Audi TT MK2 (HJ) - Repair, Workshop Manual and Electrical Wiring Diagrams
Audi TT MK2 (HJ)
AUDI TT MK2 (HJ) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS
AUDI TT MK2 (HJ) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - English Workshop Manual and Wiring Diagrams, to car Audi TT MK2 (HJ). 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 AND MORE....
Audi TT MK2 (HJ) - Repair, Workshop Manual and Electrical Wiring Diagrams
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