Audi TT MK2 (8J) - Repair, Service Manual and Electrical Wiring Diagrams

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AUDI TT MK2 (8J) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to car Audi TT MK2 (8J).
 
CONTENTS:

00 - MAINTENANCE
- 1 Overview of engines
- 2 Delivery Service
- 3 Description of work
-- 3.1 Cap for suspension strut protective tube: greasing
-- 3.2 Reading out: measured value block 32
-- 3.3 Battery: checking "no load" voltage before engine is started for first time
-- 3.4 Battery: checking
-- 3.4.1 Batteries with “magic eye”
-- 3.4.2 Battery with sealing plugs
-- 3.5 Battery: checking that battery cables are securely fitted
-- 3.6 Battery: performing battery test
-- 3.6.1 Performing battery test using battery tester -VAS 6161- (with printer)
-- 3.6.2 Performing battery load test using VAS 5097 A
-- 3.7 Tyres: checking condition, wear pattern, tread depth and correcting tyre pressures
-- 3.7.1 Inflating to correct pressures
-- 3.7.2 Spare wheel
-- 3.8 Brake system: visual check for leaks and damage
-- 3.9 Lights: checking function
-- 3.10 Brake pads: checking thickness
-- 3.11 Brake fluid level (depends on brake pad wear): checking
-- 3.11.1 Delivery Inspection
-- 3.12 Brake fluid: changing
-- 3.12.1 Changing brake fluid with brake filling and bleeding equipment -VAS 5234-
-- 3.12.2 Table - sequence for changing brake fluid / quantities
-- 3.13 S tronic gearbox: changing oil and renewing oil filter
-- 3.14 Electric windows: checking positions
-- 3.15 G17 additive: adding
-- 3.16 Ignition keys: checking operation
-- 3.17 Diesel particulate filter: reading out ash deposit mass
-- 3.18 Data memory: interrogating with vehicle diagnostic, testing and information system -VAS 5051/ 5052-
-- 3.19 Noise insulation: removing and installing
-- 3.20 Haldex coupling: changing oil
-- 3.21 Poly V-belt: renewing
-- 3.22 Fuel filter: renewing (2.0 ltr. TDI CR)
-- 3.23 Cooling system: checking coolant additive level and topping up with coolant if necessary
-- 3.24 Instrument cluster: setting the language
-- 3.25 Air cleaner: cleaning housing and renewing filter element
-- 3.25.1 6-cyl. petrol engine 3.2 MPI
-- 3.25.2 4-cyl. petrol engine 2.0 ltr. TFSI
-- 3.25.3 4-cyl. petrol engine 2.0 ltr. TFSI
-- 3.25.4 5-cyl. petrol engine 2.5 ltr. TFSI
-- 3.25.5 4-cyl. petrol engine 1.8 ltr. TFSI, 2.0 ltr. TFSI
-- 3.25.6 4-cyl. diesel engine 2.0 ltr. CR TDI engine
-- 3.25.7 General notes
-- 3.26 Bonnet arrester hook: lubricating
-- 3.27 Engine cover panel: removing
-- 3.28 Engine and engine compartment (from below): visual check for leaks and damage
-- 3.29 Engine oil: draining or extracting, changing oil filter
-- 3.29.1 4-cyl. petrol engine 1.8 ltr. TFSI, 2.0 ltr. TFSI
-- 3.29.2 4-cyl. petrol engine 2.0 ltr. TFSI, 2.5 ltr. TFSI
-- 3.29.3 4-cyl. CR TDI engines:
-- 3.29.4 6-cyl. petrol engine 3.2 ltr. MPI
-- 3.30 Bonnet hinges: lubricating
-- 3.31 Engine oil: filling up
-- 3.32 Engine: checking oil level
-- 3.33 Navigation system: releasing eject button
-- 3.34 Radio: activating anti-theft coding by entering fixed code number
-- 3.35 Road test
-- 3.36 Wheel bolts: tightening to specified torque
-- 3.36.1 Wheel bolts
-- 3.37 Tyre pressure monitoring system: updating
-- 3.38 Manual gearbox/final drive: checking oil level, topping up with oil if necessary
-- 3.38.1 6-speed dual clutch gearbox
-- 3.39 Windscreen wiper/washer system: checking jet settings, adjusting jets if necessary
-- 3.40 Headlight washer system: checking jet settings
