing
Installation is the reverse of removal, noting the following:
NOTE: Secure all hose connections with the correct hose

clamps (same as original equipment.
To secure spring-loaded hose clamps, use hose clamp pliers VAG 1921.
Check ground wiring at both ends for traces of oxidation. Remove any traces
of oxidation if necessary.

me
2006 Audi TT

Route Ground (GND) wire as shown.
Make sure connector -2- is seated properly on metal ring -1- of fuel filler
opening.
Engage Ground (GND) connection at both retaining clips (arrows).
NOTE: The illustration depicts Ground (GND) wire routing

when fuel tank is removed.
Depending on construction version, a cable binder may
be implemented in place of a clip.
Position fuel tank and mounting straps at vehicle floor using VAG1383A
engine/transmission lifter.
Fig. 30: Removing/Installing Fuel Tank Bolts

Secure fuel tank at mounting points (arrow) using bolts (26 Nm).
Bolt mounting straps first.
me
2006 Audi TT
Fig. 31: Removing/Installing Ground (GND) Wire And Screws For Fuel Filler
Unit
Tighten bolts -1- and screw on Ground (GND) connection -2-.
WARNING: After installing, check electrical Ground

connection using ohm meter between fuel pump
delivery unit and chassis.
Specified value: 0 ohms
Check installation position of rubber cup. Refer to Installing.

Install rear right wheel housing liner and tighten fastening bolt for fuel filler
neck:

Install and adjust (tension free) center and rear muffler of exhaust system.
Refer to

me
2006 Audi TT
AWP
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 LITER V6 4V
GENERIC SCAN TOOL, ENGINE CODE: BHE
Install rear axle:
NOTE: After connecting battery, be sure to activate the

electrical accessories (radio, clock, power windows).
Additional precautions for reconnecting the power
supply:
Refer to

Generate readiness code.

Refer to
01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO

FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU
me
2006 Audi TT
FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC

FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP
FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA
01 - ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO
GENERIC SCAN TOOL ENGINE CODE(S): AMU, BEA, ATC, AWP
Tightening torques
Component Nm
Mounting straps for fuel tank to 26
chassis
Fuel tank to chassis 26
Fuel filler unit to bracket 11
Ground (GND) wire at wheel housing 10
Battery terminal to battery post 5
Tank flap, component overview
me
2006 Audi TT
Fig. 32: Tank Flap, Component Overview

1 - Tensioning ring
Small diameter
2 - Tensioning ring
Large diameter
3 - Sealing cap
With seal
me
2006 Audi TT
4 - O-ring
Replace if damaged
5 - Tank flap
Removing and installing. Refer to Removing
6 - Cylinder bolt, 4 Nm
To remove tank flap, remove only three illustrated bolts. Refer to Removing
7 - O-ring
Replace if damaged
8 - Striker
9 - Compression spring
10 - Retaining plate
11 - Phillips-head screw
12 - Disengagement cable
13 - Rubber cup
With overflow hose

14 - Fuel filler unit
Tank flap, removing and installing
me
2006 Audi TT
Fig. 33: Identifying Special Hook 3370

3370 special tool
Removing
Fig. 34: Removing Tank Flap Vertically From Chassis Cut-Out Using Special
Tool 3370
Remove three bolts designated with arrows.

Remove tank flap vertically from chassis cut-out using special tool 3370.
me
2006 Audi TT
Fig. 35: Removing Bolts Of Release Cable

Remove bolts (arrows) of release cable.
Installing
Fig. 36: Identifying Overflow Hole Is Flush With Edge Of Square Hole
In order to route overflow hose without kinks, rubber cup must be installed as
follows:
The edge of the overflow hole must be flush with the edge of the square hole as
depicted (arrows).
Tightening torques
Component Nm
me
2006 Audi TT
Tank flap to body 4

Fuel pump and Fuel level sensor -G-, component overview
Fig. 37: Fuel Pump And Fuel Level Sensor -G-, Component Overview
1 - Fuel pump
Removing and installing. Refer to Fuel pump, removing and installing

Check Fuel Pump (FP) electrically. Refer to Fuel pump, electrical testing
Checking residual pressure:
me
2006 Audi TT
Refer to
2 - Seal
Always replace
To install, place into opening of fuel tank when dry.
3 - Return line
Blue
From fuel rail
To remove connector flange, press release button on connecting piece
4 - Supply line
Black
To fuel filter
To remove from connector flange or from filter, press release button on
connecting piece.
me
2006 Audi TT
For Fuel Pump (FP) and Fuel level sensor -G-
6 - Union nut, 80 Nm
Use ring nut spanner 3217 to remove and install
7 - Fuel level sensor -G-
Checking resistance values. Refer to Fuel level sensor -G-, checking

Removing and installing. Refer to Fuel level sensor -G-, removing and
installing
Fuel pump, electrical testing
me
2006 Audi TT
Fig. 38: Identifying Special Tools - Fuel Pump, Electrical Testing

Ring nut spanner 3217

VAG1348/3A Remote control
VAG1348/3-2 Adapter
VAG1526A Multimeter
VAG1594A Adapter set
Requirements
Battery voltage at least 12.7 V

Fuse S228 OK (position 28)
Fig. 39: Identifying Fuel Pump (FP) Relay J17

Relay 4 in micro-central electrics (in driver's footwell, left) OK
Fuel filter OK
Ignition switched off
Work sequence
Open cover of fuse box at left side of instrument panel.

me
2006 Audi TT
Remove fuse S228 at fuse carrier (position 28, left row, 5th large fuse from
top).
Fig. 40: Connecting VAG1348/3A Remote Control Connection Using Adapter

Cables From VAG1348/3-2 At Right Terminal Of Socket From Fuse -S228-
Connect VAG1348/3A remote control connection using adapter cables from

VAG1348/3-2 at right terminal of socket from fuse -S228- (arrow).
Connect clamping terminal to B+.
Press switch of remote control.
Noise of pump must be audible.
NOTE: Fuel Pump (FP) runs quietly. Surrounding noise should be

avoided during test of the Fuel Pump (FP).
If no noise can be heard:
TT Coupe
TT Roadster
Remove rear panel side trim.

me
2006 Audi TT


Unscrew cover -1- at right (arrows).

Disengage 4-pin electrical harness connector and remove (arrow).
me
2006 Audi TT
Fig. 43: Identifying Connector Terminals 1 And 4

Connect multimeter between terminal 1 and 4 of harness connector for voltage
measurement.
Specification: approx. battery voltage
If specified value is not obtained:
Locate and repair open circuit using wiring diagram.
Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations
If specified value is obtained, although no operating noise can be heard from pump:

Check whether electrical wires between flange and Fuel Pump (FP) are
connected, and test for continuity if necessary.
If no malfunctions are found in wires:
Fuel Pump (FP) is faulty. Replace fuel pump. Refer to Fuel pump, removing
and installing.
Fuel pump delivery quantity, checking

me
2006 Audi TT
Fig. 44: Identifying Remote Control Connection V.A.G 1348/3A

VAG1348/3A with VAG1348/3-2
Fig. 45: VAG 1318/17 (2X) Adapter

VAG1318/17
Measuring container safe for fuel
Requirements

Fuel filter OK
me
2006 Audi TT
Switch ignition off
Work sequence

Remove fuse -S228- at fuse carrier (position 28, left row, 5th large fuse from
top).


Connect clamping terminal to Battery +.
me
2006 Audi TT
Fig. 47: Removing Screw And Coolant Expansion Tank Cover

Remove screw -1- and remove coolant expansion tank cover (arrow).

Fig. 48: Disconnecting Fuel Return Line From Line Tube & Connecting
VAG1318/17 Adapter To Fuel Return Line From Engine
me
2006 Audi TT
Disconnect fuel return line -1- from line tube -2- (press release button).
Connect VAG1318/17 adapter to fuel return line from engine and hold in a
measuring container.
Operate remote control for 15 seconds (keep button pressed).
Fig. 49: Delivery Rate Diagram

Compare fuel quantity pumped with specified value.
*) Smallest quantity cm3/15 s

**) Voltage at fuel pump with engine off and pump running (approx. 2 volts less
than battery voltage).
Fuel pump, removing and installing
me
2006 Audi TT
Fig. 50: Identifying Ring Nut Spanner 3217


Removing

supply system.
WARNING: Fuel tank must be less than 1/3 full when removing
fuel pump. If necessary,empty fuel tank. Refer to
Fuel tank, emptying

me
2006 Audi TT


trunk floor.
TT Coupe
TT Roadster
me
2006 Audi TT



me
2006 Audi TT
Fig. 56: Connecting Fuel Lines

Disconnect fuel supply line -1- and fuel return line -2- (press release button).
fuel pump. If necessary, empty fuel tank. Refer to
Fuel tank, emptying
Fig. 57: Removing/Installing Union Nut With Wrench 3217

Use ring nut spanner 3217 to remove union nut.

