audi tt 2000-2006 repair manual - complete index

INDEX 1

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

ABSsee Antilock brakes (ABS)

Accelerator pedal assembly20-18

Air conditioning (A/C)basic settings 87-7blower motor 87-13blower motor control module 87-12climate control 87-2coding 87-8components 87-2, 87-11compressor 87-21condenser 87-18controls 87-6dust and pollen filter 03-77evaporator 87-11, 87-14evaporator drain hose 87-12expansion valve 87-20flap motors 87-4flow through vents 87-12functions 87-6housing 87-9overview 02-29pressure sensor 87-16receiver drier 87-18refrigerant oil 87-14refrigerant system 87-14sunlight photo sensor 70-16, 87-4

Air filter03-48

Airbags69-1, 69-10

Alarm (anti-theft) system96-19

Alignment44-3

Alternator (generator)1.8L engine 27-93.2L engine 27-12belt 03-39

Amplifier91-7, 91-9

Antenna91-8

Antifreezesee Engine cooling system

Antilock brakes (ABS)electrical components 45-5hydraulic components 45-6variants 45-1warning lights 45-3wheel speed sensor 45-7see also Electronic stabilization program (ESP)

see also Antislip regulation (ASR)

Antislip regulation (ASR)45-2see also Antilock brakes (ABS)

Anti-theft (alarm) system96-19radio 91-4

A-pillar trim70-19

ASR (antislip regulation)45-2see also Antilock brakes (ABS)

Automatic transmission 02-16applications 03-8ATF 37-2ATF cooler 37-3electrical components 37-4identification 03-8neutral start and backup light 37-8shift mechanism 37-7specifications 37-2

B

Back-up lightsautomatic transmission 37-8, 96-5DSG 34b-6, 96-5manual transmission 96-5

Battery27-3charging 27-6disconnecting and connecting 27-6remote control key batteries 57-1removing and installing 27-7service 03-33tray 27-8

Beltsribbed belt 03-39timing belt, checking 03-42timing belt, replacing 15a-11

Bleeding brakes03-28, 47-2

Blower motor87-13

Bodybumpers 63-1, 63-3fender 50-4grille 63-5lock carrier, front 50-3overview 02-25sound absorber panels 03-15wheel housing liners 66-7see also Trim

Bose91-3, 91-7

Brake fluidbleeding 47-2level 03-27replacing 03-28

Brake light switch45-8, 46-14testing 24a-7, 24b-5

Brakesantilock 45-1bleeding 47-2booster 47-7, 47-9caliper, bleeding 47-3master cylinder 47-7overview 02-24pads and discs

checking 03-50front 46-3, 46-6rear 46-9, 46-10

parking brake 46-13vacuum check-valve 47-7vacuum pump 47-6see also Antilock brakes (ABS)

Bumpersfront 63-1rear 63-3

Bus systemscomponents OBD-1

C

Caliperbleeding 47-3front 46-3rear 46-6

Camshaft1.8L engine 15a-173.2L engine 15b-7adjustment valve

3.2L engine 15b-5position sensor

1.8L engine 15a-17, 24a-3, 24a-6, 28-4

3.2L engine 24b-3, 28-6, 28-7see also Timing belt

CAN-buscomponents 97-23, OBD-2

AT06_index.fm Tuesday, September 19, 2006 9:41 AM

2 INDEX

Catalytic converter26-4, 26-9

CD changer91-6

CD player91-2

Center console70-4see also Trim

Central locking57-14

Climate control87-2see also Air conditioning (A/C)

Clutchassembly

DSG 02-17, 30-18manual 30-13

hydraulics bleeding 30-10front wheel drive 30-4all wheel drive 30-5

pedal 30-1pedal position sensor 30-18

testing 24a-7, 24b-5release bearing

front wheel drive 30-4all wheel drive 30-5

Coil springfront 40-9rear 42-4

Component locations (electrical)97-3

Compression test1.8L engine 15a-23.2Lengine 15b-2

Compressor87-21see also Air conditioning (A/C)

Condenser87-18see also Air conditioning (A/C)

Console, center70-4

see also Trim

Constant velocity (CV) jointsee CV joint

Convertible top (roadster)body 02-27assembly 61-2hydraulics 61-9

Coolantsee Engine cooling system

Coolant pump1.8L engine 19-83.2L engine 19-14

Cruise control27-1

CV joint/bootboot 03-56front 40-16rear 42-11

Cylinder head (1.8L engine)assembly 15a-4cover 15a-5valvetrain 15a-17

Cylinder head (3.2L engine)assembly 15b-3cover 15b-4valvetrain 15b-7

D

Dashboardsee Instrument panel

Diagnostic link connector (DLC)24a-2, 24b-2, OBD-1

Diagnostic trouble code (DTC)general OBD-1P-codes OBD-4U-codes OBD-28

Dimensionsexterior 02-4basic platform 50-1

Direct Shift Gearbox (DSG)02-16clutch 30-18electrical components 34b-3oil cooler 02-16, 03-69oil filter 03-72shift mechanism 34b-4specifications 34b-2

