4-Cylinder Direct Petrol Injection Engine 1.8L 2.0L
4-Cylinder Direct Petrol Injection Engine 1.8L 2.0L
4-Cylinder Direct Petrol Injection Engine 1.8L 2.0L
Workshop Manual
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr.
4-valve turbo), mechanics
Engine ID
CCT CCZ CDA CES CET
A A A A A
Edition 11.2010
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
26 - Exhaust system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Procedure before opening high-pressure section of injection system . . . . . . . . . . . . . . . . 4
3.3 Working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.5 Using testers and measuring instruments during a road test . . . . . . . . . . . . . . . . . . . . . . . . 5
3.6 Working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Rules for cleanliness when working on fuel supply system, injection system and
turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.5 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.6 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.7 Installing radiators, condensers and charge air coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.1 Poly V-belt drive - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.4 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.1 Sealing flange (gearbox end) and dual-mass flywheel - exploded view . . . . . . . . . . . . . . . . 59
2.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.3 Removing and installing sealing flange (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.1 Crankshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.3 Allocation of crankshaft bearing shells (classification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.4 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.5 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.6 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.1 Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Contents i
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1 Sump and oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.1 Sump, oil pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.2 Removing and installing coarse oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.3 Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.5 Removing and installing sump (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.6 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 181
2 Oil filter and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.1 Oil filter, engine oil cooler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.3 Removing and installing oil pressure switch F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.4 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 186
2.5 Checking oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.6 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.7 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.8 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1 Parts of cooling system (on engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.1 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.2 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
ii Contents
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
1.1 Turbocharger - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.2 Removing and installing air pipes and hoses with plug-in connectors . . . . . . . . . . . . . . . . 227
1.3 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.4 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.5 Removing and installing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
1.6 Adjusting vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.1 Turbocharging diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.2 Charge air cooler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
2.3 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
2.5 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Contents iii
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
iv Contents
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
00 – Technical data
1 Engine number
The engine number („Engine code“ and „Serial number“) can be
found at the front of the joint between engine and gearbox.
Additionally there is a sticker on the toothed belt cover showing
the „engine code“ and „serial number“.
The engine code is also indicated on the vehicle data stickers.
1. Engine number 1
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
2 Engine data
Code letters CDAA CCTA CCZA CESA
Capaci‐ ltr. 1.789 1.984 1.984 1.984
ty
Power kW at 118/4200 147/5100 147/5100 155/4300
output rpm
Torque Nm at 250/1500 280/1700 280/1700 350/1600
rpm
Bore ∅ in 82.5 82.5 82.5 82.5
mm
Stroke mm 84.2 92.8 92.8 92.8
Compression ra‐ 9.6 9.6 9.6 9.6
tio
RON 95 2) 98 1) 98 1) 95 2)
Injection/ignition FSI FSI FSI FSI
system
Firing 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
order
Knock control yes yes yes yes
Turbocharging/ yes yes yes yes
supercharging
Exhaust gas re‐ no no no no
circulation
Intake manifold no no no no
change-over
Variable valve yes yes yes yes
timing
Secondary air no no no no
system
• 1) Unleaded petrol RON 95 can also be used, but results
in reduced power
• 2) Unleaded petrol RON 91 can also be used, but results
in reduced power
3 Safety precautions
♦ ⇒ „3.1 Working on the fuel system“, page 3
♦ ⇒ „3.2 Procedure before opening high-pressure section of in‐
jection system“, page 4
♦ ⇒ „3.3 Working on the cooling system“, page 4
♦ ⇒ „3.4 Working on vehicles with start/stop system“,
page 4
♦ ⇒ „3.5 Using testers and measuring instruments during a road
test“, page 5
♦ ⇒ „3.6 Working on the exhaust system“, page 5
WARNING
Caution
3. Safety precautions 3
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
WARNING
WARNING
Caution
WARNING
WARNING
Caution
3. Safety precautions 5
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites
♦ Kinked or crushed lines
♦ Lines porous or leaking
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
1. Removing engine 9
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Procedure
Note
WARNING
Caution
WARNING
1. Removing engine 11
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
Note
– Place drip tray for workshop hoist -VAS 6208- beneath engine.
– Pull off retaining clip, remove coolant hose -1- and drain off
coolant.
1. Removing engine 13
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
Note
Note
Caution
Note
WARNING
Caution
1. Removing engine 15
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
Note
1. Removing engine 17
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Caution
– Slide the two clips in the direction of the -arrows- and remove
cover from electronics box in engine compartment.
1. Removing engine 19
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
Use removal lever -80 - 200- to lever out the wiring clips.
Caution
1. Removing engine 21
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Caution
Note
– Unbolt heat shield for drive shaft (right-side) from bevel box
-arrows-.
– Unbolt drive shaft (left-side) from gearbox flange.
– Unbolt drive shaft (right-side) from bevel box flange.
– Tie up drive shafts with cable ties.
Note
Take care not to damage the surface coating of the drive shafts.
WARNING
Note
1. Removing engine 23
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
Caution
Note
Take care not to damage the surface coating of the drive shafts.
WARNING
Four-wheel drive:
1. Removing engine 25
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Caution
Make sure not to damage the oil seal -arrow- in the propshaft
flange.
♦ Push the propshaft horizontally to the rear and towards the
right side of vehicle as far as possible.
Caution
1. Removing engine 27
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
All vehicles:
– Unplug electrical connector -1- for magnetic clutch on air con‐
ditioner compressor.
WARNING
Caution
Note
Note
1. Removing engine 29
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
Procedure
• Engine/gearbox assembly removed and attached to engine
support -T10359- .
– Attach lifting tackle -T40013- to gearbox and close lock.
– Attach workshop hoist -VAS 6100- with hooks -10 - 222 A /2-
to the lifting tackle.
Note
Note
Note
WARNING
Note
Procedure
• Gearbox detached from engine
⇒ „2 Separating 6-speed manual gearbox 02S from engine“,
page 31 or
⇒ „3 Separating dual-clutch gearbox 02E from engine“,
page 33 .
Note
WARNING
– Lift engine off engine and gearbox jack -VAS 6100- using
workshop hoist -V.A.G 1383 A- .
5 Installing engine
Tightening torques
Note
Procedure
Installation is carried out in the reverse order; note the following:
• Engine attached to engine support -T10359- .
Note
5. Installing engine 39
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
The bolts are tightened to final torque only after adjusting the as‐
sembly mountings ⇒ page 42 .