-- 3.41 Wiper blades: checking park position and checking for damage
-- 3.41.1 Park position for windscreen wiper blades
-- 3.42 Service interval display: resetting or adapting
-- 3.42.1 Service interval display: resetting (vehicles up to model year 2007)
-- 3.42.2 Service interval display: resetting (vehicles from model year 2008 onwards)
-- 3.42.3 Oil grade: adapting
-- 3.42.4 Maximum values: adapting
-- 3.42.5 Service interval display: resetting (after completing a Service) without the use of VAS 5051/5052
-- 3.43 Fuse for headlight washer system: fitting
-- 3.44 Dust and pollen filter: removing and installing
-- 3.45 Track rods, track control links, swivel joints, guide links and drive shafts on front and rear axle: checking boots, play, and secure fit
-- 3.46 Transport mode: deactivating (using vehicle diagnostic, testing and information system -VAS 5051/5052-)
-- 3.47 Door arresters, door hinges and lock cylinders: lubricating
-- 3.48 Transport locks: removing locking elements for front and rear suspension struts
-- 3.49 Underseal: visual check for damage
-- 3.50 Plenum chamber: checking and cleaning water drain
-- 3.51 Winter tyres (factory-fitted)
-- 3.52 Toothed belt for camshaft drive: renewing
-- 3.53 Clock: setting
-- 3.54 Spark plugs: renewing
-- 3.54.2 4-cyl. petrol engine 1.8 ltr. TFSI, 2.0 ltr. TFSI
-- 3.54.3 4-cyl. petrol engine 2.0 ltr. TFSI
-- 3.54.4 5-cyl. petrol engine 2.5 ltr. TFSI
- 4 Type plate, vehicle identification number
- 5 Lifting the vehicle
- 6 Tow-starting/towing
- 7 Vehicle tests carried out as part of inspection services and maintenance
01 - 4-CYLINDER TDI ENGINE (2.0 LTR. 4-VALVE COMMON RAIL -GENERATION II), MECHANICS
- 00 – Technical data
-- 1 Engine number

-- 2 Engine data
-- 3 Safety precautions
-- 3.1 Working on the fuel system
-- 3.2 Working on the cooling system
-- 3.3 Working on vehicles with start/stop system
-- 3.4 Using testers and measuring instruments during a road test
-- 3.5 Working on the exhaust system
-- 4 General repair instructions
-- 4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger
-- 4.2 Checking for leaks in the fuel system
-- 4.3 Contact corrosion!
-- 4.4 Routing and attachment of pipes, hoses and wiring
-- 4.5 Installing radiators, condensers and charge air coolers
-- 4.6 Checking vacuum system
- 10 – Removing and installing engine
-- 1 Removing engine
-- 2 Separating engine from manual gearbox
-- 3 Securing engine to engine and gearbox support
-- 4 Installing engine
-- 5 Assembly mountings
-- 5.1 Assembly mountings - exploded view
-- 5.2 Removing and installing engine mountings
-- 5.3 Checking adjustment of assembly mountings (engine/gearbox mountings)
-- 5.4 Adjusting assembly mountings
- 13 – Crankshaft group
-- 1 Cylinder block (pulley end)
-- 1.1 Poly V-belt drive without air conditioner compressor - exploded view
-- 1.2 Removing and installing poly V-belt - vehicles without air conditioner compressor
-- 1.3 Poly V-belt drive for vehicles with air conditioner compressor and tensioner - exploded view
-- 1.4 Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioner
-- 1.5 Removing and installing tensioner for poly V-belt
-- 1.6 Poly V-belt drive for vehicles with air conditioner compressor and tensioning roller - exploded view
-- 1.7 Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioning roller
-- 1.8 Removing and installing vibration damper
-- 1.9 Removing and installing bracket for ancillaries
-- 1.10 Sealing flange (pulley end) - exploded view
