Audi TT 40 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 ➤

5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics

Engine ID

Edition 12.2010

CEP

A

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.

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 ➤

5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.1 Working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.2 Procedure before opening high-pressure section of injection system . . . . . . . . . . . . . . . . 4

3.3 Working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.4 Working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.5 Using testers and measuring instruments during a road test . . . . . . . . . . . . . . . . . . . . . . . . 5

3.6 Working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.1 Rules for cleanliness when working on fuel supply system, injection system and

turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.3 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.4 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.5 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.6 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.7 Installing radiators, condensers and charge air coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Separating engine from manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3 Separating engine and dual-clutch gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.1 Assembly mountings - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.2 Checking adjustment of assembly mountings (engine/gearbox mountings) . . . . . . . . . . . . 43

6.3 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6.4 Removing and installing engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

1.1 Poly V-belt drive, bracket for ancillaries - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 53

1.2 Removing and installing poly V-belt for A/C compressor . . . . . . . . . . . . . . . . . . . . . . . . . . 55

1.3 Removing and installing poly V-belt for alternator and coolant pump . . . . . . . . . . . . . . . . 56

1.4 Removing and installing poly V-belt tensioner for air conditioner compressor . . . . . . . . . . 57

1.5 Removing and installing poly V-belt tensioner for alternator and coolant pump . . . . . . . . 57

1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

1.7 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

1.8 Sealing flange (pulley end) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

1.9 Renewing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

2.1 Dual-mass flywheel - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

2.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

2.3 Renewing crankshaft oil seal (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

3.1 Crankshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

3.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.1 Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.3 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

1 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

1.1 Timing chain covers - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1.2 Removing and installing timing chain cover (top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

1.3 Renewing oil seal in timing chain cover (top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

1.4 Removing and installing timing chain cover (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1.5 Camshaft timing chain - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1.6 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

1.7 Drive chain for valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

1.8 Removing and installing drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

2.1 Cylinder head cover and cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 99

2.2 Removing and installing camshaft control valves N205 / N318 . . . . . . . . . . . . . . . . . . . . 102

2.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

2.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

2.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

3.1 Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

3.2 Measuring axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

3.3 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

3.4 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

3.5 Renewing valve stem oil seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . 123

3.6 Renewing valve stem oil seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . 126

3.7 Checking hydraulic valve compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

3.8 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

3.9 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

3.10 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

1 Sump and oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

1.1 Sump (bottom section), sump (top section), oil pump - exploded view . . . . . . . . . . . . . . . . 134

1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 137

1.3 Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

1.4 Removing and installing sump (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

2 Oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

2.1 Oil filter bracket and engine oil cooler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

2.3 Removing and installing oil filter bracket with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . 154

2.4 Checking oil pressure switch F1 / oil pressure switch F22 / oil pressure switch for reduced oil

pressure F378 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

2.5 Removing and installing oil pressure switch F1 / oil pressure switch for reduced oil pressure

F378 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

2.6 Removing and installing oil pressure switch F22 / valve for oil pressure control N428 from

09.2010 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

2.7 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

2.8 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

2.9 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

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 ➤

5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

1.1 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

1.2 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

2 Coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

2.1 Coolant pump and thermostat with housing - exploded view . . . . . . . . . . . . . . . . . . . . . . . . 173

2.2 Removing and installing continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . 173

2.3 Removing and installing solenoid valve for coolant circuit N492 . . . . . . . . . . . . . . . . . . . . 175

2.4 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

2.5 Removing and installing thermostat with housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

2.6 Removing and installing coolant distributor housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

3.1 Coolant pipes - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

3.2 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 183

3.3 Removing and installing coolant pipe (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

3.4 Removing and installing coolant pipe (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

3.5 Removing and installing coolant pipes (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

3.6 Removing and installing coolant pipe - vehicles with dual clutch gearbox . . . . . . . . . . . . . . 189

4 Radiators and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

4.1 Radiators and radiator fans - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

4.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

4.3 Removing and installing auxiliary radiator (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

4.4 Removing and installing auxiliary radiator (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

4.5 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

4.6 Removing and installing radiator fans V7 / V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

1.1 Turbocharger - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

1.2 Removing and installing charge pressure sender G31 / intake air temperature sender 2 G299

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

1.3 Removing and installing turbocharger air recirculation valve N249 . . . . . . . . . . . . . . . . . . 209

1.4 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

2 Charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

2.1 Charge air cooler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

2.3 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

1 Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

1.1 Silencers - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

1.2 Removing and installing starter catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

1.3 Removing and installing catalytic converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

1.4 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

2 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

3 Exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

3.1 Exhaust gas temperature control - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

3.2 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 230

4 Exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

4.1 Checking vacuum unit for exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Contents iii

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

iv Contents

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00 – Technical data

1 Engine number

♦ The engine number („Engine code“ and „Serial number“) can

be found on the rear of the joint between cylinder block and sump (top section) -arrow-.

♦ There is also a sticker on the timing chain cover (top) 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 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

2 Engine data

Code letters CEPA

Capacity ltr. 2.480 Power output kW at rpm 250/5400 … 6500 Torque Nm at rpm 450/1600 … 5300 Bore ∅ in mm 82.5 Stroke mm 92.8 Compression ra‐

tio RON at least

Injection/ignition system Bosch Motronic Firing order Exhaust gas recirculation no Exhaust gas temperature control 1 senders Turbocharging/supercharging Turbocharger Knock control 2 sensors Charge air cooling yes Lambda control 1 probe before catalytic

Variable valve timing Inlet

Intake manifold change-over no Secondary air system no Valves per cylinder 4

1)

•

Unleaded premium RON 95 can also be used, but results

in reduced power

10

1)

98

1-2-4-5-3

converter 1 probe after catalytic con‐ verter

Exhaust

2 Rep. gr.00 - Technical data

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3 Safety precautions

Overview

♦ ⇒ „3.1 Working on the fuel system“, page 3

♦ ⇒ „3.2 Procedure before opening high-pressure section of in‐

jection system“, page 4

♦ ⇒ „3.3 Working on the cooling system“, page 4

♦ ⇒ „3.4 Working on vehicles with start/stop system“,

page 4

♦ ⇒ „3.5 Using testers and measuring instruments during a road

test“, page 5

♦ ⇒ „3.6 Working on the exhaust system“, page 5

3.1 Working on the fuel system

When working on the fuel system note the following warnings:

WARNING

Audi TT 2007 ➤

The fuel system operates at extremely high pressure. This can cause injury.

♦ The fuel pressure in the high-pressure section of the in‐

jection system must be reduced to a residual pressure prior to opening the system.

♦ Wrap a clean cloth around the connection and carefully

loosen the connection to allow the residual pressure to dissipate.

– Procedure before opening high-pressure section of injection

system ⇒ Rep. gr. 24 .

Observe the following to prevent injuries to persons and 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.

♦ Always switch off ignition before washing engine.

♦ Faults are stored in engine control unit(s) if electrical connec‐

tors were unplugged and engine was started: „Generate read‐ iness code“ in „Guided Functions“ ⇒ Vehicle diagnostic, testing and information system VAS 5051.

Caution

To prevent irreparable damage to the electronic components when disconnecting the battery:

♦ Observe notes on procedure for disconnecting the battery.

♦ Always switch off the ignition before disconnecting the

battery.

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .

3. Safety precautions 3

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3.2 Procedure before opening high-pres‐ sure section of injection system

WARNING

The fuel system operates at extremely high pressure. This can cause injury.

♦ The injection system consists of a high-pressure section

(maximum approx. 140 bar) and a low-pressure section (approx. 6 bar).

♦ The fuel pressure in the high-pressure section must be

reduced to a residual pressure of approx. 6 bar prior to opening the system. Procedure ⇒ Rep. gr. 24 .

3.3 Working on the cooling system

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 on coolant

expansion tank with cloth and open carefully.

3.4 Working on vehicles with start/stop sys‐ tem

When performing repairs on vehicles with start/stop system, note the following:

WARNING

Risk of injury due to automatic engine start on vehicles with start/stop system.

♦ On vehicles with activated start/stop system (this is indi‐

cated by a message in the instrument cluster display), the engine may start automatically on demand.

♦ Therefore it is important to ensure that the start/stop sys‐

tem is deactivated when performing repairs (switch off ignition, if required switch on ignition again).

4 Rep. gr.00 - Technical data

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3.5 Using testers and measuring instru‐ ments during a road test

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.

♦ Move the passenger's seat back as far as it will go.

♦ Use only vehicle diagnosis and service information sys‐

tem -VAS 5052 A- 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.

Audi TT 2007 ➤

3.6 Working on the exhaust system

When working on the exhaust system please note the following:

Caution

Avoid damage to flexible joint.

♦ Do not bend flexible joint more than 10°.

♦ Install flexible joint so that it is not under tension.

♦ Take care not to damage wire mesh on flexible joint.

3. Safety precautions 5

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

4 General repair instructions

Overview

♦ ⇒ „4.1 Rules for cleanliness when working on fuel supply sys‐

tem, injection system and turbocharger“, page 6

♦ ⇒ „4.2 Checking fuel system for leaks“, page 6

♦ ⇒ „4.3 Foreign particles in engine“, page 6

♦ ⇒ „4.4 Contact corrosion!“, page 7

♦ ⇒ „4.5 Routing and attachment of pipes, hoses and wiring“,

page 7

♦ ⇒ „4.6 Checking vacuum system“, page 7

♦ ⇒ „4.7 Installing radiators, condensers and charge air coolers“,

page 8

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 immediately with

clean plugs, e.g. from engine bung set -VAS 6122- .

♦ 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 not been stored in their packing (e.g. in tool boxes etc.).

♦ When the system is open, do not work with compressed air

and do not move the vehicle.

♦ Protect unplugged electrical connectors against dirt and mois‐

ture and make sure connections are dry when attaching.

4.2 Checking fuel system for leaks

– 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 Foreign particles in engine

♦ When performing assembly work on the engine, all open pas‐

sages in the intake and exhaust systems must be sealed with

6 Rep. gr.00 - Technical data

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suitable plugs (e.g. from engine bung set -VAS 6122- ) to pre‐ vent foreign particles from entering the engine.

4.4 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.

♦ We recommend the use of Audi accessories.

♦ Damage caused by contact corrosion is not covered under

warranty.

Audi TT 2007 ➤

4.5 Routing and attachment of pipes, hoses and wiring

♦ Mark fuel lines, hydraulic lines, vacuum lines, lines for activa‐

ted charcoal filter system and electrical wiring etc. before removal so they can be re-installed in the original positions and correctly connected. Make sketches or take photographs if necessary.

♦ To prevent damaging pipes, hoses and wiring, ensure suffi‐

cient clearance from all moving or hot components in engine compartment (little space in engine compartment).

4.6 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.

4. General repair instructions 7

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– If a fault is stored in the memory, check the vacuum lines lead‐

ing to the corresponding component and also check the re‐ maining vacuum lines in the system.

– If it is not possible to build up a vacuum with the hand vacuum

pump -VAS 6213- or if the vacuum pressure drops again im‐ mediately, check the hand vacuum pump and connecting hoses for leaks.

4.7 Installing radiators, condensers and charge air coolers

Even when the radiator, condenser and charge air cooler are cor‐ rectly installed, slight impressions may be visible on the fins of these components. This does not mean that the components are damaged. If the fins are only very slightly distorted, this does not justify renewal of the radiator, condenser or charge air cooler.

8 Rep. gr.00 - Technical data

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10 – Removing and installing engine

1 Removing engine

Special tools and workshop equipment required

♦ Removal lever -80 - 200-

♦ Hose clamps for hoses up

to 25 mm -3094-

♦ Engine and gearbox jack -

V.A.G 1383 A-

♦ Stepladder -VAS 5085-

♦ Engine bung set -VAS

6122-

♦ Drip tray for workshop hoist

-VAS 6208-

Audi TT 2007 ➤

♦ Hose clip pliers -VAS 6362-

1. Removing engine 9

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♦ Engine bracket -T03000-

Procedure

Note

♦

The engine is removed from underneath together with the gearbox.

♦

Fit cable ties in the original positions when installing.

♦

Routing and attachment of pipes, hoses and wiring in engine compartment ⇒ page 7 .

WARNING

The fuel system operates at extremely high pressure. This can cause injury.

♦ The fuel pressure in the high-pressure section of the in‐

jection system must be reduced to a residual pressure prior to opening the system.

– Reduce fuel pressure in high-pressure section of injection sys‐

tem ⇒ Rep. gr. 24 .

Caution

To prevent irreparable damage to the electronic components when disconnecting the battery:

♦ Observe notes on procedure for disconnecting the battery.

– With ignition switched off, disconnect earth cable -arrow- at

battery ⇒ Electrical system; Rep. gr. 27 .

10 Rep. gr.10 - Removing and installing engine

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WARNING

Hot steam/hot coolant can escape - risk of scalding.

♦ The cooling system is under pressure when the engine is

hot.

♦ Cover filler cap on coolant expansion tank with a cloth and

open carefully to dissipate pressure.

– Open filler cap on coolant expansion tank.

– Lift off engine cover panel -1- -arrows-.

Audi TT 2007 ➤

– Unscrew bolts -arrows- and remove air duct.

– Unplug electrical connector -3-.

– Unscrew bolts -1- and remove charge pressure sender -G31- /

intake air temperature sender 2 -G299- .

– Loosen hose clip -2-.

1. Removing engine 11

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– Remove front wheels ⇒ Wheels and tyres; Rep. gr. 44 .

– Remove front noise insulation -1- ⇒ Rep. gr. 66 .

– Remove front bottom sections of wheel housing liners (left and

right)⇒ Rep. gr. 66 .

– Remove noise insulation frame -arrow- together with rear

noise insulation ⇒ Rep. gr. 50 .

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

for air conditioner compressor with chalk or felt-tipped pen for re-installation.

– To slacken poly V-belt turn tensioner in clockwise direction

-arrow-.

– Detach poly V-belt for air conditioner compressor and release

tensioner.

12 Rep. gr.10 - Removing and installing engine

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Note

Collect drained coolant in a clean container for re-use or disposal.

– Place drip tray for workshop hoist -VAS 6208- under connec‐

tion.

– Lift retaining clip -arrow-, disconnect coolant hose (bottom)

from radiator and drain off coolant.

Vehicles with manual gearbox:

– Detach air intake grille -1- from bumper cover -arrow-.

Audi TT 2007 ➤

– Unscrew bolt -1- and remove air duct.

Note

Disregard -item 2-.

– Remove bolt -1-.

– Release hose clip -2- and detach air pipe.

1. Removing engine 13

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Vehicles with dual clutch gearbox:

– Place drip tray for workshop hoist -VAS 6208- under connec‐

tion.

– Release hose clip -arrow-, disconnect coolant hose and drain

off coolant.

– Remove nuts -arrows-.

– Release hose clip -1- and detach air pipe.

All vehicles (continued):

– Place drip tray for workshop hoist -VAS 6208- under connec‐

tion.

– Release hose clips, disconnect coolant hoses -1- and -2- and

drain off coolant.

Note

Disregard -item 3-.

– Unplug electrical connector -2- for radiator fan.

– Remove bolts -3-.

WARNING

Risk of injury caused by fuel.

♦ To allow the fuel pressure to dissipate, wrap a clean cloth

around the connection and carefully loosen the connec‐ tion before opening the fuel system.

Caution

Risk of damage caused by particles of dirt.

♦ Observe rules for cleanliness when working on the fuel

supply system ⇒ page 6 .

14 Rep. gr.10 - Removing and installing engine

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– Disengage fuel supply line from retainer and remove heat in‐

sulation sleeve -2- at fuel supply line connection.

– Disconnect fuel supply pipe (pull release ring).

– Seal off open pipes/lines and connections with clean plugs

from engine bung set -VAS 6122- .

– Disconnect hose -1- from activated charcoal filter.

– Release activated charcoal filter -arrow B-, lift off -arrow A- and

move clear to one side.

– Remove bolts -arrows- and detach bracket for activated char‐

coal filter.

Note

Disregard -item 1-.

Audi TT 2007 ➤

– Release hose clip -3- and detach coolant hose.

– Guide coolant hose downwards and drain off coolant.

Note

Disregard -items 1, 2-.

– Unplug electrical connector -1- for coolant shortage indicator

switch -F66- .

– Remove bolts -arrows- and move coolant expansion tank with

coolant pipe (right-side) to side.

1. Removing engine 15

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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

for alternator and coolant pump with chalk or felt-tipped pen for re-installation.

– To slacken poly V-belt turn tensioner in clockwise direction

-arrow-.

– Detach poly V-belt for alternator and coolant pump and re‐

lease tensioner.

– Unscrew bolts -1- and remove idler roller.

– Remove bolt -arrow- and take off tensioner.

– Remove bolt -arrow- from retaining clamp.

16 Rep. gr.10 - Removing and installing engine

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– Unplug electrical connector -3- at alternator.

– Lever off protective cap -2- and remove nut -1- for terminal 30/

B+.

– Remove nut -4- and detach wiring clamp.

– Remove bolts -arrows- and lift out alternator.

Audi TT 2007 ➤

Note

♦

Apply 1/2” socket insert AF 19 -item 1- to sliding bush if alter‐ nator is stuck in bracket.

♦

Screw a bolt M8x45 -item 2- into sliding bush and pull sliding bush out of alternator by screwing in bolt.

– Unscrew bolts -arrows- and remove idler roller.

1. Removing engine 17

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Release hose clip -2- and detach coolant hose.

Note

Disregard -item 1-.

– Move clear coolant line -1- -arrows- and move to rear.

– Remove bolts -1- and lift out radiator cowl.

– Release hose clips -2- and -3- and disconnect air hoses.

– Move clear electrical wiring harness -1- at bracket for air clean‐

er housing.

– Unscrew bolts -arrows- and detach air cleaner housing.

18 Rep. gr.10 - Removing and installing engine

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– Release hose clip -arrow- and detach coolant hose.

– Release hose clips -1- and -2- and detach coolant hoses.

Audi TT 2007 ➤

– Remove bolts -arrows-.

– Release hose clip -1- and detach air pipe.

Note

Disregard -item 2-.

– Remove electrical connector -1- for Lambda probe -G39- from

bracket and unplug connector.

– Move clear electrical wiring to Lambda probe.

Note

Disregard -items 2, 3-.

1. Removing engine 19

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Unplug electrical connector -1-.

– Remove bolts -arrows- and place exhaust gas temperature

sender 1 -G235- onto cylinder head.

– Detach vacuum hose -1- from non-return valve -arrow-.

– Pull non-return valve off brake servo.

– Release electrical connector -1- for engine wiring harness

-arrow- and detach ⇒ Removing and installing engine control unit -J623-; Rep. gr. 24 .

– Release wiring protector -1- for engine wiring harness

-arrow- and lift off.

20 Rep. gr.10 - Removing and installing engine

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– Slide the two clips in the direction of the -arrows- and remove

cover from electronics box in engine compartment.

– Remove nut -arrow-, detach terminal 30 wire from electronics

box in engine compartment and move it clear.

Audi TT 2007 ➤

– Open wiring duct brackets -arrows-.

– Unclip electrical connectors -2- and -3- from bracket and un‐

plug connectors.

– 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 on top of engine.

– Secure engine control unit to prevent it falling.

1. Removing engine 21

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Note

Use removal lever -80 - 200- to lever out the wiring clips.

Vehicles with manual gearbox:

– Unplug electrical connector -2- at starter.

– Push back protective cover -1- and unscrew B+ cable at starter

solenoid switch.

– Remove bolt -4- for earth connection.

– Unplug electrical connector -3- for reversing light switch -F4- .

– Pull locking device forwards onto stop -arrow 1- and lock by

turning anti-clockwise -arrow 2-.

– Press relay lever towards front -arrow 3-, take gate selector

cable out of end-piece.

– Detach securing clip -1- for gear selector cable from gearbox

selector lever -2- and pull cable off pin -arrow-.

22 Rep. gr.10 - Removing and installing engine

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Remove bolts -arrows-, detach cable support bracket from

gearbox and tie up to the left side.

– If a plastic pipe is installed between clutch master cylinder and

slave cylinder, clamp off supply hose to clutch master cylinder using hose clamps for hoses up to 25 mm -3094- .

Audi TT 2007 ➤

– If a pipe/hose assembly is installed between clutch master

cylinder and slave cylinder, clamp off hose -A- using hose clamps for hoses up to 25 mm -3094- .

Note

♦

Disregard -arrow-.

♦

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.

– Pull out clip -arrow- as far as stop.

– Pull plastic pipe or pipe/hose assembly -A- out of bleeder con‐

nection for clutch slave cylinder.

– Seal off open pipes/lines and connections with clean plugs

from engine bung set -VAS 6122- .

Note

Disregard -item B-.

Caution

Risk of contamination by escaping brake fluid.

♦ Do not operate clutch pedal after detaching pipe from

bleeder connection on clutch slave cylinder.

1. Removing engine 23

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Loosen bolts -arrows- for gearbox mounting approx. 2 turns.

Vehicles with dual clutch gearbox:

– Unplug electrical connector -2- at starter.

– Push back protective cover -1- and unscrew B+ cable at starter

solenoid switch.

– Remove bolt -4- for earth connection.

Caution

Risk of irreparable damage to gearbox control unit (mecha‐ tronic unit) because of static discharge.

♦ Do NOT touch connector contacts in gearbox connector

with your hands.

– Touch gearbox housing with your hand (without wearing

gloves) to eliminate static charge.

– Turn retainer catch anti-clockwise and unplug electrical con‐

nector -3- at gearbox.

– Pry ball socket of selector lever cable off gearbox selector lev‐

er using removal lever -80 - 200- .

– Release fasteners -arrows- and move selector lever cable

clear.

Note

Take care not to bend or kink selector lever cable.

– Loosen bolts -arrows- for gearbox mounting approx. 2 turns.

24 Rep. gr.10 - Removing and installing engine

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

All vehicles (continued):

– Loosen bolt -3- and push clamp onto starter catalytic convert‐

er.

– Remove bolt -2-, tie up starter catalytic converter to rear.

Note

Disregard -item 1-.

– Remove bolts -1- and -2-.

– Release hose clips -arrows- and remove air pipe.

Audi TT 2007 ➤

– Unplug electrical connector -1- on air conditioner compressor

regulating valve -N280- .

Caution

Danger of damage to refrigerant lines and hoses.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.

– Remove bolts -arrows-.

– Detach air conditioner compressor from bracket for ancillaries

and tie up to the right side.

– Remove nuts -1- and detach heat shield for drive shaft (right-

side).

– Remove drive shaft (left and right) ⇒ Rep. gr. 40 .

1. Removing engine 25

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Remove bolts -1, 2, 3- and detach pendulum support.

– Unplug electrical connector -1- at oil level and oil temperature

sender -G266- .

– Unclip bracket -2- for electrical wiring from subframe.

– Remove nuts -1- and -2-.

– Loosen clamps -1- and -2- and move to front.

– Detach catalytic converter (left and right).

26 Rep. gr.10 - Removing and installing engine

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Mark position of flexible coupling and flange for bevel box in

relation to each other for re-installation.

– Remove bolts -arrows- for flexible coupling for propshaft at

bevel box (select gear on gearbox).

Caution

Make sure not to damage the oil seal -arrow- in the propshaft flange.

♦ Push the propshaft horizontally to the rear as far as pos‐

sible.

Audi TT 2007 ➤

Note

The propshaft must be renewed if oil seal is damaged.

– Unscrew pin -T03000/1- from engine bracket -T03000- .

– Fit engine bracket -T03000- with remaining pin -3- to cylinder

block, screw in bolts -1- and -2- by hand until they make con‐ tact.

– Fit pin -T03000/1- to cylinder block and tighten to 20 Nm.

– Tighten bolts -1- and -2- to 25 Nm.

– Insert engine and gearbox jack -V.A.G 1383 A- in engine

bracket -T03000- and raise engine/gearbox assembly slightly.

1. Removing engine 27

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Note

To unscrew bolts for assembly mounting use stepladder VAS 5085- .

– Remove bolts -1- and -arrows- for engine mounting (left-side).

Note

The bolt at the rear of the cylinder block can be accessed from the wheel housing side.

– Remove bolts -arrows- securing gearbox mounting.

Caution

Danger of damage to hoses, pipes and wiring connections and to engine compartment.

♦ Check that all hoses and wiring connections between en‐

gine, gearbox, subframe and body have been detached.

♦ Carefully guide engine/gearbox assembly out of engine

compartment when lowering.

♦ Make sure there is sufficient clearance from air conditioner

compressor.

– Swing gearbox section of engine/gearbox assembly to front

and only then lower further.

28 Rep. gr.10 - Removing and installing engine

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

2 Separating engine from manual gear‐

box

Special tools and workshop equipment required

♦ Lifting tackle -2024 A-

♦ Workshop hoist -VAS 6100-

Audi TT 2007 ➤

Procedure

• Engine/gearbox assembly removed and attached to engine support -T03000- .

– Remove bolts -1, 2, 3- and detach bracket for bevel box.

– Disconnect vacuum hose -2-.

– Move clear vacuum hose -1- -arrow- and disconnect from vac‐

uum pump for brake servo.

2. Separating engine from manual gearbox 29

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Remove nuts and bolts -arrows-.

– Release hose clips -1- and -2- and detach coolant pipe (left-

side).

– Remove nuts -2- and detach wiring bracket -1- from starter.

– Remove bolts -arrows- for starter.

– Take out starter -1- downwards.

30 Rep. gr.10 - Removing and installing engine

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Engage lifting tackle -2024 A- on gearbox and workshop hoist

-VAS 6100- .

Note

To adjust to the centre of gravity of the gearbox, the perforated rails of the support hooks must be positioned as shown.

WARNING

Accident risk from loose components of lifting tackle.

♦ The support hooks and retaining pins on the lifting tackle

must be secured with locking pins -arrows-.

– Remove bolts -1, 3, 4, 5- securing gearbox to engine.

– Detach gearbox from engine.

Audi TT 2007 ➤

Note

Disregard -items 2, A, B-.

2. Separating engine from manual gearbox 31

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

3 Separating engine and dual-clutch

gearbox

Special tools and workshop equipment required

♦ Lifting tackle -2024 A-

♦ Eye-head bolt -3368-

♦ Workshop hoist -VAS 6100-

♦ Puller for ATF-supply -T40123 A-

32 Rep. gr.10 - Removing and installing engine

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Procedure

• Engine/gearbox assembly removed and attached to engine support -T03000- .

– Remove bevel box ⇒ Rep. gr. 34 .

– Remove starter ⇒ Electrical system; Rep. gr. 27 .

– Remove nut -arrow- and move electrical wiring harness clear.

– Move breather hose -1- clear -arrows-.

Audi TT 2007 ➤

– Remove eye on puller for ATF-supply -T40123 A- and screw

into lower threaded hole for starter bolt as far as stop.

– Secure eye-head bolt -3368- to housing bore of gearbox with

two lock nuts -1-.

– Attach lifting tackle -2024 A- to both eyes and to workshop

hoist -VAS 6100- as shown in illustration.

Note

To adjust to the centre of gravity of the gearbox, the perforated rails of the support hooks must be positioned as shown.

WARNING

Accident risk from loose components of lifting tackle.

♦ The support hooks and retaining pins on the lifting tackle

must be secured with locking pins -arrows-.

3. Separating engine and dual-clutch gearbox 33

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Remove bolts -1 ... 8- securing gearbox to engine.

– Detach gearbox from engine.

Note

Disregard -item A-.

34 Rep. gr.10 - Removing and installing engine

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

4 Securing engine to engine and gear‐

box support

Special tools and workshop equipment required

♦ Lifting tackle -2024 A-

♦ Engine and gearbox support -VAS 6095-

Audi TT 2007 ➤

♦ Workshop hoist -VAS 6100-

♦ Engine bracket -T03001-

4. Securing engine to engine and gearbox support 35

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Procedure

• Gearbox detached from engine.

– Secure engine support -T03001- to cylinder block.

1 - 40 Nm

2 - 25 Nm

3 - 40 Nm

– 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

Accident risk from loose components of lifting tackle.

♦ The support hooks and retaining pins on the lifting tackle

must be secured with locking pins -arrows-.

– Lift engine off engine bracket -T03000- using workshop hoist

-VAS 6100- .

– Secure engine to engine and gearbox support -VAS 6095- us‐

ing engine bracket -T03001- .

36 Rep. gr.10 - Removing and installing engine

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

5 Installing engine

Tightening torques

Note

♦

Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts.

♦

Additional lubricants such as engine or gearbox oil may be used, but do not use lubricants containing graphite.

♦

Do not use degreased parts.

♦

Tolerance for tightening torques: ± 15%.

Component Nm

Bolts/nuts M6 10

M7 15

M8 22 M10 40 M12 65

Audi TT 2007 ➤

Manual gearbox to engine

Item Bolt Nm

1 M12x65 80 2 Securing starter ⇒ Electrical system; Rep.

gr. 27 3 M10x65 40 4 M10x75 40

5

1)

M12x95 80

A, B Dowel sleeves for centralising

1)

•

Screwed into gearbox from engine side

5. Installing engine 37

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Dual-clutch gearbox to engine

Item Bolt Nm

1 M12x65 80 2, 3, 4 M12x70 80 5, 6, 7 M10x60 40

8

1)

M12x95 80

A Dowel sleeves for centralising

1)

•

Screwed into gearbox from engine side

Procedure

• Engine/gearbox assembly attached to engine bracket T10012- .

Note

♦

Renew the bolts tightened with specified tightening angle.

♦

Renew self-locking nuts and bolts as well as seals, gaskets and O-rings.

♦

Hose connections and air pipes and hoses must be free of oil and grease before assembly.

♦

Secure all hose connections with the correct type of hose clips (same as original equipment) ⇒ Electronic parts catalogue .

♦

To ensure that the air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing.

♦

Routing and attachment of pipes, hoses and wiring in engine compartment ⇒ page 7 .

♦

Fit all cable ties in the original positions when installing.

Vehicles with manual gearbox:

– If not already fitted, install dowel sleeves -A, B- for centring

engine and gearbox in cylinder block.

– Renew clutch release bearing if worn ⇒ Rep. gr. 30 .

– Lubricate splines of gearbox input shaft lightly with grease for

clutch plate splines ⇒ Electronic parts catalogue .

– Make sure that clutch plate is properly centred.

38 Rep. gr.10 - Removing and installing engine

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Vehicles with dual clutch gearbox:

– If not already fitted, install dowel sleeves -A- for centring en‐

gine and gearbox in cylinder block.

All vehicles (continued):

– Secure gearbox to engine.

– Secure bracket for bevel box ⇒ Rep. gr. 34 .

– Install coolant pipe (left-side) ⇒ page 184 .

– Guide engine/gearbox assembly into body.

– Install engine mountings ⇒ page 42 .

Vehicles with manual gearbox:

– Initially screw in bolts -arrows- for gearbox mounting by hand

until they make contact.

Audi TT 2007 ➤

Vehicles with dual clutch gearbox:

– Initially screw in bolts -arrows- for gearbox mounting by hand

until they make contact.

All vehicles (continued):

– Detach engine support -T03000- from engine.

– Install pendulum support ⇒ Rep. gr. 34 .

Caution

Make sure not to damage the oil seal -arrow- in the propshaft flange.

♦ Push the propshaft horizontally to the rear as far as pos‐

sible.

Note

The propshaft must be renewed if oil seal is damaged.

– Push engine/gearbox assembly towards plenum chamber par‐

tition panel, guiding pin on bevel box flange carefully into propshaft flange.

5. Installing engine 39

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Secure propshaft with flexible coupling to bevel box ⇒ Rear

final drive 02D, 0AV, 0BR and 0BY; Rep. gr. 39 .

Remaining installation steps are carried out in reverse sequence; note the following:

– Install catalytic converters ⇒ page 226 .

– Install starter catalytic converter ⇒ page 225 .

– Install wishbones and drive shafts ⇒ Rep. gr. 40 .

– Install heat shield for drive shaft ⇒ Rep. gr. 39 .

Vehicles with manual gearbox:

– Installing and adjusting selector mechanism ⇒ Rep. gr. 34 .

Caution

Risk of contamination by escaping brake fluid.

♦ Do not operate clutch pedal before attaching pipe/hose

assembly to bleeder connection on clutch slave cylinder.

– Connect pipe/hose assembly to bleeder connection on clutch

slave cylinder and bleed clutch system ⇒ Rep. gr. 30 .

Vehicles with dual clutch gearbox:

– Install selector lever cable ⇒ Rep. gr. 34 .

All vehicles (continued):

– Install coolant pipe (right-side) ⇒ page 182 .

– Install radiator ⇒ page 194 .

– Install air pipes ⇒ page 216 .

– Install idler rollers and poly V-belt tensioner ⇒ page 53 .

– Install alternator ⇒ Electrical system; Rep. gr. 27 .

– Install poly V-belt for alternator and coolant pump

⇒ page 56 .

– Install air conditioner compressor ⇒ Rep. gr. 87 .

– Install poly V-belt for air conditioner compressor

⇒ page 55 .

– Install starter ⇒ Electrical system; Rep. gr. 27 .

– Install noise insulation frame ⇒ Rep. gr. 50 .

– Install noise insulation and front wheel housing liners (bottom

sections) ⇒ Rep. gr. 66 .

– Fit front wheels ⇒ Wheels and tyres; Rep. gr. 44 .

– Adjust assembly mountings ⇒ page 45 .

– Install engine control unit and air cleaner housing ⇒ Rep. gr.

24 .

– Install charge pressure sender -G31- / intake air temperature

sender 2 -G299- ⇒ page 205 .

– Electrical connections and routing ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations.

– Observe notes on procedure for connecting the battery ⇒

Electrical system; Rep. gr. 27 .

– Check oil level ⇒ Maintenance ; Booklet 810 .

40 Rep. gr.10 - Removing and installing engine

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Caution

Risk of irreparable damage to control units because of exces‐ sive voltage.

♦ Never use battery charging equipment for boost starting.

– Fill up with coolant ⇒ page 166 .

Note

Drained-off coolant may only be used again if the original cylinder head and cylinder block are re-installed.

Audi TT 2007 ➤

5. Installing engine 41

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

6 Assembly mountings

Overview

♦ ⇒ „6.1 Assembly mountings - exploded view“, page 42

♦ ⇒ „6.2 Checking adjustment of assembly mountings (engine/

gearbox mountings)“, page 43

♦ ⇒ „6.3 Adjusting assembly mountings“, page 45

♦ ⇒ „6.4 Removing and installing engine mountings“,

page 49

6.1 Assembly mountings - exploded view

1 - Bolt

❑ Renew ❑ 40 Nm + turn 90° further

2 - Bolt

❑ Renew ❑ 40 Nm + turn 90° further

3 - Bolt

❑ Renew ❑ 40 Nm + turn 90° further

4 - Bracket

❑ For activated charcoal

filter

5 - Bolt

❑ Tightening torque

⇒ Item 11 (page 182)

6 - Nut

❑ 8 Nm

7 - Engine mounting

❑ Checking adjustment

⇒ page 43

❑ Adjusting ⇒ page 45 ❑ Removing and installing

⇒ page 49

8 - Connecting bracket

9 - Bolt

❑ Renew ❑ 20 Nm + turn 90° further

10 - Bolt

❑ Renew ❑ 20 Nm + turn 90° further

11 - Bolt

❑ Renew ❑ 40 Nm + turn 90° further

12 - Pendulum support

❑ Removing and installing ⇒ Rep. gr. 34

42 Rep. gr.10 - Removing and installing engine

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

13 - Bolt

❑ Tightening torque ⇒ Rep. gr. 34

14 - Bolt

❑ Tightening torque ⇒ Rep. gr. 34

15 - Bolt

❑ Tightening torque ⇒ Rep. gr. 34

16 - Bolt

❑ Tightening torque ⇒ Rep. gr. 34

17 - Bolt

❑ Tightening torque ⇒ Rep. gr. 34

18 - Gearbox mounting

❑ Checking adjustment ⇒ page 43 ❑ Adjusting ⇒ page 45 ❑ Removing and installing ⇒ Rep. gr. 34

6.2 Checking adjustment of assembly mountings (engine/gearbox mountings)

Audi TT 2007 ➤

Special tools and workshop equipment required

♦ Gauge -T40226-

Procedure

– Lift off engine cover panel -1- -arrows-.

6. Assembly mountings 43

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Remove air cleaner housing ⇒ Rep. gr. 24 .

Vehicles with manual gearbox:

– Open wiring duct brackets -arrows-.

– Cut through cable ties and press electrical wiring to side.

– Unclip wiring duct.

– Fit gauge -T40226- onto bolt heads of gearbox mounting (left-

side) and press in.

– Engage bridge of -T40226- onto rib on gearbox casting

-arrow- as shown in illustration.

• Distance of gap between adjusting tool and gearbox mounting must be equal at front and rear.

• Distance -x- rear = -x- front (parallel) or

• Dimension -x- rear = dimension -x- front = „0“ (no gap).

44 Rep. gr.10 - Removing and installing engine

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Vehicles with dual clutch gearbox:

– Ensure that edges of support arm (on gearbox side) -1- and

gearbox mounting -2- are parallel.

• Dimension -x- = dimension -x-.

All vehicles (continued):

– Check installation position at engine mounting:

• The distance -a- between support arm and engine mounting must be at least 9 mm.

Note

Audi TT 2007 ➤

Distance -a- can be checked using a ∅ 9 mm drill bit or similar.

– If the distance measured is too small, the assembly mounting

must be adjusted ⇒ page 45 .

6.3 Adjusting assembly mountings

Special tools and workshop equipment required

♦ Support bracket -10 - 222 A-

♦ Adapter -10 - 222 A /20-

6. Assembly mountings 45

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

♦ Gauge -T40226-

Procedure

– Loosen bolts -1, 2, 3- for pendulum support approx. 1 turn (do

not remove).

– Lift off engine cover panel -1- -arrows-.

– Remove air cleaner housing ⇒ Rep. gr. 24 .

46 Rep. gr.10 - Removing and installing engine

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Position support bracket -10 - 222 A- on top edges of body

flanges as shown in illustration.

• One spindle -10 - 222 A /11- should be at front, one at rear.

WARNING

Risk of accident.

♦ The support hooks and retaining pin on the lifting tackle

must be secured with a locking pin -arrow-.

– Attach spindle -10 - 222 A /11- (front) with adapter -10 - 222

A /20- to engine lifting eye (front left).

– Attach spindle -10 - 222 A /11- (rear) to engine lifting eye (rear

left).

– Apply light tension to spindles.

• The engine must be positioned in installation position, assem‐ bly mountings must not be under load.

Vehicles with manual gearbox:

– Open wiring duct brackets -arrows-.

– Cut through cable ties and press electrical wiring to side.

– Unclip wiring duct.

Audi TT 2007 ➤

– Remove bolts -arrows- securing gearbox mounting.

– Renew all three bolts one by one and screw in by hand until

they make contact.

6. Assembly mountings 47

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Fit gauge -T40226- onto bolt heads of gearbox mounting (left-

side) and press in.

– Engage bridge of gauge -T40226- onto rib on gearbox casting

-arrow- as shown in illustration.

– Place engine/gearbox assembly in installation position; en‐

sure that it is free of stress by shaking assembly to align it.

• Distance of gap between adjusting tool and gearbox mounting must be equal at front and rear.

• Distance -x- rear = -x- front (parallel) or

• Dimension -x- rear = dimension -x- front = „0“ (no gap).

– Check installation position at engine mounting:

• The distance -a- between support arm and engine mounting must be at least 9 mm.

Note

Distance -a- can be checked using a ∅ 9 mm drill bit or similar.

– Move engine/gearbox assembly sideways if necessary.

– Tighten gearbox mounting bolts -arrows- with fitted gauge -

T40226- ⇒ Rep. gr. 34 .

Vehicles with dual clutch gearbox:

– Remove bolts -arrows- securing gearbox mounting.

– Renew all three bolts one by one and screw in by hand until

they make contact.

48 Rep. gr.10 - Removing and installing engine

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Ensure that edges of support arm (on gearbox side) -1- and

gearbox mounting -2- are parallel.

• Dimension -x- = dimension -x-.

– Tighten gearbox mounting bolts ⇒ Rep. gr. 34 .

– Check installation position at engine mounting:

• The distance -a- between support arm and engine mounting must be at least 9 mm.

Note

Distance -a- can be checked using a ∅ 9 mm drill bit or similar.

Audi TT 2007 ➤

– Move engine/gearbox assembly sideways if necessary.

All vehicles (continued):

Installation is carried out in the reverse order; note the following:

– Tighten bolts -1, 2, 3- for pendulum support ⇒ Rep. gr. 34 .

– Install air cleaner housing ⇒ Rep. gr. 24 .

6.4 Removing and installing engine mount‐

ings

Special tools and workshop equipment required

♦ Support bracket -10 - 222 A-

6. Assembly mountings 49

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Removing

– Remove front wheel (right-side) ⇒ Wheels and tyres; Rep. gr.

44 .

– Remove bottom section of front wheel housing liner (right-

side) ⇒ Rep. gr. 66 .

– Remove one bolt of front wheel housing (right-side).

– Release activated charcoal filter -arrow B-, lift off -arrow A- and

move clear to one side with hose -1- connected.

Note

Disregard -item 2-.

– Remove bolts -arrows- and detach bracket for activated char‐

coal filter.

Note

Disregard -item 1-.

– Remove bolts -arrows-.

– Detach electrical connector -1- for coolant shortage indicator

switch -F66- and move coolant expansion tank with coolant pipe (right-side) to side.

50 Rep. gr.10 - Removing and installing engine

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Position support bracket -10 - 222 A- on top edges of body

flanges as shown in illustration.

• The spindle -10 - 222 A /11- is located at the front.

– Attach hook of spindle to engine lifting eye (right-side).

– Apply light tension to spindle.

– Remove bolts -1- and -arrows- for engine mounting (left-side).

Note

The bolt at the rear of the cylinder block can be accessed from the wheel housing side.

Installing

• Tightening torques

⇒ „6.1 Assembly mountings - exploded view“, page 42

– Check adjustment of assembly mountings (engine/gearbox

mountings) ⇒ page 43 .

Remaining installation steps are carried out in reverse sequence; note the following:

– Install bottom section of front wheel housing liner ⇒ Rep. gr.

66 .

– Fit front wheel ⇒ Wheels and tyres; Rep. gr. 44 .

Audi TT 2007 ➤

6. Assembly mountings 51

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

13 – Crankshaft group

1 Cylinder block (pulley end)

Overview

♦ ⇒ „1.1 Poly V-belt drive, bracket for ancillaries - exploded

view“, page 53

♦ ⇒ „1.2 Removing and installing poly V-belt for A/C compres‐

sor“, page 55

♦ ⇒ „1.3 Removing and installing poly V-belt for alternator and

coolant pump“, page 56

♦ ⇒ „1.4 Removing and installing poly V-belt tensioner for air

conditioner compressor“, page 57

♦ ⇒ „1.5 Removing and installing poly V-belt tensioner for alter‐

nator and coolant pump“, page 57

♦ ⇒ „1.6 Removing and installing bracket for ancillaries“,

page 58

♦ ⇒ „1.7 Removing and installing vibration damper“, page 59

♦ ⇒ „1.8 Sealing flange (pulley end) - exploded view“,

page 62

♦ ⇒ „1.9 Renewing sealing flange (pulley end)“, page 62

52 Rep. gr.13 - Crankshaft group

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

1.1 Poly V-belt drive, bracket for ancillaries - exploded view

1 - Bolt

❑ 35 Nm

2 - Bolt

❑ Renew ❑ 50 Nm + turn 90° further

3 - Vibration damper

❑ Removing and installing

⇒ page 59

❑ Can only be installed in

one position

4 - Poly V-belt for air condition‐ er compressor

❑ Check for wear ❑ Before removing, mark

direction of rotation with chalk or felt-tipped pen

❑ Removing and installing

⇒ page 55

❑ Do not kink ❑ When installing, make

sure it is properly seated

on pulleys.

5 - Tensioner

❑ For poly V-belt for air

conditioner compressor ❑ Removing and installing

⇒ page 57

6 - Bolt

❑ 35 Nm

7 - Tensioner

❑ For poly V-belt for alter‐

nator and coolant pump ❑ Removing and installing ⇒ page 57

8 - Poly V-belt for alternator and coolant pump

❑ Check for wear ❑ Before removing, mark direction of rotation with chalk or felt-tipped pen ❑ Removing and installing ⇒ page 56 ❑ Do not kink ❑ When installing, make sure it is properly seated on pulleys.

9 - Idler roller

10 - Bolt

❑ Tightening torque ⇒ Item 2 (page 173)

11 - Coolant pump

❑ Removing and installing ⇒ page 176

12 - Bolt

❑ 8 Nm

13 - Dowel sleeves

❑ For bracket for ancillaries

Audi TT 2007 ➤

1. Cylinder block (pulley end) 53

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

14 - Bracket for ancillaries

❑ Removing and installing ⇒ page 58

15 - Bolt

❑ Different lengths ❑ Tightening torque and sequence ⇒ page 54

16 - Bolt

❑ Tightening torque ⇒ Electrical system; Rep. gr. 27

17 - Alternator

❑ Removing and installing ⇒ Electrical system; Rep. gr. 27

18 - Sliding bush

19 - Idler roller

20 - Bolt

❑ 23 Nm

21 - Dowel sleeves

❑ For air conditioner compressor

22 - Air conditioner compressor

❑ With double-sided poly V-belt pulley ❑ Removing and installing ⇒ Rep. gr. 87

23 - Bolt

❑ Tightening torque ⇒ Rep. gr. 87

Bracket for ancillaries - tightening torque and tightening sequence

– Renew bolts for bracket for ancillaries and fit as follows:

♦ Bolts -1, 2, 3, 6- M8x30.

♦ Bolt -4- M8x60.

♦ Bolt -5- M8x110.

– Tighten bolts in 2 stages in the sequence shown:

Stage Bolts Tightening torque

1. -1 … 6- Screw in bolts by hand until they make contact

2. -1 … 6- 23 Nm

54 Rep. gr.13 - Crankshaft group

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

1.2 Removing and installing poly V-belt for A/C compressor

Removing

– Remove front wheel (right-side) ⇒ Wheels and tyres; Rep. gr.

44 .

– Remove bottom section of front wheel housing liner (right-

side) ⇒ Rep. gr. 66 .

Caution

If a used belt runs in the opposite direction when it is refitted, this can cause breakage.

Audi TT 2007 ➤

♦ Before removing, mark direction of rotation of poly V-belt

for air conditioner compressor with chalk or felt-tipped pen for re-installation.

– To slacken poly V-belt turn tensioner in clockwise direction

-arrow-.

– Detach poly V-belt for air conditioner compressor and release

tensioner.

Installing

Installation is carried out in the reverse order; note the following:

– Swivel tensioner in clockwise direction -arrow-.

– Fit poly V-belt on poly V-belt pulleys (on air conditioner pulley

last).

1 - Vibration damper

2 - Tensioner

3 - Air conditioner compressor

– Slacken tensioner.

– Check that poly V-belt is properly seated.

– Start engine and check that belt runs properly.

– Install bottom section of front wheel housing liner ⇒ Rep. gr.

66 .

– Fit front wheel ⇒ Wheels and tyres; Rep. gr. 44 .

1. Cylinder block (pulley end) 55

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

1.3 Removing and installing poly V-belt for alternator and coolant pump

Removing

– Remove poly V-belt for air conditioner compressor

⇒ page 55 .

– Release activated charcoal filter -arrow B-, lift off -arrow A- and

move clear to one side with hose -1- connected.

Note

Disregard -item 2-.

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

for alternator and coolant pump with chalk or felt-tipped pen for re-installation.

– To slacken poly V-belt turn tensioner in clockwise direction

-arrow-.

– Detach poly V-belt for alternator and coolant pump and re‐

lease tensioner.

Installing

Installation is carried out in the reverse order; note the following:

– Swivel tensioner in clockwise direction -arrow-.

– Fit poly V-belt on poly V-belt pulleys (on alternator pulley last).

1 - Tensioner

2 - Coolant pump

3 - Idler roller

4 - Alternator

5 - Idler roller

6 - Air conditioner compressor

– Slacken tensioner.

– Check that poly V-belt is properly seated.

– Install poly V-belt for air conditioner compressor ⇒ page 55 .

56 Rep. gr.13 - Crankshaft group

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

1.4 Removing and installing poly V-belt ten‐ sioner for air conditioner compressor

Removing

– Remove poly V-belt for air conditioner compressor

⇒ page 55 .

– Remove front noise insulation -1- ⇒ Rep. gr. 66 .

– Remove bolts -arrows- and detach bracket -1- for auxiliary ra‐

diator.

Audi TT 2007 ➤

– Remove bolt -arrow- and take off tensioner.

Installing

Installation is carried out in the reverse order; note the following:

• Tightening torque

⇒ „1.1 Poly V-belt drive, bracket for ancillaries - exploded view“, page 53

– Install bracket for auxiliary radiator ⇒ page 192 .

– Install front noise insulation ⇒ Rep. gr. 66 .

– Install poly V-belt for air conditioner compressor ⇒ page 55 .

1.5 Removing and installing poly V-belt ten‐ sioner for alternator and coolant pump

Removing

– Release activated charcoal filter -arrow B-, lift off -arrow A- and

move clear to one side with hose -1- connected.

Note

Disregard -item 2-.

1. Cylinder block (pulley end) 57

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– To slacken poly V-belt turn tensioner in clockwise direction

-arrow-.

– Remove poly V-belt from alternator and release tensioner.

– Remove bolt -arrow- and take off tensioner.

Installing

Installation is carried out in the reverse order; note the following:

• Tightening torque

⇒ „1.1 Poly V-belt drive, bracket for ancillaries - exploded view“, page 53

– Install poly V-belt for alternator and coolant pump

⇒ page 56 .

1.6 Removing and installing bracket for an‐

cillaries

Removing

– Remove poly V-belt tensioner for air conditioner compressor

⇒ page 57 .

– Remove alternator ⇒ Electrical system; Rep. gr. 27 .

– Remove engine mounting ⇒ page 49 .

– Remove noise insulation frame -arrow- together with rear

noise insulation ⇒ Rep. gr. 50 .

– Remove radiator cowl ⇒ page 200 .

58 Rep. gr.13 - Crankshaft group

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Unplug electrical connector -1- on air conditioner compressor

regulating valve -N280- .

Caution

Danger of damage to refrigerant lines and hoses.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.

– Remove bolts -arrows-.

– Detach air conditioner compressor from bracket and tie up to

lock carrier.

– Remove bolt -arrow-.

– Remove bolts -1 ... 6- and detach bracket for ancillaries.

Installing

Installation is carried out in the reverse order; note the following:

– Tighten bolts for bracket for ancillaries ⇒ page 54 .

– Install air conditioner compressor ⇒ Rep. gr. 87 .

– Install radiator cowl ⇒ page 200 .

– Install noise insulation frame ⇒ Rep. gr. 50 .

– Install engine mountings ⇒ page 49 .

– Install alternator ⇒ Electrical system; Rep. gr. 27 .

– Install poly V-belt tensioner for air conditioner compressor

⇒ page 57 .

Audi TT 2007 ➤

1.7 Removing and installing vibration damp‐ er

Special tools and workshop equipment required

♦ Socket -T03003-

1. Cylinder block (pulley end) 59

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

♦ Locking pin -T40069-

Removing

– Remove poly V-belt for air conditioner compressor

⇒ page 55 .

– Remove noise insulation panel -1- and -2- ⇒ Rep. gr. 66 .

– Turn crankshaft with socket -T03003- in normal direction of

rotation -arrow- to „TDC position“.

• Notch -1- in socket -T03003- must be perpendicular to sealing surface of sump.

• Marking -2- on vibration damper must be opposite marking

-3- on sealing flange.

– Unscrew plug -arrow- for „TDC“ marking from cylinder block.

60 Rep. gr.13 - Crankshaft group

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Screw locking pin -T40069- into locating groove and tighten to

15 Nm. If necessary, turn crankshaft backwards and forwards slightly to fully centralise locking pin.

– Unscrew bolts -arrow- and remove vibration damper.

Installing

Installation is carried out in the reverse order; note the following:

• Tightening torque

⇒ „1.1 Poly V-belt drive, bracket for ancillaries - exploded view“, page 53

Audi TT 2007 ➤

Note

♦

Renew the bolts tightened with specified tightening angle.

♦

The vibration damper can only be fitted in one position.

– Remove locking pin -T40069- .

– Tighten plug for „TDC“ marking ⇒ page 72 .

– Install noise insulation panels ⇒ Rep. gr. 66 .

– Install poly V-belt for air conditioner compressor ⇒ page 55 .

1. Cylinder block (pulley end) 61

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

1.8 Sealing flange (pulley end) - exploded view

1 - Bolt

❑ Tightening torque

⇒ Item 2 (page 53)

2 - Vibration damper

❑ Removing and installing

⇒ page 59

❑ Can only be installed in

one position

3 - Sealing flange (pulley end)

❑ With centring collar ❑ Renewing ⇒ page 62 ❑ Apply sealant when in‐

stalling; refer to ⇒ Elec‐ tronic parts catalogue

4 - Bolt

❑ Tightening torque and

sequence ⇒ page 62

Sealing flange (pulley end) - tightening torque and sequence

– Tighten bolts in 2 stages:

Stage Bolts Tightening torque

1. -arrow- Screw in bolts by hand until they make contact.

2. -arrow- Tighten in stages and in diagonal se‐ quence; final torque 9 Nm.

1.9 Renewing sealing flange (pulley end)

Special tools and workshop equipment required

62 Rep. gr.13 - Crankshaft group

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

♦ Assembly sleeve -T03004-

♦ Electric drill with plastic brush

♦ Safety goggles

♦ Sealant ⇒ Electronic parts catalogue

Procedure

– Remove vibration damper ⇒ page 59 .

– Remove noise insulation frame -arrow- together with rear

noise insulation ⇒ Rep. gr. 50 .

Audi TT 2007 ➤

– Remove bolts -1- and -2-.

– Release hose clips -arrows- and remove air pipe.

1. Cylinder block (pulley end) 63

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Remove bolts -arrows-.

– Carefully release sealing flange from bonded joint.

Note

Renew sealing flange.

Caution

Make sure sealant residue does not enter lubrication system.

♦ Cover open area of cylinder block with a cloth.

WARNING

Protect eyes against injuries.

♦ Wear safety goggles.

– Use e.g. rotating plastic brush to remove sealant residue on

cylinder block.

– Clean sealing surfaces and crankshaft journal; they must be

free of oil and grease.

Note

Do not additionally oil or grease sealing lip of oil seal in sealing flange.

Caution

Risk of damage to oil seal in sealing flange.

♦ To make sure sealing lip of oil seal is folded over when

installing, the following procedures must be performed.

– Open out sealing lip of oil seal in sealing flange using assembly

sleeve -T03004- as shown in illustration.

• Small diameter faces oil seal.

– Detach assembly sleeve -T03004- after a short while, turn

over and insert in oil seal again.

• Large diameter faces oil seal.

• Assembly sleeve -T03004- must protrude by distance -a- at inside of flange

• Distance -a- = approx. 3 mm.

64 Rep. gr.13 - Crankshaft group

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Note

Note the use-by date of the sealant.

– Cut off nozzle of tube at front marking (nozzle ∅ approx. 2

mm).

Caution

Make sure lubrication system is not clogged by excess sealant.

♦ The bead of sealant must not be thicker than specified.

– Apply bead of sealant -A- onto clean sealing surface of sealing

flange as shown in illustration.

• Width of sealant bead: 2.5 ... 3 mm

• The bead of sealant must project approx. 1.0 mm above the sealing surface.

Audi TT 2007 ➤

Note

The sealing flange must be installed within 5 minutes after apply‐ ing the sealant.

– Use assembly sleeve -T03004- to carefully fit sealing flange

onto crankshaft journal and press onto cylinder block evenly (note centring collar on left and right).

– Tighten sealing flange ⇒ page 62 .

– Install air pipe ⇒ page 216 .

– Install noise insulation frame ⇒ Rep. gr. 50 .

– Install vibration damper ⇒ page 59 .

1. Cylinder block (pulley end) 65

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

2 Cylinder block (gearbox end)

Overview

♦ ⇒ „2.1 Dual-mass flywheel - exploded view“, page 66

♦ ⇒ „2.2 Removing and installing dual-mass flywheel“,

page 67

♦ ⇒ „2.3 Renewing crankshaft oil seal (gearbox end)“,

page 68

Note

♦

When performing assembly work, secure engine to engine and gearbox support ⇒ page 35 .

♦

Servicing clutch ⇒ Rep. gr. 30

2.1 Dual-mass flywheel - exploded view

1 - Bolt

❑ Renew ❑ 60 Nm + turn 90° further

2 - Dual-mass flywheel

❑ Different versions avail‐

able; for allocation refer to ⇒ Electronic parts catalogue

❑ Removing and installing

⇒ page 67

❑ Can only be installed in

one position

3 - Diamond-coated washer

❑ Must always be re‐

newed if bolts for dualmass flywheel are loos‐ ened

❑ Can only be installed in

one position

4 - Sender wheel

❑ For engine speed send‐

er -G28-

❑ Can only be installed in

one position

5 - Dowel pin

6 - Crankshaft oil seal (gearbox end)

❑ Renewing ⇒ page 68

7 - Diamond-coated washer

❑ Must always be re‐

newed if bolts for dualmass flywheel are loos‐ ened

❑ Can only be installed in one position

66 Rep. gr.13 - Crankshaft group

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

2.2 Removing and installing dual-mass fly‐

wheel

Special tools and workshop equipment required

♦ Counterhold tool -3067-

Removing

• Gearbox removed.

Audi TT 2007 ➤

Caution

Make sure dual-mass flywheel is not damaged.

♦ Remove bolts -B- using normal hand tools (do not use

pneumatic wrench or impact driver, etc.).

♦ When removing the bolts, make sure that the bolt heads

do not come into contact with the dual-mass flywheel.

♦ Rotate the dual-mass flywheel -A- so that the bolts -B-

align centrally with the holes -arrows-.

– Insert counterhold tool -3067- in hole on cylinder block

-item B-, slacken and remove bolts for dual-mass flywheel.

Installing

Installation is carried out in the reverse order; note the following:

• Tightening torque

⇒ „2.1 Dual-mass flywheel - exploded view“, page 66

Caution

Make sure friction is sufficient.

♦ Always renew diamond-coated washers

⇒ Item 3 (page 66) and ⇒ Item 7 (page 66) after loosening

bolts for dual-mass flywheel.

Note

♦

Renew the bolts tightened with specified tightening angle.

♦

Dual-mass flywheel with sender wheel and diamond-coated washers can only be fitted in one position.

– Insert counterhold -3067- in hole on cylinder block -item A-.

2. Cylinder block (gearbox end) 67

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

2.3 Renewing crankshaft oil seal (gearbox end)

Special tools and workshop equipment required

♦ Fitting tool -T10122-

♦ Extractor tool -T20143/2-

Set up assembly sleeve -T10122/2- as follows:

– Machine drilling for dowel sleeve in assembly sleeve -

T10122/2- until dimension -a- = 8 mm.

Procedure

• Gearbox removed.

– Remove dual-mass flywheel ⇒ page 67 .

– Pry out oil seal using extractor tool -T20143/2- -arrow-.

– Clean contact surface and sealing surface.

68 Rep. gr.13 - Crankshaft group

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Fit assembly aid -T10122/1- onto assembly sleeve -T10122/2-

and slide oil seal -A- onto assembly sleeve.

– Detach assembly aid.

– Fit assembly sleeve -T10122/2- with oil seal -1- onto crank‐

shaft.

Audi TT 2007 ➤

– Press in oil seal uniformly until flush all round using thrust

piece -T10122/3- .

– Install dual-mass flywheel ⇒ page 67 .

2. Cylinder block (gearbox end) 69

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

3 Crankshaft

Overview

♦ ⇒ „3.1 Crankshaft - exploded view“, page 70

♦ ⇒ „3.2 Crankshaft dimensions“, page 72

♦ ⇒ „3.3 Measuring axial clearance of crankshaft“, page 72

♦ ⇒ „3.4 Measuring radial clearance of crankshaft“, page 73

Note

♦

When performing assembly work, secure engine to engine and gearbox support ⇒ page 35 .

♦

If large quantities of metal shavings or abrasion are found when performing engine repairs, this may be an indication of damage to the crankshaft or conrod bearings. To prevent fur‐ ther damage, the following steps are required after completion of repair work: clean the oil galleries carefully and renew the oil spray jets, engine oil cooler and oil filter.

3.1 Crankshaft - exploded view

1 - Bolt

❑ Renew ❑ 40 Nm + turn 90° further

2 - Bearing caps

❑ Bearing cap 1: Pulley

end

❑ Installation position: re‐

taining lugs on bearing shells in cylinder block and bearing caps must be on the same side

3 - Bearing shell

❑ For bearing cap (without

oil groove)

❑ Mark used bearing

shells for re-installation but not on bearing sur‐ face

❑ Bearing shells worn

down to base layer must be renewed

❑ Insert new bearing

shells with correct col‐ our-coding ⇒ page 71

4 - Crankshaft

❑ Measuring axial clear‐

ance ⇒ page 72

❑ Measuring radial clear‐

ance ⇒ page 73

❑ Crankshaft dimensions

⇒ page 72

5 - Thrust washers

❑ For bearing No. 3

70 Rep. gr.13 - Crankshaft group

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Audi TT 2007 ➤

5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

6 - Bearing shell

❑ For cylinder block (with oil groove) ❑ Mark used bearing shells for re-installation but not on bearing surface ❑ Bearing shells worn down to base layer must be renewed ❑ Install new bearing shells for the cylinder block with the correct coloured markings ⇒ page 71

7 - Cylinder block

Allocation of crankshaft bearing shells for cylinder block

♦ Bearing shells of the correct thickness are matched to the

bearings in the cylinder block at the factory. Coloured dots on the side of the bearing shells are used to identify the bearing shell thickness.

♦ Letter codes on the lower sealing surface of the cylinder block

indicate the thickness of the bearing shell to be fitted at each location.

Letter on cylinder block Colour coding of bearing

G = Yellow

B = Blue

W = White

Note

The -arrow- points in direction of travel.

Allocation of crankshaft bearing shells for bearing caps

♦ Bearing shells of the correct thickness are assigned to the

bearing caps at the factory. Coloured dots on the side of the bearing shells are used to identify the bearing shell thickness.

♦ The correct allocation of bearing shells to bearing cap is indi‐

cated by a sequence of letters on the pulley flange of the crankshaft. The first letter in the sequence stands for bearing „1“, the second letter for bearing „2“, etc.

Letter on crankshaft Colour coding of bearing

R = Red G = Yellow

B = Blue

W = White

Note

The -arrow- points in direction of travel.

3. Crankshaft 71

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Plug for „TDC“ marking - tightening torque

Note

Renew seal.

– Tighten plug -arrow- for „TDC“ marking to 45 Nm.

3.2 Crankshaft dimensions

Honing di‐ mension

Basic dimen‐ sion

Main bearing journal ∅mmConrod journal ∅

mm

58.000 – 0.022 – 0.042

47.800 – 0.022 – 0.042

3.3 Measuring axial clearance of crankshaft

Special tools and workshop equipment required

♦ Universal dial gauge bracket -VW 387-

♦ Dial gauge -VAS 6079-

72 Rep. gr.13 - Crankshaft group

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Procedure

– Secure dial gauge -VAS 6079- with universal dial gauge brack‐

et -VW 387- to cylinder block as shown in illustration.

– Apply dial gauge to crank web.

– Press crankshaft against dial gauge by hand and set gauge to

„0“.

– Push crankshaft away from dial gauge and read off value.

Axial clearance:

• New: 0.07 ... 0.21 mm.

• Wear limit: 0.30 mm.

3.4 Measuring radial clearance of crank‐ shaft

Special tools and workshop equipment required

♦ Plastigage

Procedure

Audi TT 2007 ➤

Note

♦

Mark used bearing shells for re-installation (but do not mark bearing surface).

♦

Bearing shells worn down to the base layer must be renewed.

– Remove bearing cap.

– Clean bearing cap and bearing journal.

– Place a length of Plastigage corresponding to the width of the

bearing on the bearing journal or in the bearing shell.

• The Plastigage must be positioned in the centre of the bearing

shell.

– Fit bearing cap and tighten bolts to 40 Nm (do not turn further)

without rotating crankshaft.

– Remove bearing cap again.

– Compare width of Plastigage with measurement scale.

Radial clearance:

• New: 0.023 ... 0.043 mm.

• Wear limit: 0.07 mm.

3. Crankshaft 73

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

4 Pistons and conrods

Overview

♦ ⇒ „4.1 Pistons and conrods - exploded view“, page 74

♦ ⇒ „4.2 Piston and cylinder dimensions“, page 77

♦ ⇒ „4.3 Measuring radial clearance of conrods“, page 77

Note

♦

All bearing and running surfaces must be oiled before assem‐ bling.

♦

Oil spray jet and pressure relief valve ⇒ page 77

4.1 Pistons and conrods - exploded view

1 - Bolts

❑ Renew ❑ Lubricate threads and

contact surface

❑ 45 Nm + turn 90° further

2 - Conrod bearing cap

❑ Note installation posi‐

tion

❑ Due to the cracking

method used to sepa‐ rate the bearing cap from the conrod in man‐ ufacture, the caps only fit in one position and only on the appropriate conrod

❑ Mark cylinder allocation

in colour -B-

❑ Installation position:

Markings -A- face to‐ wards pulley end

3 - Bearing shells

❑ Without oil drilling ❑ Installation position

⇒ page 76

❑ Mark used bearing

shells for re-installation but not on bearing sur‐ face

❑ Bearing shells worn

down to base layer must be renewed

4 - Conrod

❑ Only renew as a com‐

plete set ❑ Mark cylinder allocation in colour -B❑ Installation position: Markings -A- face towards pulley end ❑ Measuring radial clearance ⇒ page 77 ❑ Separating parts of new conrod ⇒ page 76

74 Rep. gr.13 - Crankshaft group

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5 - Circlip

❑ Renew

6 - Piston pin

❑ If difficult to remove, heat piston to approx. 60 °C ❑ Remove and install using drift -VW 222 A-

7 - Piston

❑ Checking ⇒ page 76 ❑ Mark installation position to conrod and cylinder allocation ❑ Installation position: arrow on piston crown points to pulley end ❑ Install using piston ring clamp ❑ Measuring cylinder bore ⇒ page 76 ❑ Piston and cylinder dimensions ⇒ page 77

8 - Piston rings

❑ Offset gaps by 120° ❑ Use piston ring pliers to remove and install ❑ Inscription „TOP“ faces towards piston crown ❑ Measuring ring gap ⇒ page 75 ❑ Measuring ring-to-groove clearance ⇒ page 75

Audi TT 2007 ➤

Measuring piston ring gap

– Insert ring at right angle to cylinder wall from above and push

down into lower cylinder opening approx. 15 mm from bottom of cylinder.

– To do so, use a piston without rings.

– Check gap using feeler gauge.

Piston ring new

mm

Wear limit

mm

Compression rings 0.20 … 0.40 0.8 Oil scraper ring 0.25 … 0.50 0.8

Measuring ring-to-groove clearance

– Clean annular groove of piston.

– Check gap using feeler gauge.

Piston ring new

mm

Wear limit

mm

Compression rings 0.06 … 0.09 0.20 Oil scraper ring 0.03 … 0.06 0.15

4. Pistons and conrods 75

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Checking piston

– Using a micrometer (75 ... 100 mm), measure