Caution
Caution
Note
5. Installing engine 41
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
6 Assembly mountings
♦ ⇒ „6.1 Assembly mountings - exploded view“, page 42
♦ ⇒ „6.2 Checking adjustment of assembly mountings (engine/
gearbox mountings)“, page 43
♦ ⇒ „6.3 Adjusting assembly mountings“, page 44
1 - Bolt
❑ Bracket to gearbox
❑ Tightening torque ⇒
Rep. gr. 34
2 - Bolts
❑ Pendulum support to
gearbox
❑ Different lengths
❑ Tightening torque ⇒
Rep. gr. 34
3 - Engine support
❑ With support arm
❑ Version fitted in vehicle
may differ from illustra‐
tion
4 - Bolt
❑ Engine support to en‐
gine
❑ Different lengths
❑ Renew
❑ 40 Nm + turn 180° fur‐
ther
5 - Engine mounting
❑ With support arm
6 - Bolt
❑ Engine mounting to
body
❑ Renew
❑ 40 Nm + turn 90° further
7 - Connecting bracket
8 - Bolt
❑ Connecting bracket to engine mounting
❑ Renew
❑ 20 Nm + turn 90° further
9 - Bolt
❑ Connecting bracket to body
❑ Renew
❑ 20 Nm + turn 90° further
10 - Bolt
❑ Engine mounting to body
❑ Renew
Note
6. Assembly mountings 43
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
Adjusting
• Tightening torques ⇒ page 42
– Remove engine cover panel -arrows-.
6. Assembly mountings 45
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
All vehicles:
♦ Rack -10 - 222 A /1- (2x)
♦ Spindle -10 - 222 A /11-
– Hook spindle into engine lifting eye and take up weight of en‐
gine.
WARNING
– Hook spindle -10 - 222 A /11- with lifting eye -2024 A /2- into
engine lifting eye.
Note
6. Assembly mountings 47
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
13 – Crankshaft group
1 Cylinder block (pulley end)
♦ ⇒ „1.1 Poly V-belt drive - exploded view“, page 49
♦ ⇒ „1.2 Removing and installing poly V-belt“, page 51
♦ ⇒ „1.3 Removing and installing tensioner for poly V-belt“, page
52
♦ ⇒ „1.4 Removing and installing bracket for ancillaries“,
page 55
♦ ⇒ „1.5 Removing and installing vibration damper“, page 56
1 - Vibration damper
❑ With poly V-belt pulley
❑ Removing and installing
⇒ page 56
2 - O-ring
❑ Renew
3 - Bolt
❑ Renew
❑ 150 Nm + turn 90° fur‐
ther
❑ Use counterhold tool -
T10355- when loosen‐
ing and tightening
4 - Poly V-belt
❑ Check for wear
❑ Do not kink
Caution
If a used belt runs in the
opposite direction when
it is refitted, this can
cause breakage.
Before
♦ removing, mark
direction of rotation of
poly V-belt with chalk or
felt-tip pen for re-installa‐
tion.
Removing
– Release activated charcoal filter -arrow B-, lift off -arrow A- and
move clear to one side.
Note
Caution
Note
– Fit the poly V-belt onto the crankshaft and air conditioner com‐
pressor and alternator pulleys.
Removing
– Remove noise insulation ⇒ Rep. gr. 66 .
– Remove bolt -2- at bracket for coolant pump for continued cir‐
culation -V51- .
Note
Caution
Installing
• Tightening torque
⇒ „1.1 Poly V-belt drive - exploded view“, page 49
Installation is carried out in the reverse order; note the following:
– Insert tensioner -1- for poly V-belt in bracket for ancillaries
-3- and tighten bolt -5-.
• Note installation position of support element -2-: fit lug of sup‐
port element in hole on bracket for ancillaries.
• Note position of centring sleeve -4-.
– Install poly V-belt ⇒ page 51 .
– Install continued coolant circulation pump -V51-
⇒ page 198 .
– Adjust assembly mountings ⇒ page 44 .
WARNING
Caution
Note
Removing
– Remove noise insulation ⇒ Rep. gr. 66 .
– Remove noise insulation (right-side) -arrows-.
– Remove noise insulation frame ⇒ Rep. gr. 50 .
Caution
Caution
Installing
• Tightening torque
⇒ „1.1 Poly V-belt drive - exploded view“, page 49
Installation is carried out in the reverse order; note the following:
Note
2.1 Sealing flange (gearbox end) and dual-mass flywheel - exploded view
1 - Cylinder block
❑ Removing and installing
crankshaft ⇒ page 64
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 70
2 - Dowel pin
3 - Sealing flange (gearbox
end)
❑ With oil seal
❑ Renew only as com‐
plete unit
❑ Removing and installing
⇒ page 61
❑ Do not lubricate/grease
sealing lip of oil seal
❑ Before installing, re‐
move oil residue from
crankshaft journal with a
clean cloth.
❑ Guide sleeve is not to be
removed until sealing
flange has been slipped
onto crankshaft journal
4 - Bolt
❑ Tightening sequence
⇒ page 60
5 - Intermediate plate
❑ Must be positioned on
dowel sleeves
❑ Do not damage/bend
when assembling
❑ Is fitted onto sealing
flange ⇒ page 60
6 - Bolt
❑ For dual-mass flywheel/drive plate
❑ 60 Nm + turn 90° further
❑ Renew
7 - Dual-mass flywheel
❑ Removing and installing dual-mass flywheel ⇒ page 60
❑ Can only be installed in one position. Holes are off-set
8 - Dowel pin
Removing
Caution
– Rotate the dual-mass flywheel -A- so that the bolts -B- align
centrally with the holes -arrows-.
– When unscrewing bolts -B-, ensure that none of the bolt heads
come into contact with the dual-mass flywheel -arrows-. The
flywheel will otherwise be damaged as the bolts are screwed
out further.
Note
WARNING
Note
Note
After installing the sealing flange, wait about 30 minutes for the
sealant to dry. Then (and only then) fill the engine with engine oil.
3 Crankshaft
⇒ „3.1 Crankshaft - exploded view“, page 64
⇒ „3.2 Removing and installing sender wheel“, page 65
⇒ „3.3 Allocation of crankshaft bearing shells (classification)“,
page 66
⇒ „3.4 Crankshaft dimensions“, page 67
⇒ „3.5 Measuring axial clearance of crankshaft“, page 67
⇒ „3.6 Measuring radial clearance of crankshaft“, page 68
Note
1 - Cylinder block
2 - Bearing shell for cylinder
block
❑ With oil groove
❑ Do not interchange
used bearing shells
(mark positions)
❑ Identification of crank‐
shaft bearing shells
⇒ page 66
3 - Crankshaft
❑ After removing, place it
down so that the sender
wheel -item 5- is not
damaged and the crank‐
shaft does not rest on
the sender wheel
❑ If crankshaft is renewed,
new bearing shells must
be assigned to bearing
caps ⇒ page 66
❑ Axial clearance
⇒ page 67
❑ Radial clearance
⇒ page 68
❑ Do not rotate the crank‐
shaft when checking the
radial clearance
❑ Crankshaft dimensions
⇒ page 67
4 - Bearing shell
❑ Without oil groove
❑ Do not interchange
used bearing shells
(mark positions)
❑ Classification of crankshaft bearing shells ⇒ page 66
5 - Bolt
❑ Renew
❑ Tightening sequence ⇒ page 65
6 - Bearing cap
❑ Bearing cap 1: Pulley end
❑ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side
7 - Bolt
❑ 10 Nm + turn 90 ° further
❑ Renew
❑ Sender wheel must be renewed if bolts are loosened ⇒ page 65
8 - Sender wheel
❑ For engine speed sender -G28-
❑ Can only be installed in one position. Holes are off-set
❑ Sender wheel must be renewed if bolts are loosened
❑ Removing and installing ⇒ page 65
9 - Thrust washers
❑ For bearing No. 3
10 - Bolt
❑ Renew
❑ Tightening sequence ⇒ page 65
3. Crankshaft 65
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
• Tightening torque
⇒ „3.1 Crankshaft - exploded view“, page 64
Note
3. Crankshaft 67
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Procedure
– Bolt dial gauge -VAS 6079- with universal dial gauge bracket
-VW 387- onto cylinder block and set it against crank web.