-- 1.11 Renewing crankshaft oil seal (pulley end)
-- 1.12 Removing and installing sealing flange (pulley end)
-- 2 Cylinder block (gearbox end)
-- 2.1 Dual-mass flywheel and sealing flange (gearbox end) - exploded view
-- 2.2 Removing and installing dual-mass flywheel
-- 2.3 Renewing sealing flange (gearbox end)
-- 3 Crankshaft
-- 3.1 Crankshaft - exploded view
-- 3.2 Crankshaft dimensions
-- 3.3 Measuring axial clearance of crankshaft
-- 3.4 Measuring radial clearance of crankshaft
-- 3.5 Extracting needle bearing for crankshaft
-- 3.6 Pulling spur gear off crankshaft and shrink-fitting new spur gear
-- 4 Pistons and conrods
-- 4.1 Pistons and conrods - exploded view
-- 4.2 Measuring piston projection at “TDC”
-- 4.3 Piston and cylinder dimensions
-- 4.4 Measuring radial clearance of conrods
- 15 – Cylinder head, valve gear
-- 1 Toothed belt drive
-- 1.1 Toothed belt - exploded view
-- 1.2 Removing and installing toothed belt
-- 2 Cylinder head
-- 2.1 Cylinder head cover - exploded view
-- 2.2 Removing and installing cylinder head cover
-- 2.3 Renewing injector seals
-- 2.4 Cylinder head - exploded view
-- 2.5 Removing and installing cylinder head
-- 2.6 Checking compression
-- 3 Valve gear
-- 3.1 Valve gear - exploded view
-- 3.2 Measuring axial clearance of camshafts
-- 3.3 Measuring radial clearance of camshafts
-- 3.4 Renewing camshaft oil seal
-- 3.5 Removing and installing camshafts
-- 3.6 Checking hydraulic valve compensation elements
-- 3.7 Renewing valve stem oil seals with cylinder head installed
-- 3.8 Renewing valve stem oil seals with cylinder head removed
-- 3.9 Valve dimensions
-- 3.10 Machining valve seats
-- 3.11 Checking valve guides
-- 3.12 Checking valves
- 17 – Lubrication
-- 1 Oil pump, sump, balance shaft assembly
-- 1.1 Oil pump, sump, balance shaft assembly - exploded view
-- 1.2 Removing and installing oil level and oil temperature sender -G266-
-- 1.3 Removing and installing sump
-- 1.4 Removing and installing oil pump
-- 1.5 Removing balance shaft assembly
-- 1.6 Installing a new balance shaft assembly
-- 1.7 Re-installing a used balance shaft assembly
-- 2 Oil filter bracket and engine oil cooler
-- 2.1 Oil filter bracket and engine oil cooler - exploded view
-- 2.2 Removing and installing oil filter bracket with engine oil cooler
-- 2.3 Removing and installing oil pressure switch -F1-
-- 2.4 Checking oil pressure switch -F1-
-- 2.5 Checking oil pressure
-- 2.6 Engine oil
-- 2.7 Checking oil level
- 19 – Cooling
-- 1 Cooling system
-- 1.1 Diagram of coolant hose connections
-- 1.2 Draining and filling cooling system
-- 1.3 Checking cooling system for leaks
-- 2 Coolant pump and thermostat
-- 2.1 Coolant pump and thermostat - exploded view
-- 2.2 Removing and installing coolant pump
-- 2.3 Removing and installing 4/2-way valve with thermostat
-- 2.4 Checking thermostat
-- 3 Coolant pipes, coolant temperature senders, coolant circulation pump
-- 3.1 Coolant pipes, coolant temperature senders, coolant circulation pump - exploded view
-- 3.2 Removing and installing coolant temperature sender -G62-
-- 3.3 Removing and installing radiator outlet coolant temperature sender -G83-
-- 3.4 Removing and installing pump for exhaust gas recirculation cooler -V400-
-- 3.5 Removing and installing coolant pipe (front)
-- 3.6 Removing and installing coolant pipe (top front)
-- 3.7 Removing and installing coolant pipe (left-side)
-- 3.8 Removing and installing coolant pipe (right-side)
-- 4 Radiator and radiator fans
