Audi TT 31 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 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail),
mechanics
Engine ID
Edition 04.2010
CBB
B
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 A005TT02220
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 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Rules for cleanliness when working on fuel supply system, injection system and
turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Checking for leaks in the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.4 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.5 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Separating engine from manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 Assembly mountings - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Checking adjustment of assembly mountings (engine/gearbox mountings) . . . . . . . . . . . . 38
5.3 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.1 Poly V-belt drive with tensioner and air conditioner compressor - exploded view . . . . . . . . 43
1.2 Removing and installing poly V-belt - vehicles with tensioner and air conditioner
compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.4 Poly V-belt drive without air conditioner compressor - exploded view . . . . . . . . . . . . . . . . 48
1.5 Removing and installing poly V-belt - vehicles without air conditioner compressor . . . . . . 48
1.6 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.7 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.8 Sealing flange (pulley end) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.9 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.10 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.1 Dual-mass flywheel and sealing flange (gearbox end) - exploded view . . . . . . . . . . . . . . . . 59
2.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.3 Renewing sealing flange (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.1 Crankshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.5 Extracting and driving in needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.6 Pulling spur gear off crankshaft and shrink-fitting new spur gear . . . . . . . . . . . . . . . . . . . . 74
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.1 Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2 Measuring piston projection at “TDC” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.4 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.1 Toothed belt - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.1 Cylinder head cover - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.3 Cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.1 Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.2 Measuring axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.3 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.4 Renewing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.5 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.6 Checking hydraulic tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.7 Renewing valve stem oil seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . 127
3.8 Renewing valve stem oil seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . 130
3.9 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.10 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.11 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.12 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1 Oil pump, sump, balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.1 Oil pump, sump, balance shaft assembly - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 139
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.5 Removing balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.6 Installing a new balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.7 Re-installing a used balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2 Oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.1 Oil filter bracket and engine oil cooler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.2 Removing and installing oil filter bracket with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . 153
2.3 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.4 Checking oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.5 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.6 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.7 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.1 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.2 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2 Coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.1 Coolant pump and thermostat - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.3 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.4 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.5 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3 Coolant pipes, coolant temperature senders, coolant circulation pump . . . . . . . . . . . . . . . . 175
3.1 Coolant pipes, coolant temperature senders, coolant circulation pump - exploded view . . 175
ii Contents
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 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
3.2 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 176
3.3 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 178
3.4 Removing and installing pump for exhaust gas recirculation cooler V400 . . . . . . . . . . . . 178
3.5 Removing and installing coolant pipe (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3.6 Removing and installing coolant pipe (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3.7 Removing and installing coolant pipe (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4 Radiator and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
4.1 Radiator and radiator fans - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
4.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
4.3 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
4.4 Removing and installing radiator fans V7 / V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.5 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.1 Diagram of vacuum connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.2 Turbocharger - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
1.3 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
1.4 Renewing vacuum unit with position sender for charge pressure positioner G581 . . . . . . 202
2 Charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.1 Charge air cooler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.2 Removing and installing charge pressure sender G31 / intake air temperature sender G42
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1 Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1.1 Silencers - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1.2 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1.3 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.4 Aligning tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
2 Exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
2.1 Exhaust gas temperature control - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
2.2 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 223
2.3 Removing and installing exhaust gas temperature sender 3 G495 . . . . . . . . . . . . . . . . . . 224
2.4 Removing and installing exhaust gas temperature sender 4 G648 . . . . . . . . . . . . . . . . . . 225
3 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3.1 Diagram of vacuum connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3.2 Exhaust gas recirculation with exhaust gas recirculation cooler - exploded view . . . . . . . . 227
3.3 Removing and installing exhaust gas recirculation valve N18 with exhaust gas recirculation
potentiometer G212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3.4 Checking exhaust gas recirculation cooler change-over . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3.5 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Contents iii
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Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
iv Contents
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
00 – Technical data
1 Engine number
♦ The engine number (“Engine code” and “Serial number”)
-arrow- can be found at the front of the joint between engine
and gearbox.
♦ There is also a sticker on the toothed belt cover showing the
“Engine code” and “Serial number”.
♦ Starting with the letter “C”, the engine codes consist of 4 let‐
ters.
♦ The first 3 characters of the engine code stand for the engine
capacity and the mechanical construction and design. They
are stamped on the cylinder block, together with the serial
number.
♦ The 4th character indicates the power output and torque of the
engine, and is determined by the engine control unit.