Pull fuel pump and sealing ring from opening of fuel tank.
NOTE: If Fuel Pump (FP) is still full of fuel, empty fuel before
me
2006 Audi TT
replacing.
Installing
NOTE: Insert new, dry seal for connection flange into opening
of fuel container.
When inserting Fuel Pump (FP) into fuel tank, be sure
not to bend fuel level sensor.
Make sure fuel hose is securely fastened.
Fig. 58: Pressing Connecting Flange Down Against Spring Pressure And
Bringing Connecting Flange Into Proper Installation Position
Press connecting flange down against spring pressure and bring connecting
flange into proper installation position.
Marking on connecting flange must align with marking on fuel tank (arrows).
Apply union nut by hand.
me
2006 Audi TT

Use ring nut spanner 3217 to tighten union nut (80 Nm).
Fig. 60: Connecting Fuel Lines

Connect fuel lines.
Black supply line -1- to connection with identification -V-.

Blue return line -2- to connection with identification -R-.
Connect 4-pin harness connector.

me
2006 Audi TT
supply:
Refer to
Refer to

01 - ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO
GENERIC SCAN TOOL ENGINE CODE(S): AMU, BEA, ATC, AWP
Tightening torques
Component Nm
Union nut for Fuel Pump (FP) 80
me
2006 Audi TT
Fuel level sensor -G-, checking
Fig. 61: Special Tool - Multimeter V.A.G 1526 A

VAG1526A Multimeter
Fig. 62: Identifying V.A.G 1594 A Adapter Set


Work sequence
me
2006 Audi TT
TT Coupe
TT Roadster


me
2006 Audi TT

Disconnect 4-pin electrical harness connector (arrow).
Vehicles up to 05.02
Fig. 65: Identifying Fuel Level Sensor & Terminals

Connect multimeter between terminal 2 and 3 for resistance measurement.
Component Float at lower end position Float at upper end position

Fuel level sensor -G- approx. 57 ohms approx. 290 ohms
For measured value 0 ohms there is a short circuit

For measured value infinity ohms there is an open circuit.
NOTE: To check resistance values "tank full" or "tank empty", Fuel

Pump (FP) must be removed (Refer to Fuel pump, removing
and installing) and the sensor float must be placed in the
upper or lower end position.
With fuel level sensor removed, the following values will result due to the longer
reach of the float arm:
Component float at lower end position float at upper end position

me
2006 Audi TT
Vehicles from 05.02
Fig. 66: Identifying Fuel Level Sensor & Terminals



NOTE: To check resistance values "tank full" or "tank empty", Fuel

Pump (FP) must be removed (Refer to Fuel pump, removing
and installing) and the sensor float must be placed in the
upper or lower end position.
With fuel level sensor removed, the following values will result due to the longer
reach of the float arm:

Fuel level sensor -G-, removing and installing
Removing
me
2006 Audi TT
system.
Fig. 67: Fuel Gauge Sender Connectors & Retaining Tabs

Disengage connector prongs of electrical wires -3- and -4- and disconnect.
Pry off retaining straps -1- and -2- using screwdriver and remove fuel level
sensor toward bottom (arrow).
Installing

Insert fuel level sensor into guides at Fuel Pump (FP) and press up until
engagement.
Insert connector prongs of electrical wires and check for proper engagement.
Install Fuel Pump (FP). Refer to Installing.
Observe notes for connection of battery.
FUEL SUPPLY SYSTEM COMPONENTS, SERVICING (VEHICLES WITH ALL WHEEL DRIVE)
Fuel supply system components, servicing (vehicles with All Wheel Drive)
me
2006 Audi TT
NOTE: Secure all hose connections using same type of clips

as originally installed:
VAG1921 Pliers are recommended for installing spring
clips.
Line up arrows on hose and tube connections.
Fuel tank with attachments, component overview
Fig. 68: Fuel Tank With Attachments, Component Overview

me
2006 Audi TT
1 - Heat shield
For fuel tank
With strap
2 - Fuel filter
Note installation position

Installed position: arrow points in direction of flow
3 - Supply line
Black
To fuel rail
To remove fuel filter, press release button at connection piece
4 - Screw clip
For fuel filter
Installed position. See Fig. 71
5 - Vent line
White
From Evaporative Emission (EVAP) canister
To EVAP canister purge regulator valve -N80-
6 - Supply line
Black
To fuel filter
Press release button on connector piece to remove from flange or from filter.
7 - Return line
me
2006 Audi TT
Blue
From fuel rail
To remove connector flange, press release button on connecting piece.
9 - 11 Nm
10 - Cap nut, 10 Nm
Installed position/test requirements. See Fig. 69

Check for tight fit of connector at metal ring of filler tube.
Securely tighten screw eyelet of electrical wire using cap nut item 14 under
Fuel tank with attachments, component overview.
blank portion of chassis using multimeter:
Specified value: approx. 0 ohms

12 - Nut, 10 Nm
13 - Bracket
For fuel filler tube
14 - Sealing cap
With seal
Large diameter
me
2006 Audi TT
Small diameter
17 - Rubber cup
With overflow hose

Installed position. Refer to Fig. 68
18 - Vent line
White
From EVAP canister
19 - Vent line
To EVAP canister
Only remove together with tank protection valve and gravity valve
20 - Fuel tank
and installing
21 - 26 Nm
22 - Mounting straps

and installing
Note varying lengths
23 - 26 Nm
24 - Clamping washer
Removing: turn to left

Installing: tighten to 2 Nm
me
2006 Audi TT
25 - 26 Nm


Disconnect Ground (GND) connection at both retaining clips(arrow).

Work sequence
me
2006 Audi TT

Installation position of screw clip for fuel filter
Fig. 71: Installation Position Of Screw Clip For Fuel Filter

Install screw clip (arrow) as shown.
NOTE: Illustration depicts fuel filter from front.

Fuel filler tube, component overview
me
2006 Audi TT
Fig. 72: Fuel Filler Tube, Component Overview

1 - Pressure retention valve

Clipped to fuel filler unit
Closes vent line when vacuum from intake manifold is present
Only remove together with vent line and gravity valve
2 - Vent valve
Removing and installing, checking. See Fig. 73
me
2006 Audi TT
3 - O-rings
Different sizes
Always replace
4 - Seal
Installed position: sealing lip faces fuel filler unit

5 - O-ring
Always replace
6 - Gravity valve
Only remove together with vent line and pressure retention valve
Checking. See Fig. 6
To remove, unclip valve upward and lift out.
Installed position/check requirements. See Fig. 75
Ensure secure fit of connector at metal ring of fuel filler unit
Securely tighten eyelet of electrical wire with cap nut. Refer to item 8 under
Fuel filler tube, component overview.
blank portion of chassis using multimeter: Specified value: approx. 0 ohms
8 - Cap nut, 10 Nm
9 - Vent line
To EVAP canister
Removing, installing, and checking change-over valve
me
2006 Audi TT
Fig. 73: Removing, Installing, And Checking Change-Over Valve

Removing
installing.
Remove valve by unclipping sideways and remove from delivery unit.
Remove hose coupling by pressing release button.
Checking
Blow into hose -2-.
Button -1- at rest: it must not be possible to blow through hose.

Button -1- pressed in direction of arrow: it must be possible to blow through
hose.
Removing, installing, and checking gravity valve
me
2006 Audi TT
Fig. 74: Removing, Installing, And Checking Gravity Valve

Removing
NOTE: Gravity valve -1- can only be replaced together with

pressure retention valve and vent line -3-.
installing.
Unclip pressure retention valve.
To remove, unclip gravity valve upward and lift out.
Checking
Hold valve in installation position.
It must be possible to blow through hose.
Tilt valve 45°.
It must not be possible to blow through hose.
NOTE: O-ring -2- must not be damaged; replace if necessary.

me
2006 Audi TT

Disconnect Ground (GND) connection at both retaining clips(arrow).