-- 4.1 Radiator and radiator fans - exploded view
-- 4.2 Removing and installing radiator cowl
-- 4.3 Removing and installing radiator fans -V7- and -V177-
-- 4.4 Removing and installing radiator
- 21 – Turbocharging/supercharging
-- 1 Turbocharger
-- 1.1 Diagram of vacuum connections
-- 1.2 Turbocharger - exploded view
-- 1.3 Removing and installing turbocharger
-- 2 Charge air cooling
-- 2.1 Charge air cooler - exploded view
-- 2.2 Removing and installing charge pressure sender -G31- / intake air temperature sender -G42-
-- 2.3 Removing and installing charge air cooler
-- 2.4 Checking charge air system for leaks
- 26 – Exhaust system
-- 1 Silencers
-- 1.1 Silencers - exploded view
-- 1.2 Removing and installing particulate filter
-- 1.3 Stress-free alignment of exhaust system
-- 1.4 Aligning tailpipes
-- 1.5 Checking exhaust system for leaks
-- 2 Exhaust gas temperature control
-- 2.1 Exhaust gas temperature control - exploded view
-- 2.2 Removing and installing exhaust gas temperature sender 1 -G235-
-- 2.3 Removing and installing exhaust gas temperature sender 3 -G495-
-- 2.4 Removing and installing exhaust gas temperature sender 4 -G648-
-- 3 Exhaust gas recirculation system
-- 3.1 Diagram of vacuum connections
-- 3.2 Exhaust gas recirculation with exhaust gas recirculation cooler - exploded view
-- 3.3 Checking exhaust gas recirculation cooler change-over
-- 3.4 Removing and installing exhaust gas recirculation cooler
02 - 4-CYLINDER TDI ENGINE (2.0 LTR. 4-VALVE COMMON RAIL), MECHANICS
- 00 – Technical data
-- 1 Engine number
-- 2 Engine data
-- 3 Safety precautions
-- 4 General repair instructions
-- 4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger
-- 4.2 Checking for leaks in the fuel system
-- 4.3 Contact corrosion!
-- 4.4 Checking vacuum system
-- 4.5 Routing and attachment of pipes, hoses and wiring
- 10 – Removing and installing engine
-- 1 Removing engine
-- 2 Separating engine from manual gearbox
-- 3 Securing engine to engine and gearbox support
-- 4 Installing engine
-- 5 Assembly mountings
-- 5.1 Assembly mountings - exploded view
-- 5.2 Checking adjustment of assembly mountings (engine/gearbox mountings)
-- 5.3 Adjusting assembly mountings
- 13 – Crankshaft group
-- 1 Cylinder block (pulley end)
-- 1.1 Poly V-belt drive with tensioner and air conditioner compressor - exploded view
-- 1.2 Removing and installing poly V-belt - vehicles with tensioner and air conditioner compressor
-- 1.3 Removing and installing tensioner for poly V-belt
-- 1.4 Poly V-belt drive without air conditioner compressor - exploded view
-- 1.5 Removing and installing poly V-belt - vehicles without air conditioner compressor
-- 1.6 Removing and installing vibration damper
-- 1.7 Removing and installing bracket for ancillaries
-- 1.8 Sealing flange (pulley end) - exploded view
-- 1.9 Renewing crankshaft oil seal (pulley end)
-- 1.10 Removing and installing sealing flange (pulley end)
-- 2 Cylinder block (gearbox end)
-- 2.1 Dual-mass flywheel and sealing flange (gearbox end) - exploded view
-- 2.2 Removing and installing dual-mass flywheel
-- 2.3 Renewing sealing flange (gearbox end)
-- 3 Crankshaft
-- 3.1 Crankshaft - exploded view
-- 3.2 Crankshaft dimensions
-- 3.3 Measuring axial clearance of crankshaft
-- 3.4 Measuring radial clearance of crankshaft
-- 3.5 Extracting and driving in needle bearing for crankshaft
-- 3.6 Pulling spur gear off crankshaft and shrink-fitting new spur gear
-- 4 Pistons and conrods
-- 4.1 Pistons and conrods - exploded view