Audi TT 2007 ➤
Note
♦
The 4-character engine code can be found on the type plate
(in versions for some countries only) and on the vehicle data
sticker and the engine control unit.
♦
Fitting locations of the type plate (certain countries only) and
the vehicle data sticker ⇒ Maintenance ; Booklet 810 .
1. Engine number 1
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Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
2 Engine data
Code letters CBBB
Capacity ltr. 1.968
Power output kW at rpm 125/4200
Torque Nm at rpm 350/1750 … 2500
Bore ∅ in mm 81.0
Stroke mm 95.5
Compression ra‐
tio
CN not less than 51
Firing order
Emission standards EU4 plus
Exhaust gas recirculation yes
Exhaust gas temperature control yes
Turbocharging/supercharging Turbocharger
Glow plugs Steel glow plugs
Charge air cooling yes
Lambda control 1 Lambda probe
Particulate filter yes
Valves per cylinder 4
16.5
1-3-4-2
Note
Audi TT models with a TDI engine (2.0 ltr. 4-valve common rail)
are always equipped with steel glow plugs.
2 Rep. Gr.00 - Technical data
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4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
3 Safety precautions
When working on the fuel system note the following warnings:
WARNING
Risk of injury - fuel system operates under pressure.
♦ Wrap a clean cloth around the connection before opening
the fuel system. Then release pressure by carefully loos‐
ening the connection.
♦ Wear protective gloves.
♦ Wear safety goggles.
The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
Audi TT 2007 ➤
Observe the following points to prevent personal injuries and
damage to the injection and glow plug system:
♦ Always switch off the ignition before connecting or discon‐
necting tester cables or electrical wiring for the injection or
glow plug system.
♦ Always switch off ignition before washing engine.
♦ Faults are stored in engine control unit if electrical connectors
have been unplugged:
– “Interrogate fault memory” in “Vehicle self-diagnosis”.
Caution
To prevent damage to the electronic components when dis‐
connecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery.
– Disconnect battery ⇒ Rep. Gr. 27 .
3. Safety precautions 3
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4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
When working on the cooling system note the following warnings:
WARNING
Hot steam/hot coolant can escape - risk of scalding.
♦ The cooling system is under pressure when the engine is
hot.
♦ To allow pressure to dissipate, cover filler cap coolant on
expansion tank with cloth and open carefully.
Risk of injury as the radiator fans may start up automatically.
♦ Unplug electrical connectors before starting to work in the
area of radiator cowl.
Caution
Overheating can occur if the filler cap is not fitted properly.
♦ Firmly close filler cap on coolant expansion tank.
Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
Accidents can be caused if the driver is distracted by test
equipment while road-testing, or if test equipment is not prop‐
erly secured.
Persons sitting in the front passenger's seat could be injured if
the airbag is triggered in an accident.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
TT Coupé:
Test equipment must always be secured on the rear seat with
a strap and operated from the rear seat by a second person.
TT Roadster:
♦ Move the passenger's seat back as far as it will go.
♦ Use only vehicle diagnosis and service information sys‐
tem -VAS 5052- or diagnosis system -VAS 5053- .
♦ The test equipment -1- must rest flat on the passenger's
thighs (as shown in illustration) and must be operated by
the passenger.
4 Rep. Gr.00 - Technical data
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4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
4 General repair instructions
4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger
Even small amounts of dirt can cause malfunctions. For this rea‐
son, please observe the following rules when working on the fuel
supply system, injection system and turbocharger:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal off open pipes/lines and connections using engine bung
set -VAS 6122- .
♦ Place parts that have been removed on a clean surface and
cover them over. Do not use fluffy cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have not been stored in the proper packaging (e.g. in tool
boxes etc.).
♦ When the system is open: Do not work with compressed air.
Do not move the vehicle unless absolutely necessary.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
Audi TT 2007 ➤
4.2 Checking for leaks in the fuel system
Procedure
– Allow engine to run for several minutes at moderate rpm.
– Switch off ignition.
– Check complete fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.
– Road-test vehicle and accelerate with full throttle at least once.
– Then inspect high-pressure section of fuel system again for
leaks.
4.3 Contact corrosion!
Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
used.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Note the following:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
4. General repair instructions 5
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Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
♦ We recommend the use of Audi accessories.
♦ Damage caused by contact corrosion is not covered under
warranty.
4.4 Checking vacuum system
Special tools and workshop equipment required
♦ Hand vacuum pump -VAS 6213-
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.
