INDEX WARNING Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Audi, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.
A ABS see Antilock brakes (ABS) Accelerator pedal assembly 20-18 Air conditioning (A/C) basic settings 87-7 blower motor 87-13 blower motor control module 87-12 climate control 87-2 coding 87-8 components 87-2, 87-11 compressor 87-21 condenser 87-18 controls 87-6 dust and pollen filter 03-77 evaporator evaporator 87-11, 87-14 evaporator evaporator drain hose 87-12 expansion valve 87-20 flap motors 87-4 flow through vents 87-12 functions 87-6 housing 87-9 overview 02-29 pressure sensor 87-16 receiver drier 87-18 refrigerant oil 87-14 refrigerant system 87-14 sunlight photo sensor 70-16, 87-4 Air filter 03-48 Airbags 69-1, 69-10 Alarm (anti-theft) system 96-19 Alignment 44-3 Alternator (generator) 1.8L engine 27-9 3.2L engine 27-12 belt 03-39
Amplifier 91-7, 91-9
Blower motor 87-13
Antenna 91-8
Body bumpers 63-1, 63-3 fender 50-4 grille 63-5 lock carrier, front 50-3 overview 02-25 sound absorber panels 03-15 wheel housing liners 66-7 see also Trim
Antifreeze see Engine cooling system Antilock brakes (ABS) electrical components 45-5 hydraulic components 45-6 variants 45-1 warning lights 45-3 wheel speed sensor 45-7 see also Electronic stabilization program (ESP) see also Antislip regulation (ASR) Antislip regulation (ASR) 45-2 see also Antilock brakes (ABS) Anti-theft (alarm) system 96-19 radio 91-4 A-pillar trim 70-19 ASR (antislip regulation) 45-2 see also Antilock brakes (ABS) Automatic transmission 02-16 applications 03-8 ATF 37-2 37 -2 ATF cooler 37-3 electrical components 37-4 identification 03-8 neutral start and backup light 37-8 shift mechanism 37-7 specifications 37-2
Bose 91-3, 91-7 Brake fluid bleeding 47-2 level 03-27 replacing 03-28 Brake light switch 45-8, 46-14 testing 24a-7, 24b-5 Brakes antilock 45-1 bleeding 47-2 booster 47-7, 47-9 caliper, bleeding 47-3 master cylinder 47-7 overview 02-24 pads and discs checking 03-50 front 46-3, 46-6 rear 46-9, 46-10 parking brake 46-13 vacuum check-valve 47-7 vacuum pump 47-6 see also Antilock brakes (ABS) Bumpers front 63-1 rear 63-3
B
Bus systems components OBD-1
Back-up lights automatic transmission 37-8, 96-5 DSG 34b-6, 96-5 manual transmission 96-5
C
Battery 27-3 charging 27-6 disconnecting and connecting 27-6 remote control key batteries 57-1 removing and installing 27-7 service 03-33 tray 27-8 Belts ribbed belt 03-39 timing belt, checking 03-42 timing belt, replacing 15a-11 Bleeding brakes 03-28, 47-2
1
Caliper bleeding 47-3 front 46-3 rear 46-6 Camshaft 1.8L engine 15a-17 3.2L engine 15b-7 adjustment valve 3.2L engine 15b-5 position sensor 1.8L engine 15a-17, 24a-3, 24a-6, 28-4 3.2L engine 24b-3, 28-6, 28-7 see also Timing belt CAN-bus components 97-23, OBD-2
2
INDEX Catalytic converter 26-4, 26-9
Cruise control 27-1
Drive belt ribbed belt 03-39
CD changer 91-6
CV joint/boot boot 03-56 front 40-16 rear 42-11
DSG (Direct Shift Gearbox) see Direct Shift Gearbox (DSG)
CD player 91-2 Center console 70-4 see also Trim Central locking 57-14 Climate control 87-2 see also Air conditioning (A/C) Clutch assembly DSG 02-17, 30-18 manual 30-13 hydraulics bleeding 30-10 front wheel drive 30-4 all wheel drive 30-5 pedal 30-1 pedal position sensor 30-18 testing 24a-7, 24b-5 release bearing front wheel drive 30-4 all wheel drive 30-5 Coil spring front 40-9 rear 42-4 Component locations (electrical) 97-3 Compression test 1.8L engine 15a-2 3.2Lengine 15b-2 Compressor 87-21 see also Air conditioning (A/C) Condenser 87-18 see also Air conditioning (A/C)