– Press crankshaft against dial gauge by hand and set gauge to
„0“.
– Push crankshaft away from dial gauge and read off value.
Axial clearance:
• New: 0.07 ... 0.23 mm.
• Wear limit: 0.30 mm.
Note
– Remove main bearing caps and clean bearing caps and jour‐
nals.
– Place a length of Plastigage corresponding to the width of the
bearing on the bearing journal or bearing shell.
• The Plastigage must be positioned in the centre of the bearing
shell.
3. Crankshaft 69
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
1 - Conrod bolt
❑ On vehicles with 1.8 ltr.
engine: 30 Nm + turn
90° further
❑ On vehicles with 2.0 ltr.
engine: 45 Nm + turn
90° further
❑ Renew
❑ Lubricate threads and
contact surface
❑ Use old bolts when
measuring radial clear‐
ance
❑ To measure radial clear‐
ance, tighten to 30 Nm
but do not turn further
2 - Conrod bearing cap
❑ Note installation posi‐
tion
❑ Due to the cracking
method used to sepa‐
rate the bearing caps
from the conrods in
manufacture, the caps
only fit in one position
and only on the appro‐
priate conrod
❑ Mark cylinder allocation
-A-
❑ Installation position:
Marking -B- faces to‐
wards pulley end
3 - Bearing shells
❑ Installation position
⇒ page 72
❑ Do not interchange used bearing shells (mark positions)
❑ Axial clearance when new: 0.10...0.35 mm; wear limit: 0.40 mm
❑ Check radial clearance with Plastigage - (new): 0.02 ... 0.06 mm; wear limit: 0.09 mm. Do not turn crank‐
shaft when measuring radial clearance
4 - Pressure relief valve
27 Nm
Checking piston
– Measure pistons approx 10 mm from the lower edge of skirt,
at 90° to the piston pin axis.
♦ Difference between actual and nominal diameter: not more
than 0.04 mm.
Caution
Note
Measuring the cylinder bores must not be done when the cylinder
block is mounted to the engine and gearbox stand -VAS 6095- ,
as incorrect measurements may result.
Note
1 - O-ring
❑ Renew
❑ Lubricate before instal‐
ling
2 - Guide tube for oil dipstick
3 - Bolt
❑ 9 Nm
4 - Bolt
❑ 9 Nm
5 - Camshaft control valve 1 -
N205-
❑ Removing and installing
⇒ page 76
6 - Seal
❑ Lubricate before instal‐
ling
❑ Renew if damaged
7 - Bolt
❑ Tightening sequence
⇒ page 76
8 - Timing chain cover (top)
❑ Removing and installing
⇒ page 76
9 - Gasket
❑ Renew if damaged
10 - O-ring
❑ Renew
❑ Lubricate before instal‐
ling
11 - Dowel pins
❑ For centring cover
12 - Timing chain cover (bottom)
❑ Removing and installing ⇒ page 78
13 - Bolt
❑ Renew
❑ Tightening sequence ⇒ page 76
14 - Oil seal
❑ For vibration damper
❑ Renewing ⇒ page 84
15 - Sealing plug
❑ Renew
1. Chain drive 75
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
Renew O-ring.
Note
Renew O-ring.
1. Chain drive 77
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
♦ Bits -T10099-
Removing
– Detach hose -1-.
– Release activated charcoal filter -arrow B-, lift off -arrow A- and
move clear to one side.
Note
1. Chain drive 79
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Caution
Note
Always use thrust piece -T10368- when fitting bolt for vibration
damper to avoid damaging splines.
– Fit bolt for vibration damper and thrust piece -T10368- again.
Caution
1. Chain drive 81
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
– Remove bolts -arrows- and detach guide tube for oil dipstick
from timing chain cover.
Note
Installing
• Tightening torques
⇒ „1.1 Timing chain cover - exploded view“, page 75 ,
⇒ „6.1 Assembly mountings - exploded view“, page 42 .
♦ Silicone sealant ⇒ Electronic parts catalogue
Note
WARNING
– Mask oil seal on both sides with adhesive tape to make sure
the seal remains clean.
Note
1. Chain drive 83
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
Note
After fitting cover, let sealant dry for approx. 30 minutes. Then
(and only then) fill the engine with engine oil.
1. Chain drive 85
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Removing
– Remove noise insulation ⇒ Rep. gr. 66 .
– Remove noise insulation (right-side) -arrows-.
– Remove noise insulation frame ⇒ Rep. gr. 50 .
Caution
Caution
– Use thrust piece -T10354- and bolt for vibration damper to pull
in oil seal -arrow- onto stop.
Note
1. Chain drive 87
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
1 - Bolt
❑ 9 Nm
2 - Chain tensioner
❑ Exerts spring pressure
❑ Before removing, lock in
place using locking pin -
T40011-
3 - Tensioning rail for timing
chain
4 - Guide pin
❑ 20 Nm
5 - Bolt
❑ 9 Nm
6 - Timing valve
❑ Left-hand thread
❑ 35 Nm
❑ Remove using assem‐
bly tool -T10352-
7 - Bolt
❑ Renew
❑ M6: 8 Nm + turn 90° fur‐
ther
❑ M8: 20 Nm + turn 90°
further
8 - Washer
9 - Bearing saddle
10 - Guide rail for camshaft tim‐
ing chain
11 - Camshaft housing
12 - Camshaft timing chain
❑ Before removing, mark running direction with paint
13 - Guide rail for camshaft timing chain
14 - Guide pin
❑ 20 Nm
15 - Chain sprocket
❑ Crankshaft
❑ Installation position ⇒ page 89
1. Chain drive 89
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Removing
– Remove timing chain cover (top) ⇒ page 76 .
Caution
Note
1. Chain drive 91
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
– Fit tensioning rail for timing chain and tighten bolt -2-.
– Fit guide rail for camshaft timing chain and tighten bolts -1-.