-- 4.2 Measuring piston projection at “TDC”
-- 4.3 Piston and cylinder dimensions
-- 4.4 Measuring radial clearance of conrods
- 15 – Cylinder head, valve gear
-- 1 Toothed belt drive
-- 1.1 Toothed belt - exploded view
-- 1.2 Removing and installing toothed belt
-- 2 Cylinder head
-- 2.1 Cylinder head cover - exploded view
-- 2.2 Removing and installing cylinder head cover
-- 2.3 Cylinder head - exploded view
-- 2.4 Removing and installing cylinder head
-- 2.5 Checking compression
-- 3 Valve gear
-- 3.1 Valve gear - exploded view
-- 3.2 Measuring axial clearance of camshafts
-- 3.3 Measuring radial clearance of camshafts
-- 3.4 Renewing camshaft oil seal
-- 3.5 Removing and installing camshafts
-- 3.6 Checking hydraulic tappets
-- 3.7 Renewing valve stem oil seals with cylinder head installed
-- 3.8 Renewing valve stem oil seals with cylinder head removed
-- 3.9 Valve dimensions
-- 3.10 Machining valve seats
-- 3.11 Checking valve guides
-- 3.12 Checking valves
- 17 – Lubrication
-- 1 Oil pump, sump, balance shaft assembly
-- 1.1 Oil pump, sump, balance shaft assembly - exploded view
-- 1.2 Removing and installing oil level and oil temperature sender -G266-
-- 1.3 Removing and installing sump
-- 1.4 Removing and installing oil pump
-- 1.5 Removing balance shaft assembly
-- 1.6 Installing a new balance shaft assembly
-- 1.7 Re-installing a used balance shaft assembly
-- 2 Oil filter bracket and engine oil cooler
-- 2.1 Oil filter bracket and engine oil cooler - exploded view
-- 2.2 Removing and installing oil filter bracket with engine oil cooler
-- 2.3 Removing and installing oil pressure switch -F1-
-- 2.4 Checking oil pressure switch -F1-
-- 2.5 Checking oil pressure
-- 2.6 Engine oil
-- 2.7 Checking oil level
- 19 – Cooling
-- 1 Cooling system
-- 1.1 Diagram of coolant hose connections
-- 1.2 Draining and filling cooling system
-- 2 Coolant pump and thermostat
-- 2.1 Coolant pump and thermostat - exploded view
-- 2.2 Removing and installing coolant pump
-- 2.3 Removing and installing thermostat
-- 2.4 Removing and installing 4/2-way valve with thermostat
-- 2.5 Checking thermostat
-- 3 Coolant pipes, coolant temperature senders, coolant circulation pump
-- 3.1 Coolant pipes, coolant temperature senders, coolant circulation pump - exploded view
-- 3.2 Removing and installing coolant temperature sender -G62-
-- 3.3 Removing and installing radiator outlet coolant temperature sender -G83-
-- 3.4 Removing and installing pump for exhaust gas recirculation cooler -V400-
-- 3.5 Removing and installing coolant pipe (front)
-- 3.6 Removing and installing coolant pipe (left-side)
-- 3.7 Removing and installing coolant pipe (right-side)
-- 4 Radiator and radiator fans
-- 4.1 Radiator and radiator fans - exploded view
-- 4.2 Removing and installing radiator
-- 4.3 Removing and installing radiator cowl
-- 4.4 Removing and installing radiator fans -V7-/-V177-
-- 4.5 Checking cooling system for leaks
- 21 – Turbocharging/supercharging
-- 1 Turbocharger
-- 1.1 Diagram of vacuum connections
-- 1.2 Turbocharger - exploded view
-- 1.3 Removing and installing turbocharger
-- 1.4 Renewing vacuum unit with position sender for charge pressure positioner -G581-
-- 2 Charge air cooling
-- 2.1 Charge air cooler - exploded view
-- 2.2 Removing and installing charge pressure sender -G31- / intake air temperature sender -G42-
-- 2.3 Removing and installing charge air cooler
-- 2.4 Checking charge air system for leaks
- 26 – Exhaust system
-- 1 Silencers



AND MORE......