Cylinder head (1.8L engine) assembly 15a-4 cover 15a-5 valvetrain valvetrain 15a-17
Dual-mass flywheel 30-12 Dust and pollen filter 03-77, 87-3
Cylinder head (3.2L engine) assembly 15b-3 cover 15b-4 valvetrain valvetrain 15b-7
E
D
ECM (engine control module) 24a-15, 24b-13
Dashboard see Instrument panel Diagnostic link connector (DLC) 24a-2, 24b-2, OBD-1 Diagnostic trouble code (DTC) general OBD-1 P-codes OBD-4 U-codes OBD-28 Dimensions exterior 02-4 basic platform 50-1 Direct Shift Gearbox (DSG) 02-16 clutch 30-18 electrical components 34b-3 oil cooler 02-16, 03-69 oil filter 03-72 shift mechanism 34b-4 specifications 34b-2 Disc brakes see Brakes DLC see Data link connector (DLC) Door front 57-2
Console, center 70-4 see also Trim
Door handle/latch front 57-8
Constant velocity (CV) joint see CV joint
Door panel trim 70-21
Convertible top (roadster) body 02-27 assembly 61-2 hydraulics 61-9
Door window glass 57-11 regulator 57-12 subframe 57-2
Coolant see Engine cooling system
Drive axle front 40-13 rear 42-9 boot, checking 03-57
Coolant pump 1.8L engine 19-8 3.2L engine 19-14
DTC table see Diagnostic trouble code (DTC)
EDL (electronic differential lock) 02-24 Electrical system component locations 97-3 fuses 97-24 grounds 97-28 overview 9-1 relays 97-26 troubleshooting 9-3 wiring general EWD-2 index EWD-6 Electrolyte 03-33, 27-3 Electronic differential lock (EDL) 02-24 Electronic immobilizer 96-19 Electronic power control (EPC) 20-18 Electronic stabilization program (ESP) 45-1 motion sensor 45-9 see also Antilock brakes (ABS) Emergency flasher switch 96-7 Emergency flasher relay 96-7 Engine compartment 03-14 identification 03-6 overview and technical data 1.8L engine 02-7 3.2L engine 02-10 sound absorber panels 03-15 Engine control module (ECM) 24a-15, 24b-13
INDEX WARNING Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Audi, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.
Engine coolant temperature (ECT) sensor testing 24a-8, 24b-5 see also Engine management Engine cooling fan 19-20 Engine cooling system anti-freeze concentration 03-25 components 1.8L engine 19-8 3.2L engine 19-13 coolant level 03-25 coolant pump 1.8L engine 19-8 3.2L engine 19-14 draining, filling 19-5 hoses, inspecting 03-27 pressure testing 19-3 radiator and cooling fans 19-20 thermostat 1.8L engine, 19-10 3.2L engine, 19-18 testing 19-4 troubleshooting 19-2 Engine lubrication components 1.8L engine 17-5 3.2L engine 17-8 oil change 1.8L engine 03-20 3.2L engine 03-21 oil filter assembly 1.8L engine 17-6 3.2L engine 17-9 oil pan 1.8L engine 17-5 3.2L engine 17-10 oil pressure warning system 17-2 oil pump 1.8L engine 17-5 3.2L engine 17-8
Engine management components 1.8L engine 24a-3 3.2L engine 24b-3 electronic power control (EPC) 20-18 engine control module (ECM) 1.8L engine 24a-15 3.2L engine 24b-13 engine coolant temperature (ECT) sensor 1.8L engine 24a-8 3.2L engine 24b-6 engine speed (rpm) sensor 1.8L engine 24a-6, 24a-9 3.2L engine 24b-4, 24b-6 fuel rail 1.8L engine 24a-12 3.2L engine 24b-10 intake manifold 1.8L engine 15a-7 3.2L engine 15b-6 on board diagnostics OBD-1 see also Ignition EPC (electronic power control) 20-18 ESP (electronic stabilization program) see Electronic stabilization program (ESP) Evaporative emissions control (EVAP) 20-16 Evaporator 87-11, 87-14 see also Air conditioning (A/C) Exhaust manifold 1.8L engine 21-4, 21-9 3.2L engine 26-9 Exhaust system components 1.8L engine 26-6, 26-7, 26-8 3.2L engine 26-9 installation details 26-3