1. Chain drive 93
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
1 - Bolt
❑ Renew
❑ 9 Nm
2 - Balance shaft
❑ Exhaust side
❑ Renew after removing
❑ Lubricate bearing with
engine oil
❑ Renewing ⇒ page 101
3 - Tube for balance shaft
❑ Installation position
⇒ page 95
4 - Chain tensioner
❑ 65 Nm
5 - Cylinder block
6 - Balance shaft
❑ Inlet side
❑ Renew after removing
❑ Lubricate bearing with
engine oil
❑ Renewing ⇒ page 98
7 - O-ring
❑ Lubricate with engine oil
8 - Bearing mounting
❑ Lubricate with engine oil
❑ Installation position
⇒ page 95
9 - Idler gear
❑ For balance shaft
❑ If bolt ⇒ Item 12 (page 94) was slackened, idler gear must be renewed
10 - Bolt
❑ Renew
❑ 9 Nm
11 - Washer
12 - Bolt
❑ If bolt was slackened, idler gear ⇒ Item 9 (page 94) must be renewed
❑ Tightening sequence ⇒ page 95
13 - Guide rail
❑ For timing chain
14 - Guide pin
❑ 20 Nm
15 - Tensioning rail
❑ For timing chain
16 - Guide pin
❑ 20 Nm
17 - Timing chain
❑ Removing ⇒ page 96
18 - Chain sprocket
❑ Installation position ⇒ page 89
19 - Guide rail
❑ For balance shaft timing chain
20 - Guide pin
❑ 20 Nm
Caution
1. Chain drive 95
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
– Fit timing chain; the timing chain links with coloured markings
must be positioned at the markings on the chain sprockets.
– Fit guide rail for timing chain and tighten bolts -4-.
– Fit guide rail for timing chain and tighten bolts -3-.
– Fit tensioning rail for timing chain and tighten bolt -2-.
– Apply locking fluid and fit chain tensioner for timing chain -1-;
for locking fluid refer to ⇒ Electronic parts catalogue .
Note
1. Chain drive 97
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
♦ Puller -T10055-
Removing
Note
– Screw puller -T10055- into puller -T10394- and knock out bal‐
ance shaft in direction of -arrow-.
Installing
Note
• Tightening torques
⇒ „1.8 Balance shaft timing chain - exploded view“, page 94
– Put new balance shaft for 30 minutes into freezer compart‐
ment or spray with chilling agent (commercially available) if
necessary.
– Lubricate balance shaft bearing with engine oil.
1. Chain drive 99
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
– Install new balance shaft for inlet camshaft and tighten bolt
-2-.
Caution
Note
On account of the ratio the markings only align every 7th revolu‐
tion.
♦ Puller -T10055-
Removing
Note
– Screw puller -T10055- into puller -T10394- and knock out bal‐
ance shaft.
Installing
Note
• Tightening torques
⇒ „1.8 Balance shaft timing chain - exploded view“, page 94
Note
Note
Note
2 Cylinder head
⇒ „2.1 Cylinder head without AVS - exploded view“, page 105
⇒ „2.2 Removing and installing cylinder head without AVS“, page
108
⇒ „2.3 Cylinder head with AVS - exploded view“, page 123
⇒ „2.4 Removing and installing cylinder head with AVS“,
page 126
Note
17 - To intake manifold/turbocharger
18 - Breather pipe
19 - O-ring
❑ No replacement part available
20 - Seal
❑ No replacement part available
21 - Engine cover panel
22 - Bolt
❑ Tightening sequence ⇒ page 108
23 - Crankcase breather
❑ Note correct sequence when tightening ⇒ page 108
24 - To intake manifold
25 - Gasket
❑ No replacement part available
26 - Gasket
❑ Renew if damaged
27 - Exhauster pump
❑ Removing and installing ⇒ Rep. gr. 47
28 - Bolt
❑ Tightening torque ⇒ Rep. gr. 47
29 - Bracket
30 - Bolt
❑ 9 Nm
31 - Connection
32 - O-ring
❑ Renew
❑ Lubricate with coolant
33 - Engine lifting eye
34 - Bolt
❑ 25 Nm
35 - Bolt
❑ 9 Nm
36 - Hall sender -G40-
37 - O-ring
❑ Renew
❑ Lubricate with engine oil
38 - Separating plate
Note
♦ Puller -T40039-
Removing
Note
Note
Note
WARNING
Note
– Remove banjo bolt -2- and move coolant pipe clear to one
side.
– Remove bolts -1- on oil return line.
– Remove bolt -3- on oil supply line.
Note
Note
Note
WARNING
Caution
– Release activated charcoal filter -arrow B-, lift off -arrow A- and
move clear to one side.
Caution
Note
Caution
Note
Caution
Note
WARNING
Note
Note
Note
WARNING
Note
11 - Sealing plug
❑ 5 Nm
❑ With ball head for engine cover panel
12 - Filler cap
❑ With seal
13 - O-ring
❑ Renew
❑ Lubricate with engine oil
14 - Sealing plug
15 - Bracket
16 - Bolt
❑ 9 Nm
17 - Heat shield
18 - Bolt
❑ 20 Nm
19 - Bolt
❑ 20 Nm
20 - To intake manifold/turbocharger
21 - Breather pipe
22 - O-ring
❑ No replacement part available
23 - Seal
❑ No replacement part available
24 - Engine cover panel
25 - Bolt
❑ Tightening sequence ⇒ page 125
26 - Crankcase breather
27 - To intake manifold
28 - Gasket
❑ No replacement part available
29 - Gasket
❑ Renew if damaged
30 - Exhauster pump
❑ Removing and installing ⇒ Rep. gr. 47
31 - Bolt
❑ Tightening torque ⇒ Rep. gr. 47
32 - Bracket
33 - Bolt
❑ 9 Nm
34 - Connection
35 - O-ring
❑ Renew
❑ Lubricate with coolant
Note
Removing
Note
Caution
Note
WARNING
Note
– Remove banjo bolt -2- and move coolant pipe clear to one
side.
– Remove bolts -1- on oil return line.
– Remove bolt -3- on oil supply line.
Note
Note
Note
WARNING
Caution
– Release activated charcoal filter -arrow B-, lift off -arrow A- and
move clear to one side.