Work sequence
me
2006 Audi TT


Fuel tank, emptying
A - Procedure for emptying fuel tank more than 1/3 full. Refer to A - Procedure
for fuel tank more than 1/3 full.
B - Procedure for emptying fuel tank less than 1/3 full. Refer to B - Procedure for
fuel tank less than 1/3 full.
Fig. 77: Identifying Fuel Siphoning Unit VAS 5190

VAS 5190
or
me
2006 Audi TT
Fig. 78: Fuel Siphon Device VAG1433A

VAG 1433 A
Work sequence
system.


me
2006 Audi TT


trunk floor.
WARNING: Secure VAG 1433 A or VAS 5190 Ground wire to a

bare metal part on the body.
me
2006 Audi TT
A - Procedure for fuel tank more than 1/3 full
Remove filler cap from fuel tank filler neck.
Fig. 82: Disconnecting Tapered Adapter From Shaft End Of VAS 5190
Disconnect tapered adapter -2- from shaft end -1- of VAS 5190.
Make a mark (arrow) on hose at distance a = 1415 mm from end of drain hose
using insulating tape.
Fig. 83: Fitting Shaft End Of Fuel Extractor VAS 5190 Onto Fuel Tank Filler
Neck
me
2006 Audi TT
Fit shaft end -1- of fuel extractor VAS 5190 onto fuel tank filler neck.
Push drain hose into fuel tank until marking on drain hose (arrow) coincides
with shaft end.
NOTE:
Fig. 84: Identifying Spherical Valve, Fuel Tank And

Siphoning Hose & Fuel Extractor VAS 5190
On the lower end of the fuel filler unit, there is a spherical

valve -2- in the fuel tank -1-, which must not be excessively
pressured or damaged via the siphoning hose -3-.
Therefore, the hose should only be inserted to the marking
(arrow).
Remove fuel from tank as much as possible via fuel filler unit.
Carefully remove siphoning hose.
Siphon remaining fuel in right chamber of fuel tank through opening for fuel
pump.
me
2006 Audi TT
Insert hose in left chamber of fuel tank and siphon remaining fuel.
NOTE: The procedure when using a fuel extractor without shaft

end is basically the same.
Fig. 85: Identifying Drain Hose Is Fitted Properly

In this case make a mark on drain hose at distance a = 1350 mm from end of
drain hose using insulating tape. The drain hose is fitted properly when
marking on drain hose (arrow) coincides with rim of filler neck.
If the hose does not go in easily, lubricate lightly with engine oil. Never use
lubricants containing silicone.
B - Procedure for fuel tank less than 1/3 full

Siphon remaining fuel in right chamber of fuel tank through opening for fuel
pump.
Insert hose in left chamber of fuel tank and siphon remaining fuel.
Fuel tank with attachments, removing and installing
me
2006 Audi TT
Fig. 86: Identifying Engine/Transmission Jack V.A.G. 1383 A

VAG1383A Engine/transmission jack with VAG1359/2
Removing
system.
NOTE: For weight reasons, fuel tank must be emptied for removal.
me
2006 Audi TT




trunk floor.
me
2006 Audi TT
TT Coupe
TT Roadster

Unscrew cover-1- at right (arrows).

me
2006 Audi TT

Disengage 4-pin electrical harness connector (arrow) and remove.
Open fuel flap.
Clean area surrounding fuel filler unit.
Remove center and rear muffler of exhaust system:
Refer to
AWP
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 LITER V6 4V
GENERIC SCAN TOOL, ENGINE CODE: BHE
Remove driveshaft:
Refer to 39 FINAL DRIVE, DIFFERENTIAL

Remove rear axle:
Remove right rear wheel housing liner:
me
2006 Audi TT
Unscrew Ground (GND) wire -2- and screws -1- for fuel filler unit.

Fig. 93: Disconnecting Return Line, Supply Line And Vent Line Front Right
At Fuel Tank
Disconnect return line -1- (blue), supply line -2- (black) and vent line -3-
(white) front right at fuel tank (press release button).
NOTE: Electrical wire to Leak Detection Pump (LDP) -V144- will not
me
2006 Audi TT
be disconnected.
Fig. 94: Disconnecting Vent Lines To EVAP Canister

Disconnect vent lines -1- and -2- to EVAP canister.
Place VAG1383A engine/transmission lifter under fuel tank for retrieval.
WARNING: For weight reasons, fuel tank must be emptied for

removal.
Fig. 95: Identifying Retaining Tabs, Carrier Panel, Mounting Straps

Loosen screws as follows:
Retaining tabs -1- and -5-.

Carrier panel -3- and -7-.
me
2006 Audi TT
Mounting straps -2-, -4-, -6- and -8-.
Lower fuel tank.
Installing
NOTE: Secure all hose connections with the correct hose

clamps (same as original equipment.
To secure spring-loaded hose clamps, use hose clamp
pliers VAG 1921.
Check ground wiring at both ends for traces of oxidation. Remove any traces
of oxidation if necessary.

Route Ground (GND) wire as shown.
Make sure connector -2- is seated properly on metal ring -1- of fuel filler
opening.
Engage Ground (GND) connection at both retaining clips (arrows).
NOTE: The illustration depicts Ground (GND) wire routing

when fuel tank is removed.
me
2006 Audi TT
Depending on construction version, a cable binder may

be implemented in place of a clip.
Position fuel tank with carrying sheet and mounting straps at vehicle floor
using VAG1383A engine/transmission lifter.
Fig. 97: Identifying Retaining Tabs, Carrier Panel, Mounting Straps

Secure fuel tank using bolts as follows:
Mounting straps -2-, -4-, -6- and -8-.

Carrier panel -3- and -7-.
Retaining tabs -1- and -5-.
me
2006 Audi TT
Tighten bolts -1- and screw on Ground (GND) connection -2-.
WARNING: After installing, check electrical Ground

connection using ohm meter between fuel pump
delivery unit and chassis.
Specified value: 0 ohms
Check installation position of rubber cup. Refer to Installing.

Install rear right wheel housing liner and tighten fastening bolt for fuel filler
neck:
Install driveshaft:
Refer to 39 FINAL DRIVE, DIFFERENTIAL

Install rear axle:

Install and adjust (tension free) center and rear muffler of exhaust system.
Refer to

supply:
me
2006 Audi TT
Refer to

Refer to

Tightening torques
Component Nm
Mounting straps for fuel tank to 26
chassis
Fuel tank to chassis 26
Fuel filler unit to bracket 11
Ground (GND) wire at wheel housing 10
me
2006 Audi TT

Tank flap, component overview
Fig. 99: Tank Flap, Component Overview

1 - Tensioning ring
Small diameter
2 - Tensioning ring
Large diameter
me
2006 Audi TT
3 - Sealing cap
With seal
4 - O-ring
Replace if damaged
5 - Tank flap
Removing and installing. Refer to Removing
6 - Cylinder bolt - 4 Nm
To remove tank flap, remove only three illustrated bolts. Refer to Removing.
7 - O-ring
Replace if damaged
8 - Striker
9 - Compression spring
10 - Retaining plate
11 - Phillips-head screw
12 - Disengagement cable
13 - Rubber cup
With overflow hose
14 - Fuel filler unit
me
2006 Audi TT
Fig. 100: Identifying Special Hook 3370

3370 special tool
Removing
Fig. 101: Removing Tank Flap Vertically From Chassis Cut-Out Using Special
Tool 3370
Remove three bolts designated with arrows.