Disc brakessee Brakes

DLCsee Data link connector (DLC)

Doorfront 57-2

Door handle/latchfront 57-8

Door paneltrim 70-21

Door windowglass 57-11regulator 57-12subframe 57-2

Drive axlefront 40-13rear 42-9boot, checking 03-57

Drive beltribbed belt 03-39

DSG (Direct Shift Gearbox)see Direct Shift Gearbox (DSG)

DTC table see Diagnostic trouble code (DTC)

Dual-mass flywheel30-12

Dust and pollen filter03-77, 87-3

E

ECM (engine control module) 24a-15, 24b-13

EDL (electronic differential lock)02-24

Electrical systemcomponent locations 97-3fuses 97-24grounds 97-28overview 9-1relays 97-26troubleshooting 9-3wiring

general EWD-2index EWD-6

Electrolyte03-33, 27-3

Electronic differential lock (EDL)02-24

Electronic immobilizer96-19

Electronic power control (EPC) 20-18

Electronic stabilization program (ESP)

45-1motion sensor 45-9see also Antilock brakes (ABS)

Emergency flasher switch96-7

Emergency flasher relay96-7

Enginecompartment 03-14identification 03-6overview and technical data

1.8L engine 02-73.2L engine 02-10

sound absorber panels 03-15

Engine control module (ECM) 24a-15, 24b-13


INDEX 3

WARNING


Engine coolant temperature (ECT) sensor

testing 24a-8, 24b-5see also Engine management

Engine cooling fan 19-20

Engine cooling systemanti-freeze concentration 03-25components


coolant level 03-25coolant pump


draining, filling 19-5hoses, inspecting 03-27pressure testing 19-3radiator and cooling fans 19-20thermostat

1.8L engine, 19-103.2L engine, 19-18testing 19-4

troubleshooting 19-2

Engine lubrication components


oil change 1.8L engine 03-203.2L engine 03-21

oil filter assembly 1.8L engine 17-63.2L engine 17-9

oil pan 1.8L engine 17-53.2L engine 17-10

oil pressure warning system 17-2oil pump


Engine managementcomponents

1.8L engine 24a-33.2L engine 24b-3

electronic power control (EPC) 20-18engine control module (ECM)

1.8L engine 24a-153.2L engine 24b-13

engine coolant temperature (ECT) sensor1.8L engine 24a-83.2L engine 24b-6

engine speed (rpm) sensor1.8L engine 24a-6, 24a-93.2L engine 24b-4, 24b-6

fuel rail1.8L engine 24a-123.2L engine 24b-10

intake manifold1.8L engine 15a-73.2L engine 15b-6

on board diagnostics OBD-1see also Ignition

EPC (electronic power control)20-18

ESP (electronic stabilization program)see Electronic stabilization program (ESP)

Evaporative emissions control (EVAP)

20-16

Evaporator87-11, 87-14see also Air conditioning (A/C)

Exhaust manifold1.8L engine 21-4, 21-93.2L engine 26-9

Exhaust systemcomponents

1.8L engine 26-6, 26-7, 26-83.2L engine 26-9

installation details 26-3

Expansion valveexpansion valve 87-20

F

Fender, front50-4

Flywheel, dual-mass30-12

Foglight94-10

Footwell vent/trim70-8

Front suspensionball joint 40-7checking 03-56coil spring 40-12components 40-2CV joint 40-14 drive axle 40-15

Fuel filler flap20-6, 55-1

Fuel filter03-32

Fuel injectionsee Engine management

Fuel injector1.8L engine 24a-123.2L engine 24b-10

Fuel level sensor20-11

Fuel pressure20-8

Fuel pump20-7, 20-11

Fuel storage and supply02-14, 20-3, 20-7evaporative emissions control 20-16fuel level sensor 20-11fuel pump 20-7, 20-11

Fuel tank20-3, 20-4flap 20-6, 55-1

Fuses97-24

G

Gas flapsee Fuel filler flap

Gear selectorautomatic transmission 37-7Direct Shift Gearbox (DSG) 34b-4manual transmission 34a-5

Generatorsee Alternator (generator)