– If a fault is stored in the fault memory, check the vacuum lines
leading to the corresponding component and also check the
remaining vacuum lines in the system.
– If it is not possible to build up pressure with the hand vacuum
pump -VAS 6213- or if the pressure drops again immediately,
check the hand vacuum pump and connecting hoses for leaks.
4.5 Routing and attachment of pipes, hoses and wiring
Mark hydraulic lines, vacuum lines and electrical wiring before
removal so they can be re-installed in the original positions and
correctly connected. Make sketches or take photographs if nec‐
essary.
6 Rep. Gr.00 - Technical data
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4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
10 – Removing and installing engine
1 Removing engine
Special tools and workshop
equipment required
♦ Removal lever -80 - 200-
♦ Extension -2024 A /1-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Hose clip pliers -
V.A.G 1921-
♦ Stepladder -VAS 5085-
♦ Drip tray for workshop hoist
-VAS 6208-
Audi TT 2007 ➤
1. Removing engine 7
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Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
♦ Hose clamps for hoses up
to 25 mm -3094-
♦ Engine bracket -T10012-
♦ Locking pin -T10060 A-
♦ Puller -T10369-
♦ Engine bung set -VAS
6122-
♦ Safety goggles
♦ Protective gloves
Procedure
Note
♦
The engine is removed from underneath together with the
gearbox.
♦
Collect drained coolant in a clean container for re-use or dis‐
posal.
♦
Fit cable ties in the original positions when installing.
♦
Fit heat insulation sleeves in the original positions when in‐
stalling.
Caution
To prevent damage to the electronic components when dis‐
connecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
8 Rep. Gr.10 - Removing and installing engine
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4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
– Take out luggage compartment floor covering.
– Take out luggage compartment floor mat.
– Remove rear cross panel trim if cover for negative battery ter‐
minal is located behind rear cross panel trim ⇒ Rep. Gr. 70 .
– Release retaining clips -arrows- and detach cover for negative
terminal.
– Loosen nut a few turns and disconnect battery clamp on earth
wire -arrow- from battery terminal.
WARNING
Hot steam/hot coolant can escape - risk of scalding.
♦ The cooling system is under pressure when the engine is
hot.
♦ To allow pressure to dissipate, cover filler cap on coolant
expansion tank with cloth and open carefully.
Audi TT 2007 ➤
– Open filler cap on coolant expansion tank.
– Remove engine cover panel -arrows-.
– Pull cover off air duct (release clips on sides) -arrows-.
1. Removing engine 9
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Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
– Release clips on left and right -arrow A- and unclip air duct at
bottom -2-.
– Swivel air duct (bottom) slightly to the rear and detach air duct
(bottom) from retainers -3-.
– Detach air pipe -1- from air duct (bottom) -arrow B-.
– Unplug electrical connector -1- from air mass meter -G70- .
– Detach hose -4-.
– Release hose clip -2- and detach air hose.
– Unscrew bolt -3- and remove air cleaner housing.
– Remove bolts -arrows- and detach air duct -1- from lock car‐
rier.
10 Rep. Gr.10 - Removing and installing engine
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4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
– Remove bolts -top arrows- for radiator cowl.
Note
The bolts -bottom arrows- are removed at a later stage.
– Remove both front wheels.
– Release fasteners -1 ... 4- and remove centre noise insulation.
Audi TT 2007 ➤
– Only on TT Roadster: Remove noise insulation frame
-arrow- ⇒ Rep. Gr. 50 .
– Release fasteners -arrows- and remove wheel housing liner
(bottom section) on both sides.
1. Removing engine 11
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Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
– Release hose clip -2-, lift retaining clip -1- and remove air hose.
– Release hose clip -2-, lift retaining clip -1- and remove air hose.
Note
To prevent coolant from entering, seal off connection on charge
air cooler with a clean plug from engine bung set -VAS 6122- .
– Unplug electrical connector -1-.
– Remove bolts -bottom arrows- and take out air cowl down‐
wards.
– Place drip tray for workshop hoist -VAS 6208- beneath engine.
– Lift retaining clip -arrow-, disconnect coolant hose (bottom
right) from radiator and drain off coolant.
12 Rep. Gr.10 - Removing and installing engine
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4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
– Open hose clip -arrow-, disconnect coolant hose (bottom)
leading to pump for exhaust gas recirculation cooler -V400and drain off coolant.
– Remove bolts -bottom arrows- on rear side of radiator.