Remove tank flap vertically from chassis cut-out using special tool 3370.
me
2006 Audi TT
Fig. 102: Removing Bolts Of Disengagement Cable

Remove bolts (arrows) of disengagement cable.
Installing
Fig. 103: Identifying Overflow Hole Is Flush With Edge Of Square Hole
In order to route overflow hose without kinks, rubber cup must be installed as
follows:
The edge of the overflow hole must be flush with the edge of the square hole as
depicted (arrows).
Tightening torques
Component Nm
me
2006 Audi TT
Tank flap to body 4

Fuel pump, Fuel level sensor -G- and Fuel level sensor 2 -G169-, component overview
Fig. 104: Fuel Pump, Fuel Level Sensor -G- And Fuel Level Sensor 2 -G169-,
Component Overview
1 - Fuel level sensor -G-
Checking resistance values. Refer to Fuel level sensor -G-/Fuel level sensor
2-G169-, checking
me
2006 Audi TT
installing
2 - Fuel pump
Removing and installing. Refer to Fuel pump, removing and installing
Check Fuel Pump (FP) electrically. Refer to Fuel pump, electrical testing.
Checking residual pressure:
Refer to
3 - Seal
Always replace
4 - Return line
Blue
From fuel rail
To remove connector flange, press release button on connecting piece
5 - Supply line
me
2006 Audi TT
Black
To fuel filter
To remove from connector flange or from filter, press release button on
connecting piece.
For Fuel Pump (FP), Fuel level sensor -G- and Fuel level sensor 2 -G169-

For Fuel level sensor 2 -G169-
10 - Seal
Always replace
11 - Secondary fuel pump
With connecting flange

With wiring
Removing and Installing. Refer to Secondary fuel pump, removing and
installing
12 - Fuel level sensor 2 -G169-
Checking. Refer to Fuel level sensor -G-/Fuel level sensor 2-G169-,

me
2006 Audi TT
checking
installing
13 - Hose coupling
For fuel hose to secondary fuel pump

To disconnect, press release button
14 - Retaining strap
For fuel hose from secondary fuel pump

Engage in fuel pump and press in locking mechanism
Fuel pump, electrical testing
me
2006 Audi TT
Fig. 105: Identifying Special Tools - Fuel Pump, Electrical Testing


VAG1348/3-2 Adapter
VAG1348/3A Adapter
VAG1526A Multimeter
VAG1594A Adapter kit
Requirements
me
2006 Audi TT

Fuse -S228- OK (position 28)
Fig. 106: Identifying Fuel Pump (FP) Relay J17

Relay 4 in micro-central electrics (in driver's footwell, left) OK

Fuel filter OK
Ignition switched off
Work sequence

top).

me
2006 Audi TT

Pump noise must be audible.
NOTE: Fuel Pump (FP) runs quietly. Surrounding noise should be

avoided during test of the Fuel Pump (FP).
If no noise can be heard:

TT Coupe
TT Roadster
me
2006 Audi TT


Fig. 110: Identifying Connector Terminals 1 And 4

Connect multimeter between terminal 1 and 4 of harness connector for voltage

measurement.
Specification: approx. battery voltage
me
2006 Audi TT

Locate and repair open circuit using wiring diagram.
If specified value is obtained, although no operating noise can be heard from pump,
remove connecting flange as follows:
When removing the connection flange from the fuel pump, the fuel tank should
be less than 1/3 full. If necessary, empty the fuel tank. Refer to Fuel tank,
emptying.

me
2006 Audi TT


trunk floor.

me
2006 Audi TT
Fig. 114: Disconnecting Fuel Supply Line And Fuel Return Line
fuel pump. If necessary,empty fuel tank. Refer to
Fuel tank, emptying


Remove connecting flange of fuel pump via opening of fuel tank and lay aside
with wires connected.
Check whether electrical wires between flange and Fuel Pump (FP) are
connected, check for continuity if necessary.
me
2006 Audi TT
If no malfunctions are found in wires:

Fuel Pump (FP) is faulty; replace fuel pump. Refer to Fuel pump, removing
and installing.
Fuel pump delivery quantity, checking
Fig. 116: Identifying Remote Control Connection V.A.G 1348/3A

VAG1348/3A with VAG1348/3-2 Adapter
Fig. 117: VAG 1318/17 (2X) Adapter

me
2006 Audi TT
VAG1318/17 Adapter
Measuring container safe for fuel
Requirements

Fuel filter OK
Switch ignition off
Work sequence

top).


me
2006 Audi TT
Fig. 119: Removing Screw And Coolant Expansion Tank Cover

Remove screw -1- and remove coolant expansion tank cover (arrow).

Fig. 120: Disconnecting Fuel Return Line From Line Tube & Connecting
VAG1318/17 Adapter To Fuel Return Line From Engine
me
2006 Audi TT
Disconnect fuel return line -1- from -2- (press release button).
Connect VAG1318/17 adapter to fuel return line from engine and hold in a
measuring container.
Operate remote control for 15 seconds (keep button pressed).
Fig. 121: Delivery Rate Diagram

Compare fuel quantity pumped with specified value.
*) Smallest quantity cm3/15 s

**) Voltage at fuel pump with engine off and pump running (approx. 2 volts less
than battery voltage).
Fuel pump, removing and installing
me
2006 Audi TT


Removing
system.

When removing the connection flange from the fuel pump, the fuel tank should be
less than 1/3 full.
If necessary, empty fuel tank. Refer to Fuel tank, emptying.



me
2006 Audi TT


trunk floor.
TT Coupe
TT Roadster
me
2006 Audi TT



me
2006 Audi TT
fuel pump.


Pull fuel pump and sealing ring out of opening in fuel tank and set aside with
lines attached.
me
2006 Audi TT
Fig. 130: Identifying Harness Connector, Wire, Retaining Strap & Fuel Pump
Reach into fuel tank and disconnect harness connector -1-.

Press release button of hose coupling and disconnect wire -2-.
Pull retaining strap -3- upward and disengage strap and wire -4- to fuel pump -
5-.
NOTE: Fuel pump is shown in removed condition in Fig. 130.
Pull fuel pump and sealing ring out of opening in fuel tank.
Installing
of fuel container.
not to bend fuel level sensor.
Make sure fuel hose is securely fastened.
me
2006 Audi TT
Insert Fuel Pump (FP) -5- in connecting flange of fuel tank (set aside).
Engage retaining strap -3- of wire -4- to Fuel Pump and press retaining strap
into locking mechanism.
Retaining strap must engage properly
me
2006 Audi TT
Press hose coupling of wire -2- together until engagement.

Connect 2-pin harness connector -1- to fuel level sensor.
Insert guide of connecting flange into guide of Fuel Pump (FP). Be careful of
spring.
Fig. 133: Pressing Connecting Flange Down Against Spring Pressure And
Bringing Connecting Flange Into Proper Installation Position
Press connecting flange down against spring pressure and bring connecting
flange into proper installation position.
Apply union nut by hand.
me
2006 Audi TT

Use ring nut spanner 3217 to tighten union nut.
Attach fuel line.

Black supply line -1- to connection with identification -V-.
Blue return line -2- to connection with identification -R-.
Connect 4-pin harness connector.

supply:
Refer to
me
2006 Audi TT

Refer to

Tightening torques
Component Nm
Union nut for Fuel Pump (FP) 80
Fuel level sensor -G-/Fuel level sensor 2-G169-, checking
me
2006 Audi TT
Fig. 136: Special Tool - Multimeter V.A.G 1526 A

VAG1526A Multimeter
Fig. 137: Identifying V.A.G 1594 A Adapter Set

Work sequence
TT Coupe
me
2006 Audi TT

TT Roadster



me
2006 Audi TT
Vehicles up to 05.02
Fig. 140: Identifying Fuel Level Sensor -G-, Fuel Level Sensor 2 -G169- &
Terminal
Component float at lower end float at upper end

position position
Fuel level sensor -G- and Fuel level approx. 59 ohms approx. 282 ohms
sensor 2 -G169-

NOTE: To check resistance values "tank full" or "tank empty",

Fuel Pump (FP) must be removed (Refer to Fuel pump,
removing and installing) and the sensor float must be
placed in the upper or lower end position.
When removed, both senders are measured
individually.
With fuel level sensor or fuel level sensor 2 removed, the following values will
result due to the longer reach of the float arm:

me
2006 Audi TT
position position
Fuel level sensor -G- (at fuel approx. 29 ohms approx. 147 ohms
pump)
Fuel level sensor 2 -G169- approx. 27 ohms approx. 140 ohms
Vehicles as of 05.02
Fig. 141: Identifying Fuel Level Sensor -G-, Fuel Level Sensor 2 -G169- &
Terminal

position position
Fuel level sensor -G- and Fuel level approx. 282 ohms approx. 59 ohms
sensor 2 -G169-

NOTE: To check resistance values "tank full" or "tank empty",

Fuel Pump (FP) must be removed (Refer to Fuel pump,
removing and installing) and the sensor float must be
placed in the upper or lower end position.
When removed, both senders are measured
me
2006 Audi TT
individually.
With fuel level sensor or fuel level sensor 2 removed, the following values will
result due to the longer reach of the float arm:

position position
Fuel level sensor -G- (at fuel approx. 147 ohms approx. 29 ohms
pump)
Fuel level sensor 2 -G169- approx. 140 ohms approx. 27 ohms
Fuel level sensor -G-, removing and installing
Removing
system.