Front suspension ball joint 40-7 checking 03-56 coil spring 40-12 components 40-2 CV joint 40-14 drive axle 40-15 Fuel filler flap 20-6, 55-1 Fuel filter 03-32 Fuel injection see Engine management Fuel injector 1.8L engine 24a-12 3.2L engine 24b-10 Fuel level sensor 20-11 Fuel pressure 20-8 Fuel pump 20-7, 20-11 Fuel storage and supply 02-14, 20-3, 20-7 evaporative evaporative emissions control 20-16 fuel level sensor 20-11 fuel pump 20-7, 20-11 Fuel tank 20-3, 20-4 flap 20-6, 55-1 Fuses 97-24
G Gas flap see Fuel filler flap
Expansion valve expansion valve 87-20
Gear selector automatic transmission 37-7 Direct Shift Gearbox (DSG) 34b-4 manual transmission 34a-5
F
Generator see Alternator (generator)
Fender, front 50-4 Flywheel, dual-mass 30-12 Foglight 94-10 Footwell vent/trim 70-8
3
Glass see Door window Glove compartment 70-10 Grab handle 70-5, 70-24 Grille 63-5 Grounds 97-28
4
INDEX H
K
Hand brake see Parking brake
Key remote control battery 57-1
Headlight 94-1, 94-4 adjusting 03-80 vehicle level sensor 40-6, 94-2
Knock sensor 1.8L engine 24a-3, 24a-5, 24a-6, 24a-7, 28-5 3.2L engine 24b-3, 24b-4, 28-8
Headliner 70-16 Heating and ventilation dust and pollen filter 03-77 heater core 87-9 see also Air conditioning (A/C) HID headlight 94-7 Hood engine hood 55-2 lock carrier 50-3 Horn vehicle 96-19 alarm 96-19
I Ignition system components 1.8L engine 28-4 3.2L engine 28-6 disabling 28-2 Immobilizer 96-19 Instrument cluster 90-1 dimmer 02-32 replacing 90-4 Instrument panel side covers 70-10 switches 96-6 under-dash panel, left side 70-13 see also Trim Intake air temperature sensor testing 24a-9, 24b-7 Intake manifold 1.8L engine 24a-12 3.2L engine 24b-10 Intercooler 21-3, 21-8 Interior lights 96-2
J Jacking vehicle 03-11
L License plate light 94-14 Lifting vehicle 03-11 Lights, exterior back-up 96-5 center brake 94-12 controls 96-6 foglights 94-10 headlights 94-4 interior 70-17, 96-2 license plate 94-14 rear lights 94-11 switch 96-6 see also Headlight
Manual transmission specifications 34a-2, 34a-3, 34a-4 engine to transmission torques 34a-25 oil 03-59 gear selector 34a-5 identification 03-8 removing and installing (all wheel drive) 34a-16 Mass air flow sensor testing 24a-10, 24b-8 Master cylinder brakes 47-7 clutch 30-4, 30-5 Mirror interior 70-2 outside 66-3 Muffler 1.8L engine 26-6, 26-7, 26-8 3.2L engine 26-9
N Navigation 91-10
Lock carrier, front 50-1
O
M
OBD II OBD-1
Maintenance air filter 03-48 ATF 03-63 03 -63 battery 03-33 body and interior 03-77 brake fluid 03-27 brake system 03-50 cooling 03-24 drive axle boots 03-57 dust and pollen filter 03-77 engine oil 03-17 exhaust system 03-58 fuel filter 03-32 maintenance schedules 03-84 parking brake 03-83 ribbed belt 03-39 road test 03-82 sound absorber panels 03-15 spark plugs 03-43 timing belt 03-42 tires and wheels 03-52 transmission oil Direct Shift Gearbox (DSG) 03-69 manual 03-59 underbody 03-58 under car maintenance 03-50 windshield wipers and washers 03-78 Manifold see Exhaust manifold see also Intake manifold
Oil 03-17 see also Engine lubrication Oil filter 1.8L engine 03-20 3.2L engine 03-21 On Board Diagnostics OBD-1 Oxygen sensor 26-5
P Parking brake 03-83, 46-13 Plenum see Wiper assembly Pollen filter 03-77 Power steering see Steering Power window see Door window
INDEX WARNING Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Audi, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.