Note
The bolts -top arrows- are removed at a later stage.
Audi TT 2007 ➤
– As an additional step, open hose clip -arrow-, disconnect cool‐
ant hose at top of engine oil cooler and drain off remaining
coolant.
– Remove bolts -arrows- and detach bracket -1- for air cleaner
housing.
1. Removing engine 13
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Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
– Press release tabs and disconnect crankcase breather hose
-1- from cylinder head cover.
– Move clear vacuum hoses -arrows- at air pipe.
– Loosen hose clip -2- and detach air pipe.
– Detach vacuum hose -2- from vacuum unit of turbocharger.
– Disconnect vacuum hose -3-.
Note
Disregard -item 1-.
– Detach vacuum hose -arrow- from brake servo.
Note
Place a cloth underneath heat exchanger to catch escaping cool‐
ant.
– Lift retaining clips -arrows- and detach coolant hoses from
heat exchanger.
14 Rep. Gr.10 - Removing and installing engine
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4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
– Detach electrical connector -1- from bracket and unplug.
– Move clear electrical wiring.
Note
Disregard -items 2, 3 and 4-.
– Slacken bolt -2- and remove clamp.
Note
Disregard -items 1, 3-.
Audi TT 2007 ➤
– Unplug electrical connector -2- on exhaust gas pressure sen‐
sor 1 -G450- .
– Remove bolt -1-.
Note
Disregard -arrows-.
1. Removing engine 15
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Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
– Unplug electrical connector -4- on fuel temperature sender -
G81- .
WARNING
The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
– Release hose clips -2- and -3- and disconnect fuel supply hose
and fuel return hose.
Note
Disregard items marked -1- and -arrow-.
– Release hose clip -1- and detach coolant hose.
Note
Ignore items marked -2- and -arrows-.
– Disengage fuel hose -3- at bracket.
– Pull off bracket for fuel lines towards right -arrow- and move
clear to one side.
– Unplug electrical connector -1- at supplementary fuel pump -
V393- .
– Remove bolts -2- and -4-, detach bracket with supplementary
fuel pump -V393- and move clear to one side.
16 Rep. Gr.10 - Removing and installing engine
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4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
– Release hose clip -1-, detach coolant hose from coolant ex‐
pansion tank and move coolant hose clear -arrow-.
– Lift retaining clip -arrow- and disconnect coolant hose (top left)
from radiator.
Audi TT 2007 ➤
– Unplug electrical connector -A- at high-pressure sender -G65-
-item B-.
Note
Disregard -item C-.
– Remove bolts -top arrows- at rear and lift out radiator.
1. Removing engine 17
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Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
– Pry off caps on windscreen wiper arms with a screwdriver.
– Slacken nuts -arrows- one turn.
– Apply puller -T10369/1- to wiper arm -1- as shown in illustra‐
tion.
– Apply thrust piece -2- onto wiper shaft.
– Turn bolt -3- in clockwise direction until wiper arm is pulled off
wiper shaft.
– Remove nuts and detach windscreen wiper arms.
– Remove seal -1-.
Caution
Risk of damage to plenum chamber cover.
♦ Apply a small quantity of soap solution to transition be‐
tween windscreen and plenum chamber cover -2-. Then,
starting at edge of windscreen, carefully pull plenum
chamber cover upwards off retainer at windscreen
-arrows-.
– Detach plenum chamber cover by pulling it carefully off re‐
tainer at windscreen.
– Move clear engine wiring harness at rear of plenum chamber
partition panel.
– Remove engine control unit ⇒ Rep. Gr. 23 .
– Release electrical connector -1- for engine wiring harness
-arrow- and detach.
18 Rep. Gr.10 - Removing and installing engine
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4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
– Release wiring protector -1- for engine wiring harness
-arrow- and lift off.
– Move clear and unplug electrical connector -1-.
– Open wiring duct bracket -arrows-, use removal lever -80 -
200- to unclip wiring and press wiring to side.
– Unclip wiring duct.
Audi TT 2007 ➤
– Unclip electrical connector -1- from bracket and unplug.
– Open wiring duct bracket located underneath.
– Unclip wiring harness for engine control unit from wiring duct.
– Place engine wiring harness with engine control unit on top of
engine.
– Secure engine control unit to prevent it falling.
– Unclip electrical connector -2- from bracket and unplug.
– Slide the two clips in the direction of the -arrows- and remove
cover from electronics box in engine compartment.