Remove secondary fuel pump. Refer to Secondary fuel pump, removing and
installing.
Fig. 142: Fuel Gauge Sender Connectors & Retaining Tabs

Disengage connector prongs of electrical wires -3- and -4- and disconnect.
me
2006 Audi TT
Pry off retaining straps -1- and -2- using screwdriver and remove fuel level
sensor toward bottom (arrow).
Installing
Insert fuel level sensor into guides at Fuel Pump (FP) and press up until
engagement.
Insert connector prongs of electrical wires and check for proper engagement.
Install Fuel Pump (FP). Refer to Installing.
Observe notes for connection of battery.
Fuel level sensor 2 -G169-, removing and installing
Work Sequence
system.
NOTE: The Fuel level sensor 2 -G169- is only available as a

replacement part with the secondary fuel pump assembly.
Remove secondary fuel pump. Refer to Secondary fuel pump, removing and
installing.
Secondary fuel pump, function
The electric Fuel Pump (FP) operates the secondary fuel pump in the left chamber
of the fuel tank.
The fuel pump creates an operating stream that is pressed into the secondary fuel
pump via a jet which causes acceleration. This acceleration causes the fuel in the
left chamber of the fuel tank to be drawn into the right chamber of the fuel tank.
Disturbances caused by a faulty secondary fuel pump

me
2006 Audi TT
WARNING: When the secondary fuel pump is faulty, the vehicle

may not run if the fuel tank is about 1/4 full.
Fig. 143: Identifying Secondary Fuel Pump Is Faulty

If the secondary fuel pump -2- is not functioning, up to 15 liters of fuel -3- (up to
about 1/4 of tank capacity) can remain in the left portion of the fuel tank that cannot
be drawn out by the Fuel Pump (FP).
If the vehicle will not run due to lack of fuel although the tank is about 1/4 full,
proceed as follows:
Check Fuel Pump (FP). Refer to Fuel pump, electrical testing.
If the Fuel Pump (FP) is OK, but no fuel is being pumped:
Add about 5 liters of fuel to tank.

Start engine.
If the engine starts now:
Replace secondary fuel pump. Refer to Secondary fuel pump, removing and
installing.
Secondary fuel pump, removing and installing
me
2006 Audi TT

Removing

supply system.
When removing the secondary fuel pump, the fuel tank should be less than 1/3
full. If necessary, empty the fuel tank. Refer to Fuel tank, emptying.
Remove Fuel Pump (FP). Refer to Fuel pump, removing and installing.
TT Roadster
me
2006 Audi TT

fuel pump.
Fig. 146: Using Ring Nut Spanner 3217 To Remove Union Nut

Pull connecting flange and secondary fuel pump (with fuel lines connected) out
of fuel tank opening.
Installing

me
2006 Audi TT
Insert fuel lines of secondary fuel pump through opening for secondary fuel
pump and through to right chamber of fuel tank.
of fuel container.
not to bend floating arm of fuel level sensor.
Fig. 147: Pressing Connecting Flange Into Opening

Press connecting flange into opening, note installation position:
Fig. 148: Using Ring Nut Spanner 3217 To Tighten Union Nut
me
2006 Audi TT
Use ring nut spanner 3217 to tighten union nut (80 Nm).
Install Fuel Pump (FP). Refer to Installing, (Observe notes for connecting
battery.)
Tightening torque
Component Nm
Union nut for secondary fuel pump 80
EVAPORATIVE EMISSION (EVAP) CANISTER SYSTEM, REPAIRING
Component overview
Fig. 149: Component Overview

me
2006 Audi TT

1 - Cover
For EVAP canister
2 - Vent line
3 - Vent line
From gravity valve and pressure retention valve at fuel tank
4 - Sealing piece
5 - EVAP canister
Installation location: below spare tire compartment

Removing and installing. Refer to Evaporative Emission (EVAP) canister,
removing and installing
6 - Vacuum line
To Leak Detection Pump (LDP) -V144-
7 - Bracket
For air filter
8 - Air filter
9 - O-Rings
Always replace
10 - Evaporative Emission (EVAP) canister purge solenoid valve -N115-
Checking. Refer to Evaporative Emission (EVAP) canister purge solenoid

me
2006 Audi TT
valve -N115-, checking

11 - Retaining ring
12 - 5 Nm
13 - Bracket
For Evaporative Emission (EVAP) canister purge solenoid valve -N115-
14 - Electrical 2-pin harness connector
Black
15 - Bushing
16 - Grommet
17 - Pin bolt, 16 Nm
18 - Grommet
19 - Washer
20 - Cap nut, 9 Nm
Evaporative Emission (EVAP) canister purge solenoid valve -N115-, checking
me
2006 Audi TT
Fig. 150: Identifying Special Tools - Evaporative Emission (EVAP) Canister

Purge Solenoid Valve -N115-, Checking
VAG1526A Multimeter
VAG1527B Voltage tester
VAG1594A adapter set
VAG1598/31 Test bos
VAS5051 Vehicle diagnosis, testing and information system with VAG5051/1

me
2006 Audi TT
Adapter
Checking function
Parking brake engaged.

Vehicles with manual transmission: shift lever in neutral.
Vehicles with automatic transmission: selector lever in P or N.
NOTE: Checking seal (performing leak testing). Refer to

Evaporative Emission (EVAP) system, diagnostic leak
test.
For leaking Evaporative Emission (EVAP) canister
purge solenoid valve -N115-, replace O-rings. Refer to
Fig. 149.
Ignition on.
Fig. 151: Connecting VAS 5051 Tester To DLC

VAS 5051 tester connected and -"01 Engine electrical"- selected.
me
2006 Audi TT
Fig. 152: Diagnostic System VAS 5051: Display

Display on VAS 5051:
In selection -1-, click on diagnostic function "03 - Diagnosis"

Click on delta button until Evaporative Emission (EVAP) canister purge
solenoid valve -N115- is activated
Evaporative Emission (EVAP) canister purge solenoid valve -N115- will be

activated for about 1 minute (clicks).
NOTE: The noise of the solenoid valve is audible in the area of the
rear axle
End the function "03 - Output check diagnosis" by clicking <-- button.
Select "06 - End Process".
Turn off ignition.
If the Evaporative Emission (EVAP) canister purge solenoid valve -N115- is not
activated (no noise audible):
Check internal resistance, Evaporative Emission (EVAP) canister purge

solenoid valve -N115-. Refer to Checking internal resistance.
Checking internal resistance
Vehicles with Front Wheel Drive (FWD)

me
2006 Audi TT
Fig. 153: Removing EVAP Canister Cover, Below, At Spare Tire

Compartment
Remove EVAP canister cover, below, at spare tire compartment (arrows).

Vehicles with All Wheel Drive (AWD)
Fig. 154: Disconnecting Exhaust System At Double Clamp

Disconnect exhaust system at clamping sleeve (arrows).

Remove right rear bracket for exhaust system.
Disengage rear portion of exhaust system at brackets.
NOTE: The exhaust system release element must not be bent more
than 10° , otherwise it could be damaged.
me
2006 Audi TT
Fig. 155: Removing Rear Heat Shield And Bracket For Exhaust System
Remove rear heat shield and bracket for exhaust system (arrows).
Fig. 156: Removing Rear Nut Of Cover For EVAP Canister

Remove rear nut (arrow) of cover for EVAP canister.

Fold cover for EVAP canister down at rear edge.
me
2006 Audi TT
Fig. 157: Disconnecting Electrical Harness Connector

Disconnect electrical harness connector (arrow).
NOTE: Illustration depicts a vehicle with Front Wheel Drive (FWD).
Connect multimeter at valve for resistance measurement.
Specified value: 22-26 ohms

Replace Evaporative Emission (EVAP) canister purge regulator valve -N115-.
If specified value is obtained:

Check voltage supply. Refer to Checking voltage supply.
Checking voltage supply
NOTE: Voltage supply test of Evaporative Emission (EVAP)

canister purge solenoid valve -N115- is performed via the
Fuel Pump (FP) relay.
Requirements

me
2006 Audi TT
Vehicles with automatic transmission: selector lever in P or N`.