Secondary air injection system 1.8L engine 26-10 3.2L engine 26-13 Service reminder 03-81 Shift-lock automatic transmission 37-5 Direct Shift Gearbox (DSG) 34b-3
R Radiator 19-20 Radiator grille 63-5 Radio 91-1 Rain sensor 70-2 Rear suspension coil spring 42-4, 42-8 curb weight position 42-2 overview 42-2, 42-6 shock absorber 42-5, 42-8 wheel bearing 42-2, 42-7 Refrigerant see Air conditioning (A/C) Relays 97-26 Remote control (locking) 57-1 Ribbed belt 03-39
S
T
Sill panel trim 70-20
Tailgate lid 55-4 trim 70-30
Sound absorber panels 03-15 Sound system amplifier 91-7 CD changer 91-5 general 91-1 overview 91-3 speakers 91-9 Spark plugs 03-43 Speakers 91-9 Special tool suppliers OBD-29
Technical Technical specifications 02-4 Thermostat 1.8L engine 19-10 3.2L engine 19-18 testing 19-4 Timing belt checking 03-42 removing and installing 1.8L engine 15a-11 Timing chain (camshaft drive chain) 02-15 assembly 15b-5 Tiptronic 02-16 switch 34b-3, 37-5
Stabilizer bar rear 42-6
Tires 03-52, 44-1
Starter 27-15
Toothed belt see Timing belt
Steering overview 02-20 rack 48-4 steering angle sensor 48-2 steering column 48-2, 48,3 steering column switches 96-12 steering lock 96-16 steering wheel 48-2
Tool suppliers OBD-29
Strut, front suspension 40-9
Scan tool on-board diagnostics II OBD-2 scan tool suppliers OBD-29
Sunlight photo sensor 70-16, 87-4
Seats front 72-1 rear 72-6
Taillight 94-11, 94-12
Specifications 02-4
Safety, passenger 02-2
Seatbelts child seat anchors 69-5 front 69-6 rear 69-9
Switches dashboard 96-6 door 96-10 emergency flasher 96-6 exterior lights 96-6 ignition and steering lock 96-16 instrument cluster dimmer 96-6 steering column stalk 96-12
Shock absorber shock absorber, absorber, rear 42-5, 42-8
Slave cylinder, clutch 30-4, 30-5
Sun visor 70-18 Suspension overview 02-20 see Front suspension see also Rear suspension
5
Torque converter 32-1 Towing 03-10 Transmission applications and codes 02-15 identification 03-8 see also Automatic transmission see also Direct Shift Gearbox (DSG) see also Manual transmission Trim center console 70-4 door inner trim 70-21 pillar and side trim 70-19, 70-20 rear compartment trim 70-26 sill panel trim 70-20 see also Body see also Door panel
6
INDEX Triple roller joint 40-16 Trunk see Tailgate Turbocharger 21-3, 21-8 see also Intercooler Turn signal front 94-9 rear 94-11 Turn signal flasher relay see Emergency flasher relay
Wipers and washers blades 03-79 washers 92-6 wipers 92-2 Wiring general EWD-2 indexes EWD-6 Work safety 03-3 Working under vehicle 03-13
X V Vacuum pump 47-6 Valvetrain 1.8L engine 15a-17 3.2L engine 15b-7 Vehicle Vehicle identification number (VIN) 01-1, 03-4 Ventilation dust and pollen filter 03-77 flow through vents 87-12 see also Air conditioning (A/C) see also Heating and ventilation Visor 70-18 Voltage 9-3
W Water pump 1.8L engine 19-8 3.2L engine 19-14 Weight, vehicle 02-2 Wheel alignment 44-3 Wheel bearing front 40-18 rear 42-2, 42-7 Wheel housing liners 66-7 Wheels 03-52, 44-1 alignment 44-3 bolt 44-2 lock 03-55 Window see Door window
Xenon headlights 94-7
established 1950 Automotive Reference™
