Audi TT 32 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
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Service
Workshop Manual
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve
turbo), mechanics
Engine ID
Edition 11.2006
BWA BPY
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 A005TT00520
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 direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Removing and installing engine, detaching from gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.1 Assembly mountings - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Checking adjustment of assembly mountings (engine/gearbox mountings) . . . . . . . . . . . . 26
2.3 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.1 Poly V-belt, bracket for ancillaries - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.5 Front sealing flange - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.6 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.7 Removing and installing sealing flange (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.1 Rear sealing flange and dual-mass flywheel - exploded view . . . . . . . . . . . . . . . . . . . . . . 48
2.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.3 Removing and installing sealing flange (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1 Crankshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.5 Extracting and driving in needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.6 Removing and installing chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4 Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.1 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.1 Toothed belt drive - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.1 Cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.2 Removing and installing inlet camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . 80
2.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Contents i
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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 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
3.1 Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.2 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.3 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.4 Checking axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.5 Renewing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.6 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.7 Renewing exhaust camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1 Oil pump and sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.1 Sump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.3 Balance shaft assembly with oil pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.4 Removing and installing balance shaft assembly with oil pump . . . . . . . . . . . . . . . . . . . . . . 127
2 Oil filter bracket and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.1 Oil filter bracket - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.2 Draining oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.3 Removing and installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2.4 Removing and installing oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.1 Cooling system components (on engine) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.2 Continued coolant circulation pump V51 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.3 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.4 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.5 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.6 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.7 Removing and installing coolant distributor housing with map-controlled engine cooling
thermostat F265 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.8 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.9 Radiator and radiator fans - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.10 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.11 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.12 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 163
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.1 Fitting hose connections with plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.2 Turbocharger - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.3 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.4 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.5 Removing and installing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.6 Adjusting vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.1 Charge air cooler - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.2 Turbocharging diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1 Parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.1 Exhaust system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.2 Removing and installing front exhaust pipe with catalytic converters and front silencer . . 191
1.3 Aligning exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
ii Contents
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
1.4 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Contents iii
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
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 direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
00 – Technical data
1 Engine number
The engine number (including “Engine code” and “Serial num‐
ber”) can be found on the left of the joint between engine and
gearbox.
The engine code is also stamped on the right of the cylinder head
and on the cylinder block.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (up to 3 code letters) represents the “engine
code letters”, the second part (6 digits) the “serial number”. If more
than 999 999 engines were produced with the same code letters,
the first of the 6 digits is replaced by a letter.
Additionally there is a sticker on the toothed belt cover showing
the “engine code” and “serial number”.
The engine code is also to be found on the vehicle data sticker.
Audi TT 2007 ➤
1. Engine number 1
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Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
2 Engine data
Code letters BWA BPY
Capacity ltr. 1.984 1.984
Power output kW at rpm 147/5100 147/5700
Torque Nm at rpm 280/1800 280/2000
Bore ∅ in mm 82.5 82.5
Stroke mm 92.8 92.8
Compression ratio 10.3 10.5
RON
98
1)
Injection/ignition system FSI FSI
Firing order
1-3-4-2 1-3-4-2
Knock control yes yes
Turbocharging/super‐
yes yes
charging
Exhaust gas recirculation no no
Intake manifold change-
no no
over
Variable valve timing yes yes
Secondary air system no no
1)
•
Unleaded petrol RON 95 can also be used, but results in
reduced power
98
1)
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 direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
3 Safety precautions
When working on the fuel system please note the following warn‐
ings:
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.
Observe the following to avoid injuries to persons and/or damage
to the injection and ignition system:
♦ Always switch off the ignition before connecting or discon‐
necting electrical wiring for the injection or ignition system or
tester cables.
♦ Certain tests may lead to a fault being detected by the engine
control unit and stored in the memory. You must therefore in‐
terrogate the fault memory and erase it if necessary after
completion of all tests and repair work. If you erase the fault
memory, you must then generate the readiness code in the
engine control unit in “Guided Fault Finding” mode ⇒ Vehicle
diagnosis, testing and information system VAS 5051.
♦ Always switch off the ignition before cleaning the engine.
Audi TT 2007 ➤
♦ Observe notes on procedure for disconnecting the battery
Caution
⇒ Rep. Gr. 27 .
♦ Always switch off the ignition before connecting or dis‐
connecting the battery, otherwise the engine control unit
may be damaged.
When working on the cooling system note the following warnings:
WARNING
Hot steam or hot coolant can escape when expansion tank is
opened; cover filler cap with cloth and open carefully.
Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
♦ Test equipment must always be secured on the rear seat
and operated from that position by a second person.
♦ If test and measuring instruments are operated from front
passenger's seat and the vehicle is involved in an acci‐
dent, the person sitting in this seat could be seriously
injured when the airbag is triggered.
3. Safety precautions 3
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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 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
4 Rules for cleanliness
Injection system/fuel system
Even small amounts of dirt can cause faults in the injection sys‐
tem. When working on the fuel supply/injection system, please
pay careful attention to the following basic rules:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Plug open lines and connections with suitable protective caps
immediately.
♦ Place parts that have been removed on a clean surface and
cover them over. Use only lint-free cloths.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).
♦ When the system is open: Do not work with compressed air.
Do not move the vehicle unless absolutely necessary.
♦ Unplugged electrical connectors must be kept clean and dry.
Make sure connections are dry when attaching.
Turbocharger
When working on the turbocharger, pay careful attention to the
following “5 rules”:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place parts that have been removed on a clean surface and
cover them over. Use only lint-free 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 been stored loose (e.g. in tool boxes etc.).
♦ When the system is open: Do not work with compressed air if
this can be avoided. Do not move the vehicle unless absolutely
necessary.
4 Rep. Gr.00 - Technical data
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with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
10 – Removing and installing engine
1 Removing and installing engine, de‐
taching from gearbox
1.1 Removing engine
Special tools and workshop
equipment required
♦ Drip tray for workshop hoist
-VAS 6208-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Hose clip pliers -V.A.G
1921-
♦ Stepladder -VAS 5085-
♦ Engine bracket -T10012-
♦ Removal lever -80 - 200-
Audi TT 2007 ➤
1. Removing and installing engine, detaching from gearbox 5
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Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
Lambda probe open ring spanner set -3337-
Engine bung set -VAS 6122-
Note
♦
The engine is removed from underneath together with the
gearbox.
♦
Renew all cable ties which are released or cut open when re‐
moving the engine. Refit in the same position when installing
the engine.
♦
Heat insulation sleeves removed when taking out the engine
are to be reinstalled in the original position.
♦
Collect drained coolant in a clean container for re-use or dis‐
posal.
WARNING
Observe notes on procedure for disconnecting the battery. ⇒
Electrical system; Rep. Gr. 27
– Remove luggage compartment floor covering.
– Release retaining clips -arrows- and detach cover for negative
terminal.
Note
Remove rear cross panel trim if cover for negative terminal of
battery is located under rear cross panel trim ⇒ Rep. Gr. 70 .
– With ignition switched off, disconnect earth wire -arrow- at
battery.
WARNING
Hot steam/hot coolant may escape when opening expansion
tank. Cover cap with cloth and open carefully.
– Open filler cap on coolant expansion tank
– Remove both front wheels.
6 Rep. Gr.10 - Removing and installing engine
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with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Remove centre noise insulation -fasteners 1 ... 4-.
– Remove noise insulation panels (left and right) -arrows-.
Audi TT 2007 ➤
– Remove noise insulation frame -arrow-.
– Unplug electrical connector at air mass meter -G70- -3-.
– Open clamps -1 and 2- and disconnect air intake hose from
air mass meter.
– Detach air intake connection at lock carrier -4-.
– Pull off engine cover panel.
1. Removing and installing engine, detaching from gearbox 7
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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 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Remove air intake hose -arrow- using hose clip pliers -V.A.G
1921- .
– Remove electrical connector -arrow- for Lambda probe (be‐
fore catalytic converter) from bracket, unplug and move clear.
– Unscrew Lambda probe -G39- -arrow- using tool from Lambda
probe open ring spanner set -3337- .
– Use screwdriver to pry off cover caps on wiper arms and un‐
screw hexagon nuts.
– Pull wiper arms off wiper shafts and remove.
– Pull off rubber seal -1- on plenum chamber cover.
– Detach plenum chamber cover -2-.
– Move engine wiring harness in plenum chamber clear.
– Remove engine control unit. ⇒ Rep. Gr. 24
8 Rep. Gr.10 - Removing and installing engine
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with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Unplug engine wiring harness connector -1-.
– Release wiring protector for engine wiring harness -arrow- and
lift off.
Audi TT 2007 ➤
– Open wiring duct brackets -arrows-.
– Move electrical connector -1- clear and unplug connector.
– Open wiring duct bracket located below -2-.
– Open wiring duct bracket -3-.
– Remove engine control unit wiring harness from wiring duct.
1. Removing and installing engine, detaching from gearbox 9
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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 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
Note
Use removal lever -80 - 200- to lever out the wiring clips.
– Unplug electrical connector -1- for reversing light switch.
– Disconnect earth cable -2-.
– Unplug electrical connector -3-.
– Slide cover -4- to rear.
– Detach wire -arrow- at starter and move clear.
– Press the two clips in direction of the -arrows- and remove
cover from electronics box in engine compartment.
10 Rep. Gr.10 - Removing and installing engine
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Unscrew electrical wire -1- and move clear up to engine.
– Unplug electrical connector -2-.
– Unscrew bolts -1- from above.
Audi TT 2007 ➤
– Place drip tray for workshop hoist -VAS 6208- beneath engine.
– To drain off coolant, detach bottom coolant hose -arrow-.
– Remove air pipe -1 and 2- for charge air cooler.
1. Removing and installing engine, detaching from gearbox 11
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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 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Unplug electrical connector -2-.
– Unscrew the bolts -3- and remove radiator cowl from below.
– Detach top coolant hose from radiator -arrow-.
– Detach coolant hoses going to heat exchanger -arrows-.
– Unscrew securing bolts -arrows- for front exhaust pipe/turbo‐
charger accessible from above.
Note
Shown in illustration from rear with engine removed.
12 Rep. Gr.10 - Removing and installing engine
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with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Disconnect vacuum hose -arrow- leading to brake servo.
– Unclip securing clips -1- and -2- on both selector cables.
– Pull off selector cable end-pieces from gearbox selector lever
and relay lever.
– Detach cable support bracket from gearbox -arrows- and
place to one side.
WARNING
Audi TT 2007 ➤
Do not press clutch pedal after disconnecting hose leading to
slave cylinder.
– Pull out clip -2- as far a stop in -direction of arrow- and detach
hose -1-.
WARNING
Fuel supply line is pressurised. Wear safety goggles and pro‐
tective clothing to avoid possible injury and skin contact. Before
removing from hose connection wrap a cloth around the con‐
nection. Then release pressure by carefully pulling hose off
connection.
– Mark fuel line -2- and line going to ACF -1-.
– Disconnect fuel line -2- and move clear.
– Disconnect ACF line -1- and move clear.
– Disconnect vacuum line -3- going to activated charcoal filter
(press release tabs).
– Lift out ACF.
1. Removing and installing engine, detaching from gearbox 13
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Detach coolant hoses -1 and 2-.
– Discharge the refrigerant system ⇒ Rep. Gr. 87 ; Air condi‐
tioner system with refrigerant R134a .
– Disconnect air conditioner pipes -arrows- at compressor.
– Plug the openings with sealing plugs from engine bung set -
VAS 6122- .
– 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
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with respect to the correctness of information in this document. Copyright by AUDI AG.
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Unplug electrical connector -arrow-.
– Remove air pipe -arrows-.
Audi TT 2007 ➤
– Unplug electrical connector -1- for high-pressure sender -
G65- .
– Detach air conditioner pipe from condenser -2-.
– Unplug electrical connector at oil level sender -1-.
– Unclip bracket -2-.
1. Removing and installing engine, detaching from gearbox 15
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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 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Unbolt heat shield for drive shaft (right-side) -arrows-.
– Remove drive shafts (left and right) ⇒ Rep. Gr. 40 .
– Remove nuts -1- and -2- on bracket for electrical connector for
Lambda probe on underside of vehicle and remove cover.
– Unscrew bolt -3- and move electrical wire for Lambda probe
clear.
– Detach plug connector from bracket -arrow-.
– Unplug connector for Lambda probe after catalytic converter
-G130- .
– Unscrew remaining securing nuts -arrows- for front exhaust
pipe/turbocharger from below.
16 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 direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Unbolt bracket for exhaust system and tunnel brace -arrows-.
Note
To avoid any damage, the flexible joint in the front exhaust pipe
must not be bent more than 10°.
– Separate exhaust system at clamp -arrows-.
– Remove front exhaust pipe with catalytic converter and front
silencer.
Audi TT 2007 ➤
– Remove bolts -1 ... 3- and take out pendulum support.
– Unscrew the additional coolant pump -arrows-.
1. Removing and installing engine, detaching from gearbox 17
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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 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Bolt engine bracket -T10012- with securing bolt -1- and nut
-2- to cylinder block (tightening torque: approx. 20 Nm).
– Insert engine and gearbox jack -V.A.G 1383 A- in engine
bracket -T10012- and raise engine slightly.
Note
To unscrew bolts for assembly mounting use stepladder -VAS
5085- .
– Remove bolts -arrows- of assembly mounting on engine.
– Remove bolts -arrows- of assembly mounting for gearbox.
Note
♦
Check that all hoses, pipes and wiring connections between
engine, gearbox and body have been detached.
♦
Carefully guide engine/gearbox assembly when lowering to
avoid damage.
– Pull engine/gearbox assembly as far forward as possible, and
lower gradually.
1.2 Separating engine and gearbox
• Engine/gearbox assembly removed and attached to engine
bracket -T10012- .
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 direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Unscrew bolt -1- with gearbox installed.
– Pull up cover plate -2- and remove.
Note
Shown in illustration with gearbox removed.
– Remove bolts -1 ... 8- on engine/gearbox flange.
– Detach starter.
Note
The manual gearbox can be detached from the engine without a
workshop hoist, a 2nd mechanic is required for this purpose.
Audi TT 2007 ➤
– Separate gearbox from engine.
1. Removing and installing engine, detaching from gearbox 19
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
1.3 Securing engine to assembly stand
Special tools and workshop
equipment required
♦ Lifting tackle -2024 A-
♦ Workshop hoist -VAS
6100-
♦ Engine and gearbox sup‐
port -VAS 6095-
• Gearbox detached from engine.
20 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 direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Engage lifting tackle -2024 A- on engine and workshop hoist
-VAS 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 locating pins on the lifting tackle must
be secured with locking pins (arrows in illustration).
– Lift engine off engine bracket -T10012- using workshop hoist
-VAS 6100- .
Secure engine to engine and gearbox support -VAS 6095- when
dismantling/assembling engine.
1.4 Installing engine
Audi TT 2007 ➤
• Engine installed on engine bracket -T10012- .
Installation is carried out in the reverse order; note the following:
Note
♦
Reinstall all cable ties in the same locations when assembling.
♦
Secure all hose connections with the correct type of hose clips
(same as original equipment): ⇒ Parts catalogue
♦
Renew self-locking nuts and bolts when performing assembly
work.
♦
Renew bolts which are tightened to a specified angle as well
as oil seals and gaskets.
♦
Clean input shaft splines and (in the case of used clutch plates)
the hub splines. Remove corrosion and apply only a very thin
coating of grease (⇒ Parts catalogue ) to the splines. Then
move clutch plate back and forth on input shaft until the hub
moves smoothly on the shaft. Remove any excess grease.
– Check whether dowel sleeves for centring the engine/gearbox
assembly are fitted in the cylinder block; install dowel sleeves
if necessary.
1. Removing and installing engine, detaching from gearbox 21
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Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Ensure that the intermediate plate is engaged on the sealing
flange and pushed onto the dowel sleeves -arrows-.
– Check clutch release bearing for wear; renew if necessary.
– Bolt gearbox to engine.
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%.
Securing engine to gearbox
Item Bolt Nm
1, 2 M12×65 80
3 1), 4
1)
M12×135 80
5 ... 7 M10×60 40
8 M12×90 65
1)
•
Bolt with M8 stud
A: Centring sleeves
– Push in splash plate -2- in such a way that the lower lug en‐
gages into the cylinder block and secure on top with bolt -1-.
Note
Shown in illustration with gearbox removed.
– Guide engine/gearbox assembly into the body.
– Tighten bolts -arrows- of assembly mounting for engine initially
hand-tight.
22 Rep. Gr.10 - Removing and installing engine
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Tighten bolts of assembly mounting for gearbox -arrows- ini‐
tially hand-tight.
Note
♦
Use new securing bolts.
♦
The bolts are tightened to final torque only after adjusting the
engine mountings ⇒ page 25 .
– Remove engine bracket -T10012- from engine.
Audi TT 2007 ➤
1. Removing and installing engine, detaching from gearbox 23
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
– Secure pendulum support to gearbox and subframe -1 ... 3-.
– Install drive shafts ⇒ Running gear, front-wheel drive and four-
wheel drive; Repair group 40
– Install exhaust system and align it free of stress
⇒ page 194 .
– Install Lambda probe -G39- ⇒ Rep. Gr. 24 .
– Charge refrigerant circuit ⇒ Air conditioning system; Repair
group 87
– Attach and adjust selector mechanism at gearbox: ⇒ Rep. Gr.
34 .
– Adjust engine mountings ⇒ page 27 .
– Electrical connections and routing: ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
– Bleed fuel system ⇒ Motronic direct injection and ignition sys‐
tem (4-cylinder); Repair group 24; Servicing fuel injection sys‐
tem
– Check oil level ⇒ Maintenance ; Booklet 810 .
– Connect battery ⇒ Electrical system; Rep. Gr. 27 .
– Fill up with coolant ⇒ page 147 .
– Installing air pipes with connectors ⇒ page 164
Note
♦
Drained-off coolant may only be used again if the original cyl‐
inder head and cylinder block are re-installed.
♦
Contaminated or dirty coolant must not be used again.
WARNING
Never use battery charging equipment for boost starting. There
is danger of damaging the vehicle's control units.
Tightening torque
Component
Nm
Bolts/nuts M6 10
Except for the following:
Pendulum support to gearbox
Pendulum support to subframe
M8 20
M10 45
M12 65
40 + 90°
100 + 90°
1)2)
1)2)
Terminal B+ to starter 16
Earth wire to gearbox 23
1)
•
Renew bolt
2)
•
90° = one quarter turn.
24 Rep. Gr.10 - Removing and installing engine
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