2001 Audi TT Quattro ENGINE PERFORMANCE' 'System & Component Testing

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1 FUEL SYSTEM WARNING: ALWAYS release fuel pressure before disconnecting fuel injection-related component. DO NOT allow fuel to contact engine or electrical components. FUEL INJECTOR TEST Fuel Injector Electrical Testing For electrical testing of fuel injectors, see appropriate DTC for FUEL INJECTORS under DIAGNOSTIC TROUBLE CODE DEFINITIONS in appropriate SELF-DIAGNOSTICS article. Fuel Injector Leak Test 1. Ensure fuel system pressure is within specification before performing this test. See fuel pressure specifications, see FUEL SYSTEM PRESSURE under FUEL PRESSURE TEST. Remove fuel rail complete with fuel injectors from engine. DO NOT disconnect fuel supply or return lines. Activate fuel pump. See appropriate fuel pump activation procedure under FUEL PUMP. 2. With fuel pump running, visually inspect fuel injector for leaks. Maximum allowable leakage is 1-2 drops of fuel per injector per minute. If fuel injector leaks more than 2 drops of fuel per minute, replace leaking fuel injector. Fuel Injector Resistance Test Turn ignition off. Disconnect fuel injector harness connector. Using a DVOM, measure resistance across fuel injector terminals. See FUEL INJECTOR RESISTANCE table. If resistance is not within specification, replace fuel injector. FUEL INJECTOR RESISTANCE Application (1) Ohms 1.8L Turbo (A4) (2) L Turbo (TT) (2) L Turbo & 2.8L (A4, A6 & S4) (2) L (A6) (2) (1) Measurement taken at room temperature, (approximately 68 F). (2) Add 4-6 ohms if injector is at operating temperature. Fuel Injector Quantity Test 1. Remove fuel rail, complete with fuel injectors, from engine. DO NOT disconnect fuel supply or return lines. Place fuel injector being tested into a graduated container. Using fused jumper wire connect one terminal of fuel injector to battery positive terminal.

2 2. Using fused jumper wire connect other terminal of fuel injector to ground for exactly 30 seconds. Activate fuel pump. See appropriate fuel pump activation procedure under FUEL PUMP. Fuel quantity should be as specified. See FUEL INJECTOR QUANTITY table. If fuel quantity is more than or less than specification, replace faulty fuel injector. FUEL INJECTOR QUANTITY Application Ozs. (ml) A4, A6 & S4 1.8L Turbo ( ) 2.7L Turbo ( ) 2.8L (90-125) 4.2L (95-115) TT ( ) FUEL PRESSURE RELEASE A4, A6 & S4 Loosen fuel filler cap to release pressure in fuel tank. Remove fuel pump relay. Fuel pump relay is located in position 4 of micro-electric center in driver's footwell. See Fig. 4. Start engine. Allow engine to run until it stalls. Turn ignition off. Disconnect negative battery cable. Slight pressure may remain in system. Before disconnecting any fuel system line, cover connector with a clean shop towel. Reinstall fuel pump relay.

3 Fig. 4: Locating Fuel Pump Relay TT Loosen fuel filler cap to release pressure in fuel tank. Turn ignition off. Disconnect negative battery cable. Before disconnecting any fuel system line, cover connector with a clean shop towel. Release fuel pressure by carefully loosening fuel hoses at fuel line connection point in engine compartment. Reconnect fuel hoses after pressure is released. FUEL PRESSURE TEST NOTE: Volkswagen Audi Group (VAG 1551) scan tool is necessary to activate fuel system for fuel pressure test. Fuel System Pressure 1. Ensure fuel pump relay is okay. Ensure correct fuel filter is installed. Ensure battery voltage is at least 12 volts. Release fuel pressure. See FUEL PRESSURE RELEASE. 2. Connect Pressure Gauge (VAG 1318) between fuel supply and fuel return lines in engine compartment. See Fig. 5 or Fig. 6. Disconnect and plug vacuum line from fuel pressure regulator. Start engine, and let idle. Fuel pressure should be within specification. See appropriate FUEL PRESSURE SPECIFICATIONS table.