BentleyPublishers .com
Audi TT Service Manual: 2000-2006 1.8L turbo, 3.2L including roadster and quattro
Bentley Publishers is proud to announce the publication o the Audi TT Service Manual: 2000–2006. This repair manual covers the 2000 through 2006 model year TTs, including the TT Coupe and the TT Roadster.
Price: $99.95 Bentley Stock Number: AT06 Publication Date: 2006.nov.17 ISBN-10: 0-8376-1500-3 ISBN-13: 978-0-83 978-0-8376-1500-4 76-1500-4 Audi of America Lit. No. W42 AUDITT0006SM Softcover, 8 3/8 in. x 11 in. Case quantity: 5 978 pages, 1826 photos, illustrations and diagrams Includes a 32 page color Audi TT Familiarization section
Although the do-it-yoursel Audi owner will fnd this manual indispensable as a source o theory o operation and step-by-step maintenance and repair inormation, the Audi owner who has no intention o working on his or her car will fnd that reading and owning this manual will make it possible to discuss repairs more intelligently intelligentl y with a proessional technician. Technical Highlights: • Covers TT Coupe and Roadster (convertible) models 2000-2006. • Maintenance procedures: rom oil changes to belt replacement. • Engine and cylinder head service, including timing belt replacement or 4-cylinder engines. • Removal, installation and testing o Motronic uel injection system components. • Exhaust system component replacement, including including Secondary Air Injection system. • Drivetrain maintenance, troubleshooting, troubleshooting, adjustment and repair, including clutch, gearshit linkage, and drive axles.. • Suspension component replacement, including ront struts, rear shocks, springs, ront stabilizer bar and alignment procedures and specifcations. • Heating and air conditioning component replacement. • Body adjustment and repairs, including ront door components, enders, bumper covers and convertible top replacement. • Wiring schematics with use/relay locations including an easy-to-use illustrated component locator section. • Audi OBD II diagnostic trouble codes, SAE-defned OBD II P-codes, as well as basic scan tool operation. • Comprehensive Audi actory tolerances, wear limits, adjustments, and tightening torques.
Bentley repair manuals provide the highest level o clarity and comprehensiveness comprehensiven ess or service and repair procedures. I you’re looking or better understanding o your Audi TT, look no urther than Bentley.
Bentley technical editors working on a TT Roadster.
Location of ignition components on 3.2L engine. 28 Ignition System
Engines covered:
• 1.8L turbo gasoline (engine code: ATC, AWP, AWP, AMU, B EA) • 3.2L gasoline (engine code: BHE) Transmissions Transmi ssions covered:
• 02J 5-speed manual (front wheel drive) • 02M/02Y 5- and 6-speed manual (all wheel drive) • 09G 6-speed automatic (front wheel drive) • 02E 6-speed DSG (all wheel drive)
Bentley Publishers, 1734 1734 Massachusetts Avenue, Cambridge, MA 02138-180 4 USA Tel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235 http://www.bentleypublis http://www .bentleypublishers.com/contact-sales hers.com/contact-sales