Glasssee Door window

Glove compartment70-10

Grab handle70-5, 70-24

Grille63-5

Grounds97-28


4 INDEX

H

Hand brakesee Parking brake

Headlight94-1, 94-4adjusting 03-80vehicle level sensor 40-6, 94-2

Headliner70-16

Heating and ventilationdust and pollen filter 03-77heater core 87-9see also Air conditioning (A/C)

HID headlight94-7

Hoodengine hood 55-2lock carrier 50-3

Hornvehicle 96-19alarm 96-19

I

Ignition systemcomponents


disabling 28-2

Immobilizer96-19

Instrument cluster90-1dimmer 02-32replacing 90-4

Instrument panelside covers 70-10switches 96-6under-dash panel, left side 70-13see also Trim

Intake air temperature sensortesting 24a-9, 24b-7

Intake manifold1.8L engine 24a-123.2L engine 24b-10

Intercooler21-3, 21-8

Interior lights96-2

J

Jacking vehicle03-11

K

Keyremote control battery 57-1

Knock sensor1.8L engine 24a-3, 24a-5, 24a-6, 24a-7, 28-5

3.2L engine 24b-3, 24b-4, 28-8

L

License plate light94-14

Lifting vehicle03-11

Lights, exteriorback-up 96-5center brake 94-12controls 96-6foglights 94-10headlights 94-4interior 70-17, 96-2license plate 94-14rear lights 94-11switch 96-6see also Headlight

Lock carrier, front50-1

M

Maintenanceair filter 03-48ATF 03-63battery 03-33body and interior 03-77brake fluid 03-27brake system 03-50cooling 03-24drive axle boots 03-57dust and pollen filter 03-77engine oil 03-17exhaust system 03-58fuel filter 03-32maintenance schedules 03-84parking brake 03-83ribbed belt 03-39road test 03-82sound absorber panels 03-15spark plugs 03-43timing belt 03-42tires and wheels 03-52transmission oil

Direct Shift Gearbox (DSG) 03-69manual 03-59

underbody 03-58under car maintenance 03-50windshield wipers and washers 03-78

Manifoldsee Exhaust manifoldsee also Intake manifold

Manual transmissionspecifications 34a-2, 34a-3, 34a-4engine to transmission torques 34a-25

oil 03-59gear selector 34a-5identification 03-8removing and installing (all wheel drive) 34a-16

Mass air flow sensortesting 24a-10, 24b-8

Master cylinderbrakes 47-7clutch 30-4, 30-5

Mirrorinterior 70-2outside 66-3

Muffler1.8L engine 26-6, 26-7, 26-83.2L engine 26-9

N

Navigation91-10

O

OBD IIOBD-1

Oil03-17see also Engine lubrication

Oil filter1.8L engine 03-203.2L engine 03-21

On Board DiagnosticsOBD-1

Oxygen sensor26-5

P

Parking brake03-83, 46-13

Plenumsee Wiper assembly

Pollen filter03-77

Power steeringsee Steering

Power windowsee Door window


INDEX 5

WARNING


R

Radiator 19-20

Radiator grille63-5

Radio91-1

Rain sensor70-2

Rear suspensioncoil spring 42-4, 42-8curb weight position 42-2overview 42-2, 42-6shock absorber 42-5, 42-8wheel bearing 42-2, 42-7

Refrigerantsee Air conditioning (A/C)

Relays97-26

Remote control (locking)57-1

Ribbed belt03-39

S

Safety, passenger02-2

Scan toolon-board diagnostics II OBD-2scan tool suppliers OBD-29

Seatbeltschild seat anchors 69-5front 69-6rear 69-9

Seatsfront 72-1rear 72-6

Secondary air injection system1.8L engine 26-103.2L engine 26-13

Service reminder03-81

Shift-lockautomatic transmission 37-5Direct Shift Gearbox (DSG) 34b-3

Shock absorbershock absorber, rear 42-5, 42-8

Sill panel trim70-20

Slave cylinder, clutch30-4, 30-5

Sound absorber panels03-15

Sound systemamplifier 91-7CD changer 91-5general 91-1overview 91-3speakers 91-9

Spark plugs03-43

Speakers91-9

Special tool suppliersOBD-29

Specifications02-4

Stabilizer barrear 42-6

Starter27-15

Steeringoverview 02-20rack 48-4steering angle sensor 48-2steering column 48-2, 48,3steering column switches 96-12steering lock 96-16steering wheel 48-2

Strut, front suspension40-9

Sunlight photo sensor70-16, 87-4

Sun visor70-18

Suspensionoverview 02-20see Front suspensionsee also Rear suspension

Switchesdashboard 96-6door 96-10emergency flasher 96-6exterior lights 96-6ignition and steering lock 96-16instrument cluster dimmer 96-6steering column stalk 96-12