Fuse for Evaporative Emission (EVAP) canister purge solenoid valve -N115-
OK
Disconnect connector at Evaporative Emission (EVAP) canister purge solenoid

valve -N115-.
Fig. 158: 2-Pin Electrical Harness Connector & Terminals

Connect VAG1527B voltage tester as follows:
Electrical harness connector terminal number Measure to

1 Ground (GND)
Operate starter briefly (OK for engine to start).
LED must light

If LED does not light:
me
2006 Audi TT

Check electrical wire connection from terminal 1 via fuse to Fuel Pump (FP)
relay for open circuit.
Repair open circuit if necessary.

If wire connection is OK:
Check Fuel Pump (FP) relay.
Refer to
If LED lights:
me
2006 Audi TT
Check activation. Refer to Checking activation.

Checking activation
Requirement
Voltage supply OK

Connect VAG1527B voltage tester to connector terminals 1 (B+) and 2.
Electrical harness connector terminal number Measure to

2 Battery +
Initiate output Diagnostic Test Mode (DTM) and activate evaporative emission
(EVAP) canister purge solenoid valve -N115- as described under Checking
function.
LED must blink
If LED does not blink:
Switch ignition off.

Remove wiper arms.
Remove plenum chamber cover and set aside on windshield side.
Disengage locking tabs and remove control module connector.
me
2006 Audi TT
Fig. 161: Connecting VAG1598/31 Test Box To Connector Of Wiring Harness

Connect VAG1598/31 test box to connector of wiring harness. Ground (GND)
clip (arrow) at test box must be clipped to battery negative. Engine Control
Module (ECM) must not be attached.
Refer to

me
2006 Audi TT

Check following wire connection for open circuit and short circuit to Ground
(GND) and B+:
Electrical VAG1598/31 test box

Harness connector socket
Terminal
2 116 (4-cyl.)
2 116 (6-cyl.)
Repair open circuit or short circuit if necessary.
If wire connection is OK, but the Evaporative Emission (EVAP) Canister Purge
Solenoid Valve does not function:
Replace Engine Control Module (ECM).
Refer to

me
2006 Audi TT

Observe safety precautions after re-connecting Engine Control Module (ECM).

Refer to

Refer to

Evaporative Emission (EVAP) canister, removing and installing
me
2006 Audi TT
NOTE: Checking for proper seal (leak testing). Refer to Evaporative

Emission (EVAP) system, diagnostic leak test.
Removing
system.
Fig. 163: Removing EVAP Canister Cover At Bottom Of Spare Tire Well
Remove EVAP canister cover at bottom of spare tire well (arrows).
me
2006 Audi TT
Fig. 164: Disconnecting Exhaust System At Double Clamp

Disconnect exhaust system at clamping sleeve (arrows).

Remove right rear bracket for exhaust system.
Disengage rear portion of exhaust system at brackets.
NOTE: The exhaust system release element must not be bent more
than 10° , otherwise it could be damaged.
Fig. 165: Removing Rear Heat Shield And Bracket For Exhaust System
Remove rear heat shield and bracket for exhaust system (arrows).
Fig. 166: Removing Rear Bolts Of Subframe

me
2006 Audi TT
Remove rear bolts -3- of subframe at left and right.
WARNING: Subframe will sink about 100 mm when bolts are

loosened.
NOTE: To avoid the need for an alignment, subframe must only be

released (i.e. lowered) on rear side.
Remove bolts -1- and -2- of stabilizer at left and right.

Swing stabilizer down.
Fig. 167: Removing Cover Of EVAP Canister At Bottom Of Spare Tire Well
Remove cover of EVAP canister at bottom of spare tire well (arrows).

me
2006 Audi TT
Fig. 168: Removing Vacuum Line & Disconnecting Electrical Harness

Connector For Evaporative Emission (EVAP) Canister Purge Solenoid Valve -
N115-
Remove vacuum line -1- to Leak Detection Pump (LDP) -V144- by pressing
on release button.
Disconnect electrical harness connector for Evaporative Emission (EVAP)
canister purge solenoid valve -N115- -2-.
Fig. 169: Disconnecting Hose Connections And At Vent Lines

Disconnect hose connections -1- and -2- at vent lines.

Unscrew pin bolts (arrows) and remove EVAP canister.
Installing
NOTE: Secure all hose connections using hose clamps appropriate

for the model type
Secure subframe using new bolts:

me
2006 Audi TT
Secure stabilizer:
Adjust exhaust system to be tension free
Refer to

Tightening torques
Component Nm
EVAP canister at chassis 16
Cover at spare tire well 9
Evaporative Emission (EVAP) canister purge regulator valve -N80-, component overview
me
2006 Audi TT
Fig. 170: Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-
, Component Overview
NOTE: Arrows on the hose and/or pipe connections must line up

across from each other.
1 - Grommet
2 - Bushing
3 - 8 Nm
me
2006 Audi TT
4 - Vacuum reservoir
5 - Check valve
Inserted in vacuum reservoir
6 - Bracket
For Evaporative Emission (EVAP) canister purge regulator valve -N80-
7 - Test connection
8 - Evaporative Emission (EVAP) canister purge regulator valve -N80-
Checking function and activation:
Refer to

9 - From EVAP canister
For Evaporative Emission (EVAP) canister purge regulator valve -N80-
11 - Check valve
Only vehicles with turbocharger

me
2006 Audi TT
Installed position (light/dark half): arrow points in direction of flow, as shown

in Fig. 170
12 - To intake tubes at turbocharger

13 - Check valve

in Fig. 170
14 - To intake manifold
15 - Grommet
16 - To EVAP canister
17 - Grommet
18 - Bracket
For vacuum reservoir

19 - 8 Nm
Evaporative Emission (EVAP) canister system with Leak Detection Pump (LDP), hose diagram
me
2006 Audi TT
Fig. 171: Evaporative Emission (EVAP) Canister System With Leak Detection
Pump (LDP), Hose Diagram
1 - Evaporative Emission (EVAP) canister purge regulator valve -N80-
Installation location: front right in engine compartment

Component overview. Refer to Evaporative Emission (EVAP) canister
purge regulator valve -N80-, component overview
Checking:
Refer to
me
2006 Audi TT

2 - Air filter
For Leak Detection Pump (LDP) -V144-
3 - Leak Detection Pump (LDP) -V144-
Installation location: in front right wheel housing under wheel housing liner
Checking. Refer to Leak Detection Pump (LDP) -V144-, checking
Removing and installing. Refer to Leak Detection Pump (LDP) -V144-,
4 - Test connection
5 - Vent line
From gravity valve and pressure retention valve at fuel tank
6 - EVAP canister
Installation location: bottom of spare tire well

Removing and installing. Refer to Evaporative Emission (EVAP) canister,
7 - Air filter
me
2006 Audi TT
For Evaporative Emission (EVAP) canister purge solenoid valve -N115-
8 - Evaporative Emission (EVAP) canister purge solenoid valve -N115-
Checking. Refer to Evaporative Emission (EVAP) canister purge solenoid

valve -N115-, checking
9 - Check valve

in Fig. 171
10 - Turbocharger
11 - Throttle valve control module -J338-
12 - Check valve

in Fig. 171.
13 - Check valve
Inserted in vacuum reservoir
14 - Vacuum reservoir

Component overview. Refer to Evaporative Emission (EVAP) canister
purge regulator valve -N80-, component overview
Evaporative Emissions (EVAP) system diagnostic leak test, function
The EVAP system diagnostic leak test recognizes leaks in the entire fuel system
me
2006 Audi TT
including the fuel tank, Evaporative Emission (EVAP) canister, EVAP canister
purge regulator valve -N80- and the EVAP canister purge solenoid valve -N115-.
On the mechanical side, the leak detection system consists primarily of a vacuum
activated diaphragm pump with a reed contact on an activating rod at the pump
diaphragm. The pump is supplied its vacuum via the engine intake.
When the diagnostic leak test is initiated, the Leak Detection Pump (LDP)
increases pressure in the fuel system to 20-30 mbar.
Once the specified pressure is reached, the pump membrane remains expanded
so that the reed contact at the operating rod remains in the "open" position.
If pressure falls (indicating a leak), the diaphragm moves and the reed contact
closes.
First the diagnostic will test whether the reed contact closes within 10 seconds.
If it does not, the fuel system is sealed.
If the reed contact closes within 10 seconds, however, the system has a leak. If
this is the case, the membrane pump will pump four additional strokes. The
Engine Control Module (ECM) measures the time between these four strokes
and closure of the reed contact. Based on this measurement, the ECM
recognizes whether the leak is larger than 1 mm in diameter and can
distinguish a "small leak" from a "large leak."
Leak testing is initiated shortly following every engine start. If a malfunction is