4 FUEL PRESSURE SPECIFICATIONS (1.8L A4 & 2.7L TURBO A6 & S4) Function System Pressure With Engine Idling (1) With Engine Idling (2) Residual Pressure (3) (1) With fuel pressure regulator vacuum hose connected. (2) With fuel pressure regulator vacuum hose disconnected. (3) After 10 minutes. Specification 50 psi (3.5 bar) 58 psi (4 bar) 36 psi (2.5 bar) FUEL PRESSURE SPECIFICATIONS (1.8L TT) Function System Pressure With Engine Idling (1) With Engine Idling (2) Residual Pressure (3) (1) With fuel pressure regulator vacuum hose disconnected. Specification 44 psi (3.0 bar) 36 psi (2.5 bar) psi (1.5 bar) (2) With fuel pressure regulator vacuum hose connected. (3) After 10 minutes. FUEL PRESSURE SPECIFICATIONS (2.8L) Function System Pressure With Engine Idling (1) With Engine Idling (2) Residual Pressure Cold Engine (3) Warm Engine (3) (1) With fuel pressure regulator vacuum hose connected. (2) With fuel pressure regulator vacuum hose disconnected. (3) After 10 minutes. Specification psi ( bar) psi ( bar) 32 psi (2.2 bar) 44 psi (3.0 bar) FUEL PRESSURE SPECIFICATIONS (4.2L) Function System Pressure With Engine Idling (1) Specification 50 psi (3.5 bar)

5 With Engine Idling (2) Residual Pressure (3) (1) With fuel pressure regulator vacuum hose connected. (2) With fuel pressure regulator vacuum hose disconnected. (3) After 10 minutes. 58 psi (4.0 bar) 36 psi (2.5 bar) 3. If fuel pressure is within specification, connect vacuum hose to fuel pressure regulator. Pressure should drop as specified. See appropriate FUEL PRESSURE SPECIFICATIONS table. If fuel pressure is not within specification, check fuel pressure regulator, fuel pump and fuel lines and repair or replace as necessary. Fig. 5: Connecting Fuel Pressure Gauge (A4, A6 & S4)

6 Fig. 6: Connecting Fuel Pressure Gauge (TT) Fuel System Residual Pressure

7 1. Connect Pressure Gauge (VAG 1318) between fuel supply and fuel return lines in engine compartment. See Fig. 5 or Fig. 6. Start engine and let it idle. Turn engine off. 2. After 10 minutes observe fuel pressure gauge. If residual fuel pressure is as specified, residual fuel pressure is okay. See appropriate FUEL PRESSURE SPECIFICATIONS table, go to FUEL SYSTEM PRESSURE. If residual fuel pressure is less than minimum, check fuel lines for leaks and repair as necessary. Check fuel pressure regulator for leaks. Check fuel injectors for leaks. See FUEL INJECTOR TEST. FUEL PUMP Fuel Pump Activation (A4 & S4) 1. Ensure battery voltage to be 12 volts or more. Check fuse No. 28 (15-amp). Fuse is located in instrument panel fuse box. Check fuel pump relay. Check that fuel filter is right one for vehicle, and not clogged. If no problem is found, go to next step. If problem is found, repair as necessary before continuing testing. 2. Remove cover from instrument panel fuse box. Remove fuse No. 28. Connect remote control switch (VAG1348/3A) or equivalent, and appropriate adapter to right side terminal of fuse No. 28. Connect other end of remote control switch to battery voltage. Press remote control switch to ON position. Fuel pump should activate. Fuel pump should be able to be heard running (surrounding noise should be kept to a minimum, as fuel pump runs quietly). If fuel pump cannot be heard, go to next step. 3. Remove rear seat bench by lifting up, and pulling forward. Remove fuel pump access cover. Disconnect fuel pump assembly 4-pin harness connector. Connect DVOM between fuel pump assembly harness connector terminals No. 1 and 4. See Fig. 7. Press remote control switch to ON position. If battery voltage does not exist, go to next step. If battery voltage exists, go to step Check for and repair, open or shorted circuits between fuel pump and instrument panel fuse box. See WIRING DIAGRAMS article. 5. Remove fuel pump closing flange. See REMOVAL, OVERHAUL & INSTALLATION article. Check wiring and connections between flange and fuel pump. If problem is found, repair as necessary. After repair, retest fuel pump with remote control switch. If no problem with wiring is found, replace fuel pump. See REMOVAL, OVERHAUL & INSTALLATION article.