Note
Caution
Note
WARNING
Note
WARNING
3 Checking compression
Special tools and workshop equipment required
♦ Spark plug socket and extension -3122 B-
♦ Puller -T40039-
Test sequence
Note
Note
Note
4 Valve gear
⇒ „4.1 Valve gear without AVS - exploded view“, page 138
⇒ „4.2 Removing and installing camshafts without AVS“,
page 140
⇒ „4.3 Valve gear with AVS - exploded view“, page 149
⇒ „4.4 Removing and installing camshafts with AVS“, page 151
⇒ „4.5 Renewing valve stem oil seals with cylinder head installed“,
page 163
⇒ „4.6 Renewing valve stem oil seals with cylinder head re‐
moved“, page 167
⇒ „4.7 Checking valve guides“, page 170
Note
1 - Exhaust valve
❑ Do not machine, only
grinding-in is permitted
❑ Valve dimensions
⇒ page 139
❑ Checking valve guides
⇒ page 170
2 - Cylinder head
3 - Valve guide
❑ Checking ⇒ page 170
4 - Valve stem oil seal
❑ Renewing: with cylinder
head installed
⇒ page 163 , with cylin‐
der head removed
⇒ page 163
5 - Valve spring
6 - Valve spring plate
7 - Cotters
8 - Hydraulic compensation el‐
ement
❑ Do not interchange
❑ Lubricate contact sur‐
face
9 - Exhaust camshaft
❑ Removing and installing
⇒ page 140
❑ Check radial clearance
with Plastigage (roller
rocker fingers removed)
❑ Radial clearance:
0.024 ... 0.066 mm
❑ Runout: max. 0.04 mm
10 - Cylinder head cover
❑ With integrated camshaft bearings
❑ Clean sealing surface; machining not permitted
❑ Remove old sealant residues
11 - Bolt
❑ Renew
❑ Slackening ⇒ page 139
❑ Tightening sequence ⇒ page 139
12 - O-ring
❑ Renew
❑ Lubricate with engine oil
13 - Sealing plug
14 - Inlet camshaft
❑ Removing and installing ⇒ page 140
❑ Check radial clearance with Plastigage (roller rocker fingers removed)
Note
Valve dimensions
Note
Removing
Note
Note
Caution
Note
Caution
Caution
– Dirt and sealant residue must not be allowed to get into the
cylinder head.
Installing
• Tightening torques ⇒ page 138
Note
WARNING
Caution
Note
Note
WARNING
Note
1 - Exhaust valve
❑ Do not machine, only
grinding-in is permitted
❑ Valve dimensions
⇒ page 151
❑ Checking valve guides
⇒ page 170
2 - Cylinder head
3 - Valve guide
❑ Checking ⇒ page 170
4 - Valve stem oil seal
❑ Renewing: with cylinder
head installed
⇒ page 163 , with cylin‐
der head removed
⇒ page 167
5 - Valve spring
6 - Valve spring plate
7 - Valve cotters
8 - Hydraulic compensation el‐
ement
❑ Do not interchange
❑ Lubricate contact sur‐
face
9 - Exhaust camshaft
❑ Removing and installing
⇒ page 151
❑ Check radial clearance
with Plastigage (roller
rocker fingers removed)
❑ Radial clearance:
0.024 ... 0.066 mm
❑ Runout: max. 0.04 mm
10 - Cylinder head cover
❑ With integrated camshaft bearings
❑ Clean sealing surface; machining not permitted
❑ Remove old sealant residues
11 - Bolt
❑ Renew
❑ Slackening ⇒ page 150
❑ Tightening sequence ⇒ page 150
12 - O-ring
❑ Renew
❑ Lubricate with engine oil
13 - Actuator for variable valve timing
14 - Bolt
❑ 5 Nm
15 - O-ring
❑ Renew
❑ Lubricate with engine oil
16 - Sealing plug
17 - Inlet camshaft
❑ Removing and installing ⇒ page 151
❑ Check radial clearance with Plastigage (roller rocker fingers removed)
❑ Radial clearance: 0.024 ... 0.066 mm
❑ Runout: max. 0.04 mm
18 - Sealing cap
❑ Renew
❑ Removing sealing cap with cylinder head cover installed: pierce on one side with an awl and pry out
❑ Installing ⇒ page 161
19 - Inlet valve
❑ Do not machine, only grinding-in is permitted
❑ Valve dimensions ⇒ page 151
❑ Checking valve guides ⇒ page 170
Note
Valve dimensions
Note
♦ Spacers -T40191-
Removing
Note
Note
Caution
Caution
Note
Note
Note
Caution
Caution
– Dirt and sealant residue must not be allowed to get into the
cylinder head.
Installing
• Tightening torques
⇒ „4.1 Valve gear without AVS - exploded view“, page 138
Note
WARNING
Caution
WARNING
Note
Note
Note
WARNING
Note
4.5 Renewing valve stem oil seals with cylinder head installed
– Pull off valve stem oil seal with valve stem seal puller -3364- .
Caution
Make sure valve stem oil seals are not damaged when instal‐
ling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.
Note
4.6 Renewing valve stem oil seals with cylinder head removed
Procedure
– Remove camshafts ⇒ page 140 .
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Attach tensioning device -VAS 6419- to engine and gearbox
support -VAS 6095- .
– Secure cylinder head in tensioning device -VAS 6419- as il‐
lustrated.
– Connect compressed air line to tensioning device -VAS 6419- .
– Using lever -arrow-, slide air pad under combustion chamber
where valve stem oil seals are to be removed.
– Apply just enough compressed air to bring air pad into contact
with valve heads.
– Fit guide plate for 2.0 ltr. and 3.0 ltr. FSI engine -VAS
5161/19B- onto cylinder head.
– Secure guide plate with knurled screws -VAS 5161/12- .
Exhaust side:
– Engage pressure fork -VAS 5161/2- at snap-in device, as
shown in illustration.
Continuation for both sides:
– Press down with pressure fork for assembly cartridge.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Turn knurled screw in both directions.
• The valve cotters are forced apart and are taken up by the
cartridge.
– Release pressure fork.
– Take out assembly cartridge.
– Detach guide plate and turn to one side.
– Detach valve spring with valve spring plate.
– Pull off valve stem oil seal with valve stem seal puller -3364- .
Caution
Make sure valve stem oil seals are not damaged when instal‐
ling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.
Test sequence
– Insert valve into guide. Valve stem end must be flush with
guide. Only insert inlet valve into inlet guide and exhaust valve
into exhaust guide, as the stem diameters are different.
Note
17 – Lubrication
1 Sump and oil pump
⇒ „1.1 Sump, oil pump - exploded view“, page 172
⇒ „1.2 Removing and installing coarse oil separator“, page 174
⇒ „1.3 Removing and installing sump (bottom section)“,
page 174
⇒ „1.4 Removing and installing oil pump“, page 177
⇒ „1.5 Removing and installing sump (top section)“, page 178
⇒ „1.6 Removing and installing valve for oil pressure control N428
“, page 181
Note
Caution
21 - Bolt
❑ Renew
❑ Tightening sequence ⇒ page 173
22 - Suction pipe
❑ Clean strainer if dirty
23 - O-ring
❑ Renew
24 - Seal
25 - O-ring
❑ Renew
26 - Non-return valve
27 - Oil drain plug
❑ Renew
❑ 30 Nm
28 - Nut
❑ 9 Nm
Note
Caution
Installing
Note
Caution
Note
WARNING
– Apply the bead of silicone sealant onto the clean sealing sur‐
face of the sump (bottom section), as illustrated.