1. Removing engine 19
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Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
– Remove nut -arrow-, detach terminal 30 wire from electronics
box in engine compartment and move it clear.
– Unplug electrical connector -1-.
Note
Disregard -arrows-.
– Unplug electrical connector -7- (push retainer to the rear and
press down release catch).
– Push back protective sleeve -6-.
– Remove nut -1- and detach B+ wire -item 2- from starter sol‐
enoid switch.
– Remove nut -5- and detach earth wire -4-.
– Remove top starter bolt -3-.
– Detach securing clip -3- for gear selector cable from gearbox
selector lever -1- and pull cable off pin -arrow-.
Metal selector relay lever:
– Detach securing clip -4- for gate selector cable from selector
relay lever -2- and pull cable off pin -arrow-.
20 Rep. Gr.10 - Removing and installing engine
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4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
Plastic selector relay lever:
• To prevent damage to gate selector cable, cable end-piece
must be detached from gate selector cable before removing.
– Pull locking device forwards onto stop -arrow 1- and lock by
turning anti-clockwise -arrow 2-.
– Press selector relay lever towards front -arrow 3-.
All vehicles (continued):
– Remove cable support bracket -arrows- from gearbox and
place to one side (selector cables remain fitted).
Audi TT 2007 ➤
– If a plastic pipe is installed between clutch master cylinder and
slave cylinder, clamp off supply hose to clutch master cylinder
using hose clamp -3094- .
Note
♦
Make sure brake fluid does not come into contact with starter
or gearbox when performing the following operations. If it
does, clean affected area thoroughly.
♦
Seal off open pipes/lines and connections with clean plugs
from engine bung set -VAS 6122- to prevent dirt from entering.
– If a pipe/hose assembly is installed between clutch master
cylinder and slave cylinder, clamp off hose -A- using hose
clamp for hoses up to 25 mm -3094- .
Note
Disregard -arrow-.
1. Removing engine 21
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Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
– Pull out clip -arrow- as far as stop.
– Pull plastic pipe or pipe/hose assembly -A- out of clutch slave
cylinder and seal end of pipe.
Note
Disregard -item B-.
Caution
Risk of contamination by escaping brake fluid.
♦ Do not operate clutch pedal after detaching pipe from
bleeder screw on clutch slave cylinder.
– Unplug electrical connector -2- for reversing light switch -F4- .
– Remove nut -1- and press bracket to side.
– Remove bottom starter bolt and detach starter.
– Loosen bolts -arrows- for assembly mounting (engine end)
approx. 2 turns.
– Loosen bolts -arrows- for assembly mounting (gearbox end)
approx. 2 turns.
22 Rep. Gr.10 - Removing and installing engine
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4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
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-tipped pen for re-installation.
– To slacken poly V-belt turn tensioner in clockwise direction
-arrow-.
– Lock tensioner with locking pin -T10060 A-
– Take off poly V-belt.
– Unplug electrical connector -2- on air conditioner compressor
regulating valve -N280- .
Caution
Make sure that air conditioner compressor and refrigerant
pipes and hoses are not damaged.
Audi TT 2007 ➤
♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Remove bolts -arrow-, detach air conditioner compressor -1-
with refrigerant lines connected and tie up to front.
– Unplug electrical connector -1- at oil level and oil temperature
sender -G266- .
– Unclip bracket -2- for wire to oil level and oil temperature
sender -G266- from subframe.
– Remove bolts -arrows- and detach heat shield for drive shaft
(right-side).
– Detach drive shaft (left-side) from flange shaft of gearbox and
tie up.
– Detach drive shaft (right-side) from flange shaft of bevel box.
1. Removing engine 23
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Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
– Remove bolts -1, 2, 3- and remove pendulum support.
– Mark position of nuts -arrows- securing swivel joint.
– Remove nuts for swivel joint (right-side).
– If fitted, remove nut on bracket for front right vehicle level
sender -G289- .
– Detach swivel joint from wishbone.
– Swing suspension strut (right-side) outwards and support with
extension -2024 A /1- as shown in illustration.
WARNING
Accident risk from loose components of support bracket.
♦ Secure retaining pin and swivel joint with locking pin
-arrow- and nut -1-.
Note
The illustration shows the installation position on front suspension
(left-side).
– Mark position of flexible coupling and flange for bevel box in
relation to each other.
– Unbolt flexible coupling for propshaft at bevel box -arrows-
(counterhold using a suitable lever at the triangular flange).
24 Rep. Gr.10 - Removing and installing engine
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