8 Fig. 7: Identifying Fuel Pump Assembly Harness Connector Terminals (A4 & S4) Fuel Pump Activation (A6 & TT) 1. Ensure battery voltage to be 12 volts or more. Check fuse No. 28 (15-amp). Fuse is located in instrument panel fuse box. Check fuel pump relay. Check that fuel filter is right one for vehicle, and not clogged. If no problem is found, go to next step. If problem is found, repair as necessary before continuing testing. 2. Remove cover from instrument panel fuse box. Remove fuse No. 28. Connect remote control switch (VAG1348/3A) or equivalent, and appropriate adapter to right side terminal of fuse No. 28. Connect other end of remote control switch to battery voltage. Press remote control switch to ON position. Fuel pump should activate. Fuel pump should be able to be heard running (surrounding noise should be kept to a minimum, as fuel pump runs quietly). If fuel pump cannot be heard, go to next step. 3. Remove rear seat bench by lifting up, and pulling forward. Remove fuel pump access cover. Disconnect fuel pump assembly 4-pin harness connector. Connect DVOM between fuel pump assembly harness connector terminals No. 1 and 4. See Fig. 8. Press remote control switch to ON position. If battery

9 voltage does not exist, go to next step. If battery voltage exists, and fuel pump does not run go to step Check for and repair, open or shorted circuits between fuel pump and instrument panel fuse box. See WIRING DIAGRAMS article. If problem is found, repair as necessary. After repair, retest fuel pump with remote control switch. 5. Remove fuel pump closing flange from tank. See REMOVAL, OVERHAUL & INSTALLATION article. Check wiring and connections between flange and fuel pump. If problem is found, repair as necessary. After repair, retest fuel pump with remote control switch. If no problem with wiring is found, replace fuel pump. See REMOVAL, OVERHAUL & INSTALLATION article. Fig. 8: Identifying Fuel Pump Assembly Harness Connector Terminals (A6 & TT) FUEL PUMP RELAY Fuel Pump (FP) relay supplies voltage to the fuel pump as well as several other fuel injection components. ECM grounds FP relay when ECM receives RPM signal. FP relay is located in position No. 4 of micro-central electronics center in driver's side footwell. See Fig. 4.

10 To test fuel pump relay, see appropriate DTC under DIAGNOSTIC TROUBLE CODE DEFINITIONS in appropriate SELF-DIAGNOSTICS article. IGNITION COIL(S) To test ignition coils, see appropriate DTC under DIAGNOSTIC TROUBLE CODE DEFINITIONS in appropriate SELF-DIAGNOSTICS article. 1.8L TURBO 1. Turn ignition off. Connect VAS 5051 or equivalent scan tool to Data Link Connector (DLC). DLC is located under cover on left side of instrument panel. Start engine. On scan tool from selection 1 select diagnostic function 08 - READ MEASURING VALUE BLOCK. From button field 2, enter 014 to select DISPLAY GROUP 014, press "Q" button to confirm input, and go to next step. 2. On scan tool observe misfire recognition in display fields No. 3 and 4. See Fig. 9. If displayed value is more than specified, go to next step. If displayed value is as specified, go to step On scan tool press "UP ARROW" or from button field 2, enter 015 to select DISPLAY GROUP 015. Observe misfire recognition in display fields 1-4. See Fig. 10. If displayed values are as specified, go to next step. If specified value is exceeded in any display field, go to step On scan tool press "UP ARROW" or from button field 2, enter 016 to select DISPLAY GROUP 016. Observe misfire recognition in display fields 1 and 4. See Fig. 11. If specified value is exceeded in display field 1, go to next step. If displayed values are as specified, go to step If displayed value is more than zero, perform following tests: Check spark plugs. Replace as necessary. Check spark plug connector between ignition coil and spark plug. Maximum resistance in connector is 2000 ohms. Check for cracks or tears in connector. Check ignition coil and power output stage. For diagnostic procedure, see DIAGNOSTIC TROUBLE CODE DEFINITIONS in appropriate SELF-DIAGNOSTICS article. Check fuel injectors. See FUEL INJECTOR TEST under FUEL SYSTEM. If problem is found, repair as necessary. After repair go to next step. 6. Using scan tool, clear DTCs and generate a ECM readiness code. See FUNCTION 05 - CLEARING DIAGNOSTIC TROUBLE CODES and READINESS CODE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article. Test drive vehicle. Using scan tool, retrieve DTCs. If DTC does not reset, testing is complete.

11 Fig. 9: Display Group 014: Misfire Recognition (1.8L Turbo) Fig. 10: Display Group 015: Misfire Recognition Cylinder Nos. 1, 2 & 3 (1.8L Turbo)

12 Fig. 11: Display Group 016: Misfire Recognition Cylinder No. 4 (1.8L Turbo)

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