recognized, a DTC entry follows. The Malfunction Indicator Lamp (MIL) in the
instrument cluster will light if the malfunction is recognized for two subsequent
starts. Leak detection can also be activated using the VAS5051 tester. Refer to
Evaporative Emission (EVAP) system, diagnostic leak test.
Automatic diagnostic leak test
With engine running, the control module performs a diagnostic leak test in certain
intervals.
Whether an automatic diagnostic leak test is just being performed can be

determined with a connected VAS 5051 tester in measuring value block 071,
Guided fault finding in the VAS 5051.. Refer to Evaporative Emission (EVAP)
me
2006 Audi TT
system, diagnostic leak test.

Evaporative Emission (EVAP) system, diagnostic leak test
Fig. 172: VAS 5051 Vehicle Diagnosis, Testing & Information System
VAS 5051

supply system.
NOTE: All hose connections are secured with clips.

Requirements
Vehicles with automatic transmission: selector lever in P or N.
Engine is running at idle
Electrical consumers switched off (coolant fan must NOT run during test)
A/C switched off
me
2006 Audi TT

VAS 5051 tester connected and -"01 Engine electrical" selected.

No DTCs in DTC memory
Intake Air Temperature (IAT) less than 90° C. Refer to display group 004,
display field 4
Coolant Temperature less than 95° C. Refer to display group 004, display field
3
Throttle valve angle less than 10° % display group 003, display field 3
Work sequence
me
2006 Audi TT

In selection -1-, click on diagnostic function "04 - Basic setting".

1 - Enter display group
Select function "071" in button field -2- for "display group number 071" and
press Q button to confirm input.
me
2006 Audi TT
Fig. 176: Diagnostic System VAS 5051: Display -- Display Fields

Check indication in display field 1.
Specification: "Reed closed"
NOTE: If "Reed cl" (closed) is displayed, continue test.

If display indicates "Reed open": briefly open and close
fuel filler cap to release pressure from fuel tank. This
will close the reed contact.
Activate basic setting by pressing button A.

Specification: "Test ON"
The system test lasts several minutes.
Specification: "System OK"
System is sealed, test is terminated.
End function "04 - Basic setting" by pressing <-- button.

me
2006 Audi TT
DTC display
If a DTC is recognized during the system test, the DTC evaluation follows.

On VAS 5051 display in display field -4-:

In case of malfunction: System not OK
Check diagnosis evaluation in display field -2-.

"Small leak" or "large leak"
End function "04 - Basic setting" by pressing <-- button.
If the system recognizes a small or large leak:
Checking fuel supply and ventilation systems for leaks. Refer to Checking fuel
supply and ventilation systems for leaks.
After that, repeat leak test.
Checking fuel supply and ventilation systems for leaks
NOTE: The following describes areas in the fuel supply and

ventilation systems that should be checked for possible
leaks. After making necessary repairs, perform leak test
again to ensure that all leaks were successfully repaired.
me
2006 Audi TT

Check whether fuel filler cap was completely closed for test.
Check seal of fuel filler cap for damage. Replace if necessary.
TT Coupe

TT Roadster


TT Roadster

me
2006 Audi TT

Check whether seals under connection flanges are OK and union nuts are
properly tightened. Also check fuel line connections.
NOTE: Observe installation notes for connector flanges. Refer to

Installing, Installing, or Removing.
Visually check all wires and hose connections of fuel supply system and
replace loose lines, e.g.:
Line from EVAP canister to Evaporative Emission (EVAP) Canister Purge

Regulator Valve -N80 (in engine compartment)
Lines from EVAP canister to Leak Detection Pump (under front right wheel
housing liner)
Line from fuel tank to Evaporative Emission (EVAP) canister (under cover for
EVAP canister)
Lines from EVAP system (under right wheel housing liner)
Fuel lines to engine
me
2006 Audi TT
NOTE: Leaks at lines and components of fuel supply system can

sometimes be located using a non-flammable,
environmentally sound leak detection spray. For this,
initiate leak testing several times in sequence to build
pressure in the system. Leaks can be detected via bubbles
forming at the leak.
Visually check components of fuel supply system and EVAP system.

Fuel tank
EVAP canister
Leak Detection Pump (LDP) -V144-
Evaporative Emission (EVAP) canister purge regulator valve -N80-
Evaporative Emission (EVAP) canister purge solenoid valve -N115-
NOTE: Because of the shape or function of these components

it is not always possible to find leaks by applying spray.
It may be necessary to clamp off the relevant
component using 3094 hose clamps and initiate the
leak detection diagnostic. If the leak is no longer
detected, the component that was clamped off is faulty.
If the clamp is placed directly on the diagnostic pump
and a leak is still detected, then the diagnostic pump
itself is leaking.
Checking Evaporative Emission (EVAP) canister purge
regulator valve -N80-
Refer to

me
2006 Audi TT

For leaking Evaporative Emission (EVAP) canister purge solenoid valve -
N115-, replace O-rings. Refer to Fig. 149.
Work sequence
Ignition on

VAS 5051 tester connected and "01 Engine electrical" selected.

Checking function
me
2006 Audi TT

Click on diagnostic function -1- "03 Output check diagnosis"

Click delta button until leak detection pump begins functioning.
Leak Detection Pump (LDP) -V144-, component overview
me
2006 Audi TT
Fig. 182: Leak Detection Pump (LDP) -V144-, Component Overview

1 - Bracket
For air filter
2 - Air filter
3 - Hose
4 - Leak Detection Pump (LDP) -V144-

me
2006 Audi TT
Installation location: in front right wheel housing under wheel housing liner
Checking. Refer to Leak Detection Pump (LDP) -V144-, checking
Removing and installing. Refer to Leak Detection Pump (LDP) -V144-,
6 - Vacuum line
To EVAP canister
7 - Set pin
8 - Bracket
9 - Grommet
10 - Grommet
11 - Bushing
12 - 8 Nm
13 - Vacuum line
To vacuum reservoir, at right in engine compartment
14 - 8 Nm
15 - Bushing
16 - Grommet
17 - 5 Nm
Leak Detection Pump (LDP) -V144-, checking
me
2006 Audi TT
Fig. 183: Identifying Special Tools - Leak Detection Pump (LDP) -V144-,
Checking
VAG1526A Multimeter
VAG1527B Voltage tester
VAG1598/31 Test box
VAS5051 Vehicle diagnosis, testing and information system

me
2006 Audi TT
Requirements
Ignition on

VAS 5051 tester connected and "01 Engine electrical" selected

Checking function


me
2006 Audi TT
Click on diagnostic function -1- "03 Output check diagnosis"

Click delta button until leak detection pump is activated.
Leak Detection Pump (LDP) -V144- will be activated for approximately 1

minute.
NOTE: Operating noise of Leak Detection Pump (LDP) is audible at

front right wheel housing.
Click <-- button to end the function "03-Output check diagnosis"

Select 06 End sequence.
If LDP is not activated (no audible operating noise):

Remove Leak Detection Pump (LDP) -V144-(Refer to Leak Detection Pump
(LDP) -V144-, removing and installing), and disconnect harness connectors.
Checking internal resistance
Fig. 186: Locating 3-Pin Connector At Fuel System Leak Detection Pump
V144
Connect multimeter for resistance measurement as follows.
Leak Detection Pump (LDP) -V144- terminals Specified value

me
2006 Audi TT
1+3 640-720 ohms

2+3 15-17 ohms
If specified values are not obtained:
Replace Leak Detection Pump (LDP) -V144-. Refer to Leak Detection Pump
(LDP) -V144-, removing and installing.
If specified values are obtained:

Check voltage supply at harness connector of Leak Detection Pump (LDP).
Refer to Checking voltage supply.
Checking voltage supply
NOTE: Voltage supply for the Leak Detection Pump (LDP) runs via
the Fuel Pump (FP) relay.
Requirement
Fuse for Leak Detection Pump (LDP) OK
Disconnect connector at Leak Detection Pump (LDP).
Fig. 187: Identifying 3-Pin Connector Terminals 1 & 3

me
2006 Audi TT
Electrical harness connector terminal Measure to

3 Engine Ground (GND)
Operate starter briefly.
LED must light

If LED does not light:

Check electrical wire connection from terminal 3 via fuse to Fuel Pump (FP)
relay for open circuit.
Repair open circuit if necessary.

