Audi TT 12 User Manual
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
Workshop Manual
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine
(165-176 kW), mechanics
Engine ID
Edition 12.2005
AMU APX BAM BEA BFV
Service Department. Technical Information
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
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.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A0057006320
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Checking adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1 Servicing work on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.1 Poly V-belt drive - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.4 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.5 Toothed belt - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.6 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.7 Removing toothed belt from camshaft sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.8 Positioning crankshaft at “TDC” with engine installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.9 Positioning crankshaft at “TDC” with engine removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2 Removing and installing sealing flanges and dual-mass flywheel . . . . . . . . . . . . . . . . . . . . 57
2.1 Sealing flanges and dual-mass flywheel - exploded view of components . . . . . . . . . . . . . . 57
2.2 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.3 Removing and installing sealing flange (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.1 Crankshaft - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.3 Removing and installing drive chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.1 Pistons and conrods - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.3 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.1 Cylinder head - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.4 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.1 Valve gear - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.2 Checking axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.3 Renewing exhaust camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.4 Renewing inlet camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Contents i
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
2.5 Removing and installing camshafts and hydraulic chain tensioner/camshaft adjuster . . . . 101
2.6 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.7 Renewing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.8 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.9 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.10 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.11 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3 Checking variable valve timing - vehicles with engine code BAM, BEA, BFV . . . . . . . . . . 116
3.1 Checking function of variable valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.2 Checking inlet camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.1 Lubrication system - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.4 Oil filter and oil cooler - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.5 Checking oil pressure and oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.6 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.7 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.1 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.2 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.4 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.5 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.6 Removing and installing coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.7 Checking continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.8 Radiator and radiator fan - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.9 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.10 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1 Servicing charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.2 Test requirements for checking turbocharging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.3 Diagram of connections for charge pressure control system and vacuum system . . . . . . 157
1.4 Effects of leaks in charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.5 Checking turbocharger and charge pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.6 Checking mechanical air recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.7 Checking air recirculation valve for turbocharger N249 . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.8 Checking solenoid valve for charge pressure control N75 . . . . . . . . . . . . . . . . . . . . . . . . 171
1.9 Checking charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2 Servicing charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.2 Turbocharger - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.3 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.4 Charge air cooler - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.5 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
1.1 Exhaust system - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
1.2 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
ii Contents
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
1.3 Removing and installing catalytic converter with front exhaust pipe . . . . . . . . . . . . . . . . . . 196
1.4 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.5 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2 Exhaust gas temperature monitoring - vehicles with engine code BAM, BEA, BFV . . . . . . 204
2.1 Checking exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3 Secondary air system - vehicles with engine code AMU, APX, BEA . . . . . . . . . . . . . . . . . . 208
3.1 Principle and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3.2 Checking secondary air inlet valve N112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3.3 Checking secondary air pump relay J299 and secondary air pump motor V101 . . . . . . . . 216
3.4 Checking combination valve for secondary air system for proper operation and leakage . . 221
3.5 Removing and installing combination valve for secondary air system . . . . . . . . . . . . . . . . 222
3.6 Removing and installing secondary air pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Contents iii
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
iv Contents
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
00 – Technical data
1 Technical data
1.1 Engine number
♦ The engine number (“Engine code” and “Serial number”) can
be found at the front of the joint between engine and gearbox.
♦ There is also a sticker on the cylinder head cover showing the
“engine code” and “serial number”.
♦ The engine code is also included on the vehicle data sticker.
Note
The engine code is additionally marked at the engine lifting eye
(right-side).
Audi TT 1999 ➤
1.2 Engine data
Code letters AMU APX BAM
Capacity ltr. 1.781 1.781 1.781
Power output kW at rpm 165/5900 165/5900 165/5900
Torque Nm at rpm 280/2200 … 5500 280/2200 … 5500 280/2200 … 5500
Bore ∅ in mm 81.0 81.0 81.0
Stroke mm 86.4 86.4 86.4
Compression
ratio
RON at least
Injection/ignition system Motronic Motronic Motronic
Firing order 1-4-3-2 1-4-3-2 1-4-3-2
Emissions standard TLEV EU2+D3 EU3
Exhaust gas temperature control no no yes
Turbocharging/supercharging yes yes yes
Catalytic converter yes yes yes
Knock control yes yes yes
Charge air cooling yes yes yes
Lambda control 2 probes 1 probe 2 probes
Variable valve timing no no yes
Secondary air system yes yes no
1)
•
In exceptional circumstances, fuel with not less than 95 RON can also be used, but this will cause a
loss of power.