T

Tailgatelid 55-4trim 70-30

Taillight94-11, 94-12

Technical specifications02-4

Thermostat1.8L engine 19-103.2L engine 19-18testing 19-4

Timing beltchecking 03-42removing and installing

1.8L engine 15a-11

Timing chain (camshaft drive chain)02-15assembly 15b-5

Tiptronic02-16switch 34b-3, 37-5

Tires03-52, 44-1

Toothed beltsee Timing belt

Tool suppliersOBD-29

Torque converter32-1

Towing03-10

Transmissionapplications and codes 02-15identification 03-8see also Automatic transmissionsee also Direct Shift Gearbox (DSG)see also Manual transmission

Trimcenter console 70-4door inner trim 70-21pillar and side trim 70-19, 70-20rear compartment trim 70-26sill panel trim 70-20see also Bodysee also Door panel


6 INDEX

Triple roller joint40-16

Trunk see Tailgate

Turbocharger21-3, 21-8see also Intercooler

Turn signalfront 94-9rear 94-11

Turn signal flasher relaysee Emergency flasher relay

V

Vacuum pump47-6

Valvetrain1.8L engine 15a-173.2L engine 15b-7

Vehicle identification number (VIN)01-1, 03-4

Ventilationdust and pollen filter 03-77flow through vents 87-12see also Air conditioning (A/C)see also Heating and ventilation

Visor70-18

Voltage9-3

W

Water pump1.8L engine 19-83.2L engine 19-14

Weight, vehicle02-2

Wheel alignment44-3

Wheel bearingfront 40-18rear 42-2, 42-7

Wheel housing liners66-7

Wheels03-52, 44-1alignment 44-3bolt 44-2lock 03-55

Windowsee Door window

Wipers and washersblades 03-79washers 92-6wipers 92-2

Wiring general EWD-2indexes EWD-6

Work safety03-3

Working under vehicle03-13

X

Xenon headlights94-7


established 1950Automotive Reference™

Bentley Publishers, 1734 Massachusetts Avenue, Cambridge, MA 02138-1804 USATel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235http://www.bentleypublishers.com/contact-sales

Audi TTService Manual: 2000-20061.8L turbo, 3.2Lincluding roadster and quattro

Price: $99.95Bentley Stock Number: AT06Publication Date: 2006.nov.17ISBN-10: 0-8376-1500-3ISBN-13: 978-0-8376-1500-4Audi of America Lit. No. W42 AUDITT0006SMSoftcover, 8 3/8 in. x 11 in.Case quantity: 5978 pages, 1826 photos, illustrations and diagramsIncludes a 32 page color Audi TT Familiarization sectionBentley Publishers is proud to announce the publication of 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.

Although the do-it-yourself Audi owner will find this manual indispensable as a source of theory of operation and step-by-stepmaintenance and repair information, the Audi owner who has no intention of working on his or her car will find that reading and owning this manual will make it possible to discuss repairs more intelligently with a professional technician.

Technical Highlights:• Covers TT Coupe and Roadster (convertible) models 2000-2006.• Maintenance procedures: from oil changes to belt replacement.• Engine and cylinder head service, including timing belt replacement for 4-cylinder engines. • Removal, installation and testing of Motronic fuel injection system components.• Exhaust system component replacement, including Secondary Air Injection system.• Drivetrain maintenance, troubleshooting, adjustment and repair, including clutch, gearshift linkage, and drive axles..• Suspension component replacement, including front struts, rear shocks, springs, front stabilizer bar and alignment procedures and specifications.• Heating and air conditioning component replacement.• Body adjustment and repairs, including front door components, fenders, bumper covers and convertible top replacement.• Wiring schematics with fuse/relay locations including an easy-to-use illustrated component locator section.• Audi OBD II diagnostic trouble codes, SAE-defined OBD II P-codes, as well as basic scan tool operation.• Comprehensive Audi factory tolerances, wear limits,

adjustments, and tightening torques.

Bentley repair manuals provide the highest level of clarity and comprehensiveness for service and repair procedures. If you’re looking for better understanding of your Audi TT, look no further than Bentley.

Engines covered:

• 1.8L turbo gasoline (engine code: ATC, AWP, AMU, BEA) • 3.2L gasoline (engine code: BHE)

Transmissions 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 technicaleditors working on aTT Roadster.

Location of ignition componentson 3.2L engine.28 Ignition System

BentleyPublishers.com

audi tt 2000-2006 repair manual - complete index

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