Checking output wire
me
2006 Audi TT

Electrical harness connector terminal Measure to

2 Battery +
Initiate output Diagnostic Test Mode. Refer to Checking function.

LED must blink.
If LED does not blink:
Click <-- button to end function "03 Output check diagnosis"

Select "06 End sequence"

me
2006 Audi TT

Connect VAG1598/31 test box to connector of wiring harness. Engine Control
Module (ECM) must not be attached. Ground (GND) clip (arrow) at test box
must be clipped to battery negative terminal (arrow).
Refer to

(GND) and B+:
Electrical harness connector terminal VAG1598/31 test box

socket
me
2006 Audi TT
2 25
If no malfunctions are found, but Leak Detection Pump (LDP) does not function
during output Diagnostic Test Mode (DTM):
Replace Leak Detection Pump (LDP) -V144-. Refer to Leak Detection Pump
(LDP) -V144-, removing and installing.
Refer to

Checking input wire
me
2006 Audi TT

Connect VAG1598/31 test box to connector of wiring harness. Engine Control
Module (ECM) must not be attached. Ground (GND) clip (arrow) at test box
must be clipped to battery negative terminal (arrow).
Refer to

me
2006 Audi TT

(GND) and B+:
Electrical harness connector terminal VAG1598/31 test box

socket
1 80

Refer to

me
2006 Audi TT
Refer to
Leak Detection Pump (LDP) -V144-, removing and installing
Removing
Remove right front wheel.

Remove cover for vacuum lines.
Remove right rear wheel housing liner.
Refer to 66 EXTERIOR EQUIPMENT .
Fig. 194: Identifying Hose Connections, LDP & Harness Connector

me
2006 Audi TT

Disconnect hose connections -2- and -3- (connector coupling at metal sheet,
engine side).
Remove bolts (arrows).
Remove LDP, disengage harness connector -1- with ignition off and
disconnect.
Installing
NOTE: Secure all hose connections using hose clamps appropriate

for the model type.
Tightening torque
Component Nm
Bracket for leak detection pump at 8
wheel housing
ACCELERATOR PEDAL CABLE, SERVICING
Accelerator pedal cable, servicing
me
2006 Audi TT
Fig. 195: Accelerator Pedal Cable, Servicing Remove/Install Components

1 - Rubber pedal cover

2 - 10 Nm

4 - Accelerator pedal module
With Throttle Position (TP) sensor -G79- and Accelerator pedal position sensor
2 -G185-
me
2006 Audi TT
Removing and installing accelerator pedal module with Throttle Position (TP)
sensor -G79- and Accelerator pedal position sensor 2 -G185-
Remove driver-side storage compartment.
Refer to 68 - INTERIOR EQUIPMENT
Fig. 196: Identifying 6-Pin Harness Connector, Nuts & Accelerator Pedal
Module
Disconnect 6-pin harness connector -2-.

Remove nuts -1- and -3-.
Remove accelerator pedal module.
Installation is the reverse of removal.

Tightening torque
Component Nm
Accelerator pedal module at pedal 10
mount
me
2006 Audi TT
Vehicles with automatic transmissions or Direct Shift automatic transmission

If Accelerator pedal position sensor 2 -G185- or Engine Control Module (ECM) is
replaced, kick-down function must be adapted on vehicles with automatic
transmission or Direct Shift automatic transmission.
Conditions

Connect VAS 5051 scan tool and select vehicle system "01 -Engine electrical"
in selection.
No DTCs recorded in DTC memory.
Engine stopped, ignition switched on.
Enter "063" for "display group number 063".
me
2006 Audi TT

Display on VAS 5051
Monitor display fields -3- and -4-.
Indication on display: "Activate Kick-down"

Depress accelerator pedal completely, past kick-down point, and hold down.
Indicated on display: "Kick-down ADP running"

Check desired values in display fields -3- and -4-.
Indicated on display: "Kick-down ADP OK"
NOTE: If "Kick-down ERROR" is displayed, check DTC memory

"ERROR" may be displayed, if accelerator pedal is not
pressed immediately when instructed by tester, or if
accelerator pedal was released while adaptation was
already running but process was not yet complete. In
both cases exit "04 - basic setting" mode by clicking
the <-- button and performing adaptation again.
End "04 - Basic Setting" by clicking <-- button.

Select diagnostic function "06 - End Sequence".
me
2006 Audi TT
Switch ignition off and disconnect diagnostic connection.
me

Fuel

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Fuel

Uploaded by

Copyright:

Available Formats

2006 Audi TT

ENGINE Fuel Supply System

Fuel Supply System

General repair notes

Observe safety precautions. Refer to Safety rules when working on fuel

Fuel Pump (FP) relay and activation, checking:

WARNING: Fuel supply lines are under pressure! Before

Switch ignition off and disconnect battery Ground (GND) strap.

Fuel tank may be only a maximum of 1/3 full.

Thoroughly clean all connections and the surrounding area before

Only install clean components: Only unpack replacement parts immediately

NOTE: Secure all hose connections using same type of clips

VAG1921 Pliers are recommended for installing spring clips.

Fig. 1: Identifying Special Tools - Fuel Tank With Attachments, Component

Removing and installing. Refer to Fuel tank with attachments, removing

Note installation position

Installed position: arrow points in direction of flow

For fuel filter

8 - 4-pin harness connector

11 - Ground (GND) connection

Installed position/test requirements. See Fig. 2

Specified value: approx. 0 ohms

For fuel filler tube

With overflow hose

Removing and installing. Refer to Fuel tank with attachments, removing

Fig. 2: Installation Position Of Ground (GND) Connection

NOTE: Depending on construction version, a cable binder may be

Specified value 0 ohms

Fig. 3: Installation Position Of Screw Clip For Fuel Filter

NOTE: Illustration depicts fuel filter from front.

Fig. 4: Fuel Filler Tube, Component Overview

1 - Pressure retention valve

Installed position: sealing lip faces fuel filler unit

7 - Ground (GND) connection

Fig. 5: Removing, Installing, And Checking Change-Over Valve

Blow into hose -2-.

Button -1- at rest: it must not be possible to blow through hose.

Fig. 6: Removing, Installing, And Checking Gravity Valve

NOTE: Gravity valve -1- can only be replaced together with

It must be possible to blow through hose.

Tilt valve 45°.

It must not be possible to blow through hose.

NOTE: O-ring -2- must not be damaged; replace if necessary.

Fig. 7: Installation Position Of Ground (GND) Connection

NOTE: Depending on construction version, a cable binder may be

Fig. 8: Tightening Eyelet Of Electrical Wire At Chassis Using Cap Nut

After installing, check electrical Ground connection using an ohmmeter

Specified value 0 ohms

Special tools and equipment

Fig. 9: Identifying Fuel Siphoning Unit VAS 5190

Fig. 10: Fuel Siphon Device VAG1433A

Vehicles with 4-cylinder engine

Fig. 11: Removing Cover Above Battery

If installed, remove cover above battery.

Open battery protective casing (Velcro).

Fig. 12: Disconnecting Battery Ground (GND) Strap

Vehicles with 6-cylinder engine

Fig. 13: Disconnecting Battery Ground (GND) Strap

Continued for all vehicles

WARNING: Secure VAG 1433 A or VAS 5190 Ground wire to a

A - Procedure for fuel tank more than 3/4 full

Remove filler cap from fuel tank filler neck.

Fig. 16: Identifying Spherical Valve, Fuel Tank And

On the lower end of the fuel filler unit, there is a spherical