9.0 9.0 9.0
98
1)
98
1)
98
1)
Code letters BEA BFV
Capacity ltr. 1.781 1.781
Power output kW at rpm 165/5900 176/5700
Torque Nm at rpm 280/2200 … 5500 320/2300 … 5000
Bore ∅ in mm 81 81
Stroke mm 86.4 86.4
1. Technical data 1
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
Code letters BEA BFV
Compression
9.0 9.0
ratio
RON at least
98
1)
98
1)
Injection/ignition system Motronic Motronic
Firing order 1-4-3-2 1-4-3-2
Emissions standard LEV EU3
Exhaust gas temperature control yes yes
Turbocharging/supercharging yes yes
Catalytic converter yes yes
Knock control yes yes
Charge air cooling yes yes
Lambda control 2 probes 2 probes
Variable valve timing yes yes
Secondary air system yes no
1)
•
In exceptional circumstances, fuel with not less than 95 RON can also be used, but this will cause a
loss of power.
2 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
10 – Removing and installing engine
1 Removing and installing engine
1.1 Removing engine
♦ Hose clamps for hoses up
to 25 mm Ø -3094-
♦ Drip tray for workshop hoist
-VAS 6208- or V.A.G 1306-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Hose clip pliers -V.A.G
1921-
♦ Stepladder -VAS 5085-
♦ Engine bracket -T10012-
Audi TT 1999 ➤
♦ Locking pin -T10060 A-
1. Removing and installing engine 3
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Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
♦ Used oil collection and extraction unit -V.A.G 1782-
Procedure
Note
♦
The engine is removed from underneath together with the
gearbox.
♦
The following description corresponds to the removal and in‐
stallation on vehicles with secondary air system. Certain work
steps may not apply to vehicles without secondary air system.
♦
All heat insulation sleeves which are removed must be fitted
in the same position when installing.
♦
All cable ties which are released or cut open when removing
must be fitted in the same position when installing.
♦
Collect drained coolant in a clean container for re-use or dis‐
posal.
– Remove engine cover -arrows- and cover in front of intake
manifold.
– Remove covers -1- and -2- at lock carrier (left-side) and above
battery -arrows-.
4 Rep. Gr.10 - Removing and installing engine
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
– Remove covers -1- and -2- at lock carrier (right-side) and
above coolant expansion tank -arrows-.
Caution
Observe notes on procedure for disconnecting the battery ⇒
Rep. Gr. 27 .
– With ignition switched off, disconnect battery earth cable
-arrow-.
WARNING
Hot steam or hot coolant can escape when expansion tank is
opened; cover filler cap with cloth and open carefully.
Audi TT 1999 ➤
– Open filler cap on coolant expansion tank.
– Remove both front wheels.
– Unbolt bracket for headlight range control sender in wheel
housing (left-side, top) -arrows-.
– Remove centre noise insulation -1 ... 3-.
1. Removing and installing engine 5
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
– Remove left noise insulation -arrows-.
– Remove right noise insulation -arrows-.
– If fitted, detach power steering line from connecting pipe for
charge air coolers -arrows-.
– Unbolt connecting pipe for charge air coolers on left side
-arrows-.
6 Rep. Gr.10 - Removing and installing engine
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
– Unbolt connecting pipe for charge air coolers on right side and
detach air intake hoses from charge air coolers -arrows-.
– Remove connecting pipe for charge air coolers.
– Place drip tray for workshop hoist -VAS 6208- under engine.
– Turn drain plug -1- on radiator anti-clockwise and drain coolant
(attach hose to connection if necessary).
– Disconnect coolant hose from radiator by pulling off retaining
clip -2- at bottom.
Audi TT 1999 ➤
– Disconnect bottom coolant hose from oil cooler -arrow-, and
drain off remaining coolant.
– Remove cross piece -1- for suspension strut -arrows-, if fitted.
1. Removing and installing engine 7
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
– Disconnect vacuum line and coolant pipe at locations marked
with -arrows-.
– If fitted, detach air intake hose -1- leading to secondary air
pump at air cleaner housing.
– Release hose clip -2- and detach air intake hose from air mass
meter -G70- .
– Unplug electrical connector at air mass meter -G70-
-item 3-.
– Unscrew bolts -4- and -5- and remove air cleaner housing.
Detach air duct between air cleaner and turbocharger as follows:
– Remove pressure control valve of crankcase breather -1- and
mechanical air recirculation valve -2- from air duct.
– Detach hose going to activated charcoal filter at non-return
valve -3-.