Caution
Note
Note
After fitting sump assembly, the sealant must dry for approx. 30
minutes. Then (and only then) fill the engine with engine oil.
– Fill with engine oil and check oil level ⇒ Maintenance ; Booklet
810 .
Further assembly is basically carried out in reverse order of dis‐
mantling.
Removing
– Remove noise insulation ⇒ Rep. gr. 66 .
– Remove noise insulation frame ⇒ Rep. gr. 50 .
– Unplug electrical connector -1- for oil level and oil temperature
sender -G266- .
– Drain off engine oil.
DANGER!
Injury risk! The chain tensioner spring for oil pump drive jumps
from sump (top section) to timing chain cover (bottom) when
detaching sump (top section). Do not reach between sump (top
section) and timing chain cover (bottom) when removing sump
(top section).
Caution
Lever off sump (top section) at gearbox end first. Take care
timing chain cover is not bent when levering off.
Installing
• Tightening torques
⇒ „1.1 Sump, oil pump - exploded view“, page 172
♦ Silicone sealant: ⇒ Electronic parts catalogue
Note
WARNING
Caution
Note
– Pull brake pad wear tester -VW 136- out of guide rail -arrow-.
The spring now returns to installation position.
– Install sealing flange (gearbox end) ⇒ page 61 .
– Install oil pump ⇒ page 177 .
– Renew baffle plate.
– Install timing chain cover (bottom) ⇒ page 78 .
Further assembly is basically carried out in reverse order of dis‐
mantling.
Removing
– Remove noise insulation ⇒ Rep. gr. 66 .
– Position used oil collection and extraction unit -V.A.G 1782-
below engine.
– Unplug electrical connector -1-.
– Remove bolt -2- and detach valve for oil pressure control -
N428- -item 3-.
Installing
• Tightening torque
⇒ „1.1 Sump, oil pump - exploded view“, page 172
Installation is carried out in the reverse order; note the following:
Note
9 - Bolt
❑ 23 Nm
10 - Connection
11 - Seal
❑ Renew
12 - Engine oil cooler
❑ See note ⇒ page 171
❑ Ensure clearance from surrounding components
❑ Diagram of coolant hose connections ⇒ page 189
❑ Removing and installing ⇒ page 184
13 - Seal
❑ Renew
14 - Bolt
❑ Tightening sequence ⇒ page 50
Removing
WARNING
– Unscrew bolts -4 and 5- and remove engine oil cooler -3- to‐
gether with seal -2-.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques
⇒ „2.1 Oil filter, engine oil cooler - exploded view“, page 183
Note
Note
Note
♦ Renew seal.
♦ Fit the new oil pressure switch -F22- into the connection im‐
mediately to avoid loss of oil.
Note
Note
♦ Renew seal.
♦ Fit the new oil pressure switch for reduced oil pressure -F378-
into the connection immediately to avoid loss of oil.
Test requirements
• Oil level OK; checking ⇒ Maintenance ; Booklet 810
• Engine oil temperature at least 80°C (radiator fan must have
run once).
Test sequence
Note
Note
During the running-in period, the oil pressure at 2000 rpm can be
between 3.0 and 4.0 bar.
Assembling
• Tightening torques
⇒ „2.1 Oil filter, engine oil cooler - exploded view“, page 183
– Install oil pressure switch.
19 – Cooling
1 Parts of cooling system (on engine)
⇒ „1.1 Diagram of coolant hose connections“, page 189
⇒ „1.2 Draining and filling cooling system“, page 191
⇒ „1.3 Checking cooling system for leaks“, page 196
⇒ „1.4 Continued coolant circulation pump V51 - exploded view“,
page 198
⇒ „1.5 Removing and installing continued coolant circulation
pump V51 “, page 198
⇒ „1.6 Coolant pipes - exploded view“, page 200
⇒ „1.7 Removing and installing coolant pipes (front)“, page 200
⇒ „1.8 Removing and installing small coolant pipe“, page 203
⇒ „1.9 Coolant pump and thermostat - exploded view“,
page 206
⇒ „1.10 Removing and installing coolant temperature sender G62
“, page 207
⇒ „1.11 Removing and installing toothed belt for coolant pump“,
page 208
⇒ „1.12 Renewing oil seal for coolant pump drive“, page 210
⇒ „1.13 Removing and installing coolant pump“, page 211
⇒ „1.14 Removing and installing thermostat“, page 213
WARNING
Note
1 - Radiator
❑ If renewed, refill system
with fresh coolant
2 - Continued coolant circula‐
tion pump -V51-
3 - Coolant pump
4 - Thermostat
5 - Engine oil cooler
6 - Cylinder head and cylinder
block
7 - Turbocharger
8 - Coolant expansion tank
❑ With filler cap
❑ Checking pressure re‐
lief valve in filler cap
⇒ page 196
9 - Heat exchanger for heater
10 - Coolant hose/pipe con‐
nection
1 - Radiator
2 - Continued coolant circula‐
tion pump -V51-
3 - Coolant pump
4 - Thermostat
5 - Engine oil cooler
6 - Cylinder head and cylinder
block
7 - Turbocharger
8 - Coolant expansion tank
❑ With filler cap
❑ Checking pressure re‐
lief valve in filler cap
⇒ page 196
9 - Heat exchanger for heater
10 - Gear oil cooler
11 - Coolant hose/pipe con‐
nection
12 - Thermostat for gear oil
cooler
Draining
WARNING
Note
– Place drip tray for workshop hoist -VAS 6208- beneath engine.
– Disconnect coolant hose -1- from radiator (bottom) and drain
off coolant.
Note
Note
Note
– Close both valves -A- and -B- (turn lever at right angles to di‐
rection of flow).
– Connect hose -3- to compressed air.
• Pressure: 6 ... 10 bar.
Note
♦ If the needle does not reach the green zone, repeat the proc‐
ess.
♦ Check cooling system for leaks if the vacuum is not main‐
tained.
WARNING
Note
♦ Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ To ensure that the charge air hoses can be properly secured
at their connections, spray rust remover onto the worm thread
of used hose clips before installing.
Procedure
• Engine must be warm.
WARNING
1 - Bracket
2 - Bolt
❑ 5 Nm
3 - Coolant hose
4 - Coolant hose
5 - Continued coolant circula‐
tion pump -V51-
6 - Bracket
Removing
WARNING
Removing
WARNING
Note
Note
– Place drip tray for workshop hoist -VAS 6208- beneath engine.
– Disconnect coolant hoses from continued coolant circulation
pump -V51- -arrows-.
Note
Note
Removing
– Drain coolant ⇒ page 191 .
– Unscrew bolts -arrows- and remove air duct.
– Detach air duct at bottom together with air hose.
Note
Note
Note
♦ Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ To ensure that the charge air hoses can be properly secured
at their connections, spray rust remover onto the worm thread
of used hose clips before installing.
1 - O-rings
❑ Renew
2 - Connection
3 - Retaining clip
❑ Check that it is securely
seated
4 - Coolant temperature send‐
er -G62-
❑ Removing and installing
⇒ page 207
5 - O-ring
❑ Renew
6 - Bolt
❑ Tightening sequence
⇒ page 207
7 - Coolant pump
❑ Removing and installing
⇒ page 211
❑ New coolant pump: re‐
move protective cap
8 - Seal
❑ Renew
9 - Centring pin
❑ 2x
10 - Toothed belt
❑ For coolant pump
❑ Removing and installing
⇒ page 208
11 - Toothed belt cover
12 - Bolt
❑ 9 Nm
13 - Bolt
❑ Left-hand thread
❑ Renew
❑ 10 Nm + turn 90° further
14 - Toothed belt drive sprocket
❑ Note installation position
15 - Oil seal
❑ Renewing ⇒ page 210
16 - Balance shaft
17 - Thermostat
❑ Removing and installing ⇒ page 213
18 - Centring pin
19 - Connection
20 - Bolt
❑ 9 Nm
21 - O-ring
❑ Renew
Note
– Remove support for intake manifold (remove nut -2- and bolt
-1-).
Note
Note
Removing
– Remove small coolant pipe ⇒ page 203 .
– Move coolant hose -2- and wiring harness -1- clear.
– Remove bolt -arrow- and remove bracket.
– Remove bolt -2- at bracket for coolant pump for continued cir‐
culation -V51- .
Note
Caution
Note
– Apply thrust piece -T10353- to oil seal -1- and press into cyl‐
inder block as far as stop using bolt -2- (take care not to tilt oil
seal).
– Install toothed belt for coolant pump ⇒ page 208 .
– Install continued coolant circulation pump -V51- ⇒ page 198 .
– Install small coolant pipe ⇒ page 203 .
– Fill up with coolant ⇒ page 193 .
Note
Note
Disregard -arrow-.
Installing
• Tightening torque
⇒ Fig. “„Coolant pump - tightening sequence““ , page 207
Installation is carried out in the reverse order; note the following:
Note
Note
Note
Note
– Remove bolt -2- at bracket for coolant pump for continued cir‐
culation -V51- .
Note
– Loosen nut -2-, remove bolt -1- and swivel support for intake
manifold slightly to right.
Note
WARNING
WARNING
Note
Removing
Note
Note
Note
Note
Note
♦ Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ To ensure that the charge air hoses can be properly secured
at their connections, spray rust remover onto the worm thread
of used hose clips before installing.
21 – Turbocharging/supercharging
1 Turbocharger
⇒ „1.1 Turbocharger - exploded view“, page 223
⇒ „1.2 Removing and installing air pipes and hoses with plug-in
connectors“, page 227
⇒ „1.3 Removing and installing turbocharger“, page 227
⇒ „1.4 Checking vacuum unit for turbocharger“, page 232
⇒ „1.5 Removing and installing vacuum unit for turbocharger“,
page 234
⇒ „1.6 Adjusting vacuum unit for turbocharger“, page 234
Note
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment).
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. However (applies only
to plug-in connectors); the seal and the sealing surface of plug-
in connectors should be lubricated lightly with oil
⇒ page 227 .
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Hose clip pliers -VAS 6362- or hose clip pliers -V.A.G 1921-
are recommended for use when installing spring-type clips.
♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ After installing turbocharger, allow engine to idle for approx. 1
minute and do not rev up immediately to ensure turbocharger
is supplied with oil.
♦ Observe rules for cleanliness ⇒ page 6 .
1 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold and vacuum
unit as one unit
❑ Removing and installing
⇒ page 227
2 - To activated charcoal filter
3 - Vacuum unit for turbocharg‐
er
❑ Checking ⇒ page 232
❑ Removing and installing
⇒ page 234
❑ Adjusting ⇒ page 234
4 - Hose
5 - Hose
6 - Bolt
❑ 3 Nm
7 - Charge pressure control
solenoid valve -N75-
8 - Hose
9 - Connection
10 - Securing clip
11 - Bolt
❑ 9 Nm
12 - Seal
❑ Renew
13 - Turbocharger air recircu‐
lation valve -N249-
❑ Note installation position ⇒ page 224
14 - Bolt
❑ 7 Nm
15 - Seal
❑ Renew
1. Turbocharger 223
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Part II
1 - Seal
❑ Renew
2 - Bolt
❑ 30 Nm
3 - Oil supply line
4 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold and vacuum
unit as one unit
❑ Removing and installing
⇒ page 227
5 - Bolt
❑ 9 Nm
6 - Bolt
❑ 9 Nm
7 - Seal
❑ Renew
8 - Bolt
❑ 35 Nm
9 - Bolt
❑ 9 Nm
10 - Bolt
❑ 35 Nm
11 - Seal
❑ Renew
12 - Coolant supply line
13 - O-ring
❑ Renew
14 - Bolt
❑ 9 Nm
15 - Gasket
❑ Renew
Part III
1 - Gasket
❑ Renew
2 - Nut
❑ Renew
❑ Tightening sequence
⇒ page 226
❑ Lubricate exhaust mani‐
fold studs with high-tem‐
perature paste. For
high-temperature paste
refer to ⇒ Electronic
parts catalogue
3 - Bolt
❑ 35 Nm
4 - Seal
❑ Renew
5 - Coolant return hose/pipe
6 - Bolt
❑ 9 Nm
7 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold and vacuum
unit as one unit
❑ Removing and installing
⇒ page 227
8 - Bracket
9 - Bolt
❑ 30 Nm
❑ Coat with high-tempera‐
ture paste; for high-tem‐
perature paste refer to ⇒ Electronic parts catalogue
10 - Bolt
❑ 30 Nm
❑ Coat with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts catalogue
11 - Nut
❑ Do not open when removing turbocharger
❑ Renew
❑ 30 Nm
❑ Lubricate exhaust manifold studs with high-temperature paste. For high-temperature paste refer to ⇒
Electronic parts catalogue
1. Turbocharger 225
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
12 - Fastening strip
Part IV
1 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold and vacuum
unit as one unit
❑ Removing and installing
⇒ page 227
2 - Vacuum unit for turbocharg‐
er
❑ Checking ⇒ page 232
❑ Removing and installing
⇒ page 234
❑ Adjusting ⇒ page 234
3 - Bolt
❑ 10 Nm
4 - Nut
❑ 9 Nm
❑ Secure with sealant
paint; for sealing paint
refer to ⇒ Electronic
parts catalogue
5 - Locking plate
6 - Knurled nut
Component Nm
Air pipe to bracket 10
Installing
Note
1. Turbocharger 227
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Caution
Removing
– Remove noise insulation ⇒ Rep. gr. 66 .
– Remove noise insulation (right-side) -arrows-.
– Remove noise insulation frame ⇒ Rep. gr. 50 .
– Drain coolant ⇒ page 191 .
– Remove front exhaust pipe with catalytic converter
⇒ page 249 .
Note
– Remove banjo bolt -2- and move coolant pipe clear to one
side.
– Remove bolts -1- on oil return line.
– Remove bolt -3- on oil supply line.
1. Turbocharger 229
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
Note
Note
1. Turbocharger 231
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
Installing
• Tightening torques
⇒ „1.1 Turbocharger - exploded view“, page 223
Installation is carried out in the reverse order; note the following:
Note
Test condition:
♦ Hose from turbocharger via charge pressure control solenoid
valve -N75- to vacuum unit must not be blocked.
♦ Charge pressure control solenoid valve -N75- OK.
Procedure:
– Remove engine cover panel -arrows-.
Caution
The pressure must not exceed 750 mbar. The vacuum unit
could be damaged if the pressure is exceeded.
Note
1. Turbocharger 233
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Adjusting
• Tightening torques ⇒ page 226
1. Turbocharger 235
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
1. Turbocharger 237
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
The dial gauge values (mm) listed here include the 1 mm preload
that is initially set on the gauge.
Note
1. Turbocharger 239
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr. 4-valve turbo), mechanics - Edition 11.2010
Note
♦ Hose connections and air pipes and hoses must be free of oil and grease before assembly.
♦ Secure all hose connections with the correct type of hose clips (same as original equipment) ⇒ Electronic
parts catalogue .
♦ To ensure that the charge air hoses can be properly secured at their connections, spray rust remover onto
the worm thread of used hose clips before installing.
♦ If there are slight impressions on the fins, refer to ⇒ page 8 .
1 - Bolt
❑ 5 Nm
2 - Mounting
❑ For charge air cooler
3 - Charge air cooler
4 - Charge air pipe
❑ Fitting hose connec‐
tions with plug-in con‐
nectors ⇒ page 227
5 - Bolt
❑ 10 Nm
6 - Charge air hose
❑ Fitting hose connec‐
tions with plug-in con‐
nectors ⇒ page 227
7 - Hose clip
8 - Charge air hose
❑ To throttle valve module
-J338-
9 - Hose clip
10 - Bolt
❑ 10 Nm
11 - Charge air pipe
12 - Hose clip
13 - Charge air hose
❑ Fitting hose connec‐
tions with plug-in con‐
nectors ⇒ page 227
14 - Seal
❑ Renew
15 - Charge pressure sender -G31-
❑ Removing and installing ⇒ page 242
16 - Bolt
❑ 5 Nm
17 - Bolts
❑ 10 Nm
– Fit adapter -V.A.G 1687/5- onto charge air hose -A- and turn
by approx. 90° -B-.
Prepare charge air system tester -V.A.G 1687- as follows:
Note
Make sure knob is pulled out before turning pressure control valve
-2-.
Note
If sight glass contains water, loosen drain plug and drain water
-6-.
Caution
The pressure must not exceed 0.5 bar. If the pressure is set
too high this can damage the engine.
Note
Removing
– Remove radiator ⇒ page 217 .
– Remove bumper cover (front) ⇒ Rep. gr. 63 .
WARNING
Caution
– Release hose clip -arrow- and detach air hose from charge air
cooler.
– Release hose clips -1- and -2- and remove air hose.
Note
• Tightening torques
⇒ „2.2 Charge air cooler - exploded view“, page 241
Note
26 – Exhaust system
1 Components of exhaust system
⇒ „1.1 Silencers - exploded view“, page 248
⇒ „1.2 Removing and installing front exhaust pipe with catalytic
converter and front silencer“, page 249
⇒ „1.3 Aligning exhaust system“, page 253
⇒ „1.4 Checking exhaust system for leaks“, page 254
Note
1 - Bolt
❑ 23 Nm
2 - Bracket for exhaust system
3 - Clamp
❑ Align exhaust system so
it is free of stress before
tightening clamp
⇒ page 253
❑ Installation position
⇒ page 249
❑ Tighten bolt connec‐
tions evenly.
4 - Nut
❑ 23 Nm
5 - Bracket for exhaust system
6 - Rubber mounting
❑ Renew if damaged
7 - Bolt
❑ 23 Nm
8 - Mounting
❑ Renew if damaged
9 - Bolt
❑ 23 Nm
10 - Cross piece
11 - Gasket
❑ Renew
12 - Nut
❑ 40 Nm
❑ Renew
❑ Coat studs of turbocharger with high-temperature paste
❑ High-temperature paste ⇒ Parts catalogue
13 - Lambda probe -G39- and Lambda probe heater -Z19-
❑ 55 Nm
❑ Grease only the threads with high-temperature paste. The paste must not penetrate into the slots on the
Lambda probe body
❑ High-temperature paste ⇒ Parts catalogue
❑ Removing and installing ⇒ Rep. gr. 24
14 - Front exhaust pipe with catalytic converter and front silencer
❑ Do not bend flexible joint more than 10° - otherwise it can be damaged
❑ Install flexible joint so that it is not under tension.
❑ Take care not to damage wire mesh on flexible joint.
❑ Protect catalytic converter from damage by knocks and impact
❑ Removing and installing ⇒ page 249
❑ Do not remove protective packaging from replacement part until you are ready to fit the flexible joint
❑ Align exhaust system so it is free of stress ⇒ page 253
15 - Lambda probe after catalytic converter -G130- and Lambda probe heater 1 after catalytic converter -Z29-
❑ 55 Nm
❑ Grease only the threads with high-temperature paste. The paste must not penetrate into the slots on the
Lambda probe body
❑ High-temperature paste ⇒ Parts catalogue
❑ Removing and installing ⇒ Rep. gr. 24
16 - Rear silencer
❑ Align exhaust system so it is free of stress ⇒ page 253
17 - Rubber mounting
❑ Renew if damaged
18 - Nut
❑ 23 Nm
Note
Four-wheel drive:
– Mark position of flexible coupling and flange for bevel box in
relation to each other for re-installation.
– Remove bolts -arrows- for flexible coupling for propshaft at
bevel box (counterhold using a suitable lever at the triangular
flange).
Caution
Make sure not to damage the oil seal -arrow- in the propshaft
flange.
♦ Push the propshaft horizontally to the rear and towards the
right side of vehicle as far as possible.
Caution
Note
Aligning tailpipe:
– Align tailpipes so that distance -a- (left-side) is the same as
distance -a- (right-side).
– At the same time, distance -b- must be obtained between
bumper cut-out and top of tailpipes.
♦ Dimension b = at least 21 mm
– If necessary, unfasten rear silencer mounting to align tailpipes.
2 Exhaust manifold
The exhaust manifold and the turbocharger are combined as one
unit; removing and installing ⇒ page 222 .