– Disconnect electrical connector -4- at charge pressure control
solenoid valve -N75- .
– Detach hoses -5- and -6- from charge pressure control sole‐
noid valve -N75- .
– Detach air duct -7- from connection on turbocharger and pull
out hose -5-, guiding as required.
– Detach coolant hoses going to to heat exchanger at bulkhead
-arrows- by releasing retaining clips.
8 Rep. Gr.10 - Removing and installing engine
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
– Open cover of main fuse box.
– Unclip protective cover -2- for electrical cables.
– Unscrew black wire -1- at fuse block.
– Remove battery.
– Lift off side wall -1- together with main fuse box.
– Remove battery tray -arrows-.
Audi TT 1999 ➤
– Unscrew earth wire -1- at engine/gearbox connection.
– Detach electrical wiring -3- and -4- at starter.
– Detach electrical connector -2- from bracket and unplug.
– Disengage wiring from bracket on starter and move it clear to
the side.
– Use screwdriver to pry off caps on wiper arms -arrows- and
slacken off nuts several turns.
– Loosen wiper arms -1- from wiper shafts by tilting slightly.
– Remove nuts completely and take off wiper arms.
1. Removing and installing engine 9
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
– Pull off rubber seal -1- on plenum chamber cover.
– Pull off rubber seal -2- and plenum chamber cover -3-.
– Detach the washer hose and electrical connectors at wind‐
screen washer jets.
– Lay aside plenum chamber cover (towards windscreen).
– Unclip cover -2-.
– Detach multi-pin connector -1- at engine control unit.
– Release retaining tab -arrow- and pull engine control unit for‐
wards out of the bracket.
Note
The multi-pin connector -3- remains attached to the engine control
unit.
– Open cable duct (left-side) in engine compartment -arrows-.
– Unplug electrical connector in cable duct.
– Take electrical connector out of bracket (near left-side head‐
light) and unplug connector -arrow-.
Note
On some vehicles the connector is obstructed by the headlight
(left-side). In this case, remove the headlight ⇒ Rep. Gr. 94 .
– Release wiring harness leading to engine control unit.
– Place engine control unit with wiring harness on top of engine.
– Secure the engine control unit to prevent it falling.
10 Rep. Gr.10 - Removing and installing engine
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
– Unbolt cable support bracket from gearbox -arrows-.
Vehicles to 06.2001:
– Press locking sleeve in direction of -arrow 1- as far as stop and
lock by turning anti-clockwise in direction of -arrow 2- to re‐
lease cable end-piece for gate selector cable and gear selec‐
tor cable.
– Disengage cables from cable end-piece.
Audi TT 1999 ➤
Vehicles from 07.2001:
– Unclip retaining clip -1- from gear selector cable and retaining
clip -2- from gate selector cable.
– Pull selector cable end-pieces with selector cables off selector
shaft lever and relay lever.
All models:
– Clamp off hydraulic line to clutch slave cylinder using a hose
clamp -3094- .
– Pull out retainer towards the top -arrow- and disconnect hy‐
draulic line -1- from hose connector.
Caution
Do not press clutch pedal after disconnecting hydraulic line.
1. Removing and installing engine 11
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
– Unplug electrical connector at charge pressure sender -G31-
and unclip wiring from air intake hose.
– Detach air intake hose from throttle valve module -J338- .
– Remove coolant hose -1- between engine and radiator.
Vehicles with secondary air system:
– Unplug electrical connector -arrow- at secondary air inlet valve
-N112- .
Vehicles with exhaust temperature control:
– Unplug electrical connector -arrow- at exhaust gas tempera‐
ture sender 1 -G235- .
12 Rep. Gr.10 - Removing and installing engine
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
All models:
– Unplug electrical connector -right arrow- at continued coolant
circulation pump -V51- .
– Unbolt continued coolant circulation pump -V51- from radiator
cowl -left arrows- (coolant hoses remain connected).
– Unscrew bolts for radiator cowl which are accessible from
above.
– Remove air pipe -arrows-.
Audi TT 1999 ➤
– Detach vacuum line -2- from intake manifold.
– Detach coolant hose -1- from coolant pipe/coolant expansion
tank.
Note
Before removing, mark direction of rotation of poly V-belt with
chalk or felt-tipped pen. If the belt runs in the opposite direction
when it is refitted, this can cause breakage.
– Turn the tensioner in the direction of the -arrow- to slacken the
poly V-belt.
– Remove poly V-belt.
1. Removing and installing engine 13
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
– Lock tensioner in position with locking pin -T10060 A- .
WARNING
The fuel system is pressurised. Before opening the system
place a clean cloth around the connection. Then release pres‐
sure by carefully loosening the connection.
– Disconnect fuel supply pipe -1- and fuel return pipe -2- by
pressing release tabs.
– Loosen bolts -arrows- of assembly mounting for engine ap‐
prox. 2 turns.
– Loosen bolts -arrows- of assembly mounting for gearbox ap‐
prox. 2 turns.
14 Rep. Gr.10 - Removing and installing engine
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
– Unbolt pulley -1- for power steering pump.
– Use hose clamps -3094- to clamp off both hydraulic hoses to
power steering pump.
– Unplug electrical connector -1- at power assisted steering
pressure switch -F88- .
– Place used oil collection and extraction unit -V.A.G 1782- un‐
der power steering pump.
– Disconnect hydraulic hoses from power steering pump.
– Unscrew power steering pump from bracket -arrows-.
Audi TT 1999 ➤
– Detach power steering cooling pipe from gearbox -arrows-.
– Unplug electrical connector -arrow- for reversing light switch -
F4- on gearbox.
1. Removing and installing engine 15
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
Vehicles with secondary air system:
– Unplug electrical connector at secondary air pump motor -
V101- , detach hoses and remove nuts -arrows-.
– Detach secondary air pump.
– Release wiring harness leading to body from retainers, etc.
All models:
– Detach electrical connectors -arrows- for radiator fan on bot‐
tom left of radiator cowl.
– Unscrew bolts on radiator cowl (accessible from below) and
remove radiator cowl with both fans from below.
Vehicles with air conditioning:
– Unplug electrical connector -1- for magnetic clutch of air con‐
ditioner compressor.
WARNING
The air conditioner refrigerant circuit must not be opened.
– Unscrew bolts -arrow- for air conditioner compressor.
– Tie up air conditioner compressor together with refrigerant ho‐
ses to radiator (refrigerant hoses remain connected).
– Unscrew heat shield for drive shaft (right-side) from bevel box
-arrows-.
– Unbolt drive shafts (left and right) from gearbox flange shafts.
16 Rep. Gr.10 - Removing and installing engine
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
– Remove cross piece -arrows-.
Vehicles with 2 Lambda probes:
– Unbolt protective cover -2- -arrows-.
– Unplug electrical connector for Lambda probe after catalytic
converter -G130- -item 1- and move wiring clear.
Audi TT 1999 ➤
All models:
– Unbolt catalytic converter from front exhaust pipe -arrows-.
– Separate exhaust system at clamp -arrows-.
– Push the clamp back and remove the catalytic converter.
1. Removing and installing engine 17
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
– Remove rubber mounting -arrow- for front exhaust pipe.
– Unbolt front exhaust pipe from turbocharger connection and
move to rear.
Note
♦
The top bolts securing the front exhaust pipe are accessible
through the brake pipe opening in the right wheel housing (re‐
move plug).
♦
To avoid any damage, the flexible joint in the front exhaust
pipe must not be bent more than 10°.
– Mark position of flexible coupling on bevel box.
– Unscrew propshaft with flexible coupling from bevel box
-arrows- (counter-hold using a suitable lever at the triangular
flange).
Caution
Avoid damaging the seal -arrow- in the propshaft flange when
removing. If a seal is damaged the propshaft must be renewed.
– Push propshaft horizontally as far back as possible.
18 Rep. Gr.10 - Removing and installing engine
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
Caution
After unscrewing the bolts -A-, the engine/gearbox assembly
swings slightly forward.
– First remove bolts -A-, then bolts -B- and remove pendulum
support.
– Unbolt coupling rod from anti-roll bar -arrow- on left and right
side of vehicle.
– Push engine forward. At the same time swivel right drive shaft
towards front and tie up with wire.
– Tie up left-side drive shaft with wire.
Note
Audi TT 1999 ➤
Take care not to damage the surface coating of the drive shafts.
Vehicles with secondary air system:
– Remove bracket for secondary air pump -arrows-.
All models:
– Attach engine bracket -T10012- with nut and bolt to cylinder
block: approx. 20 Nm.
– Insert engine and gearbox jack -V.A.G 1383 A- in engine
bracket -T10012- and raise engine slightly.
1. Removing and installing engine 19
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
– Remove bolts -arrows- of assembly mounting on engine.
Note
To unscrew bolts for assembly mounting use stepladder VAS 5085- .
– Remove bolts -arrows- of assembly mounting on gearbox.
Note
Check that all hoses, pipes and wiring connections between en‐
gine, gearbox and body have been detached.
– Pull engine/gearbox assembly as far forward as possible, and
lower gradually using engine and gearbox jack V.A.G 1383 A- .
Note
Carefully guide engine/gearbox assembly when lowering to avoid
damage.
1.2 Separating engine and gearbox
Procedure
• Engine/gearbox assembly removed and attached to engine
bracket -T10012- .
– Unplug electrical connector -arrow- at speedometer sender -
G22- on gearbox and release wiring from retainers, etc.
Vehicles with cast bracket for bevel box:
– Remove bolts -A ... C- on bracket for bevel box.
Note
Leave bracket in position. It cannot be removed at this stage.
20 Rep. Gr.10 - Removing and installing engine
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
Vehicles with pressed steel bracket for bevel box:
– Remove bolts -A ... C- on bracket for bevel box.
Note
Leave bracket in position. It cannot be removed at this stage.
All models:
Note
The small cover plate -2- for the flywheel is located behind the
bevel box and is not visible with the bevel box installed. Shown in
illustration with gearbox removed.
Audi TT 1999 ➤
– Unscrew bolt -1- and lift out cover plate.
– Remove bottom engine/gearbox securing bolts -1 ... 8-.
– Separate gearbox from engine.
Note
Second mechanic is required to separate engine/gearbox as‐
sembly.
1. Removing and installing engine 21
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
1.3 Securing engine to assembly stand
Special tools and workshop
equipment required
♦ Support clamp -VW 313-
♦ Engine and gearbox sup‐
port -VW 540-
♦ Lifting tackle -2024 A-
♦ Workshop hoist -6100- or -
V.A.G 1202 A-
Procedure
– Hook lifting tackle -2024 A- onto engine and workshop hoist
-6100- .
Note
To adjust to the centre of gravity of the assembly, the perforated
rails of the support hooks must be positioned as shown.
WARNING
The support hooks and retaining pins on the lifting tackle must
be secured with locking pins -arrows-.
– Lift engine off engine and gearbox jack -V.A.G 1383 A- using
workshop hoist -6100- .
22 Rep. Gr.10 - Removing and installing engine
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
– When carrying out repairs, secure engine to assembly stand
with engine and gearbox support -VW 540- .
1.4 Installing engine
Note
♦
On assembly, renew oil seals and gaskets as well as selflocking nuts and bolts that are tightened by turning through to
a specified angle.
♦
Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
♦
Fit all heat insulation sleeves in the original position when in‐
stalling.
♦
Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.
♦
Fit all cable ties in the original positions when installing.
– Check whether dowel sleeves for centring the engine/gearbox
assembly are fitted in the cylinder block; install dowel sleeves
if necessary.
– Engage intermediate plate on sealing flange and slip onto
dowel sleeves -arrows-.
Audi TT 1999 ➤
– Check that clutch plate is correctly centred.
– Check clutch release bearing for wear, renew if necessary.
– Lightly grease clutch release bearing, release bearing guide
sleeve and splines on input shaft with grease for clutch plate
splines -G 000 100- .
Note
♦
Tightening torques apply only to lightly greased, oiled,
phosphated or black-finished nuts and bolts.
♦
Additional lubricant such as engine oil or gearbox oil may be
used, but do not use lubricant containing graphite.
♦
Do not use degreased parts.
♦
Tolerance for tightening torques ± 15 %.
– Fit bracket for bevel box before fitting engine/gearbox securing
bolts.
– Use new securing bolts.
1. Removing and installing engine 23
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
4-cylinder 1.8 ltr. 5-valve turbocharged engine (165-176 kW), mechanics - Edition 12.2005
Securing engine to gearbox
Item
1, 2
3 1), 4
1)
1)
Bolt
2
Nm
M12x55 80
M12x165 80
5 M10x105 40
6, 7 M10x50 40
8 M12x70 80
A Dowel sleeves for centralising
1)
•
Bolt with M8 stud
2)
•
Renew bolts.
– Install new engine/gearbox securing bolts accessible from be‐
low.
– Push in small cover plate -2- for flywheel behind bevel box in
such a way that lug at bottom engages into cylinder block and
secure with bolt -1-.
Vehicles with cast bracket for bevel box:
– Fit bolts -A ... C- for bevel box bracket. Note tightening se‐
quence:
1. Initially tighten bolts -A- to 3 Nm.
2. Tighten bolts -B- and -C- to 35 Nm.
3. Tighten bolts -A- to 45 Nm.
24 Rep. Gr.10 - Removing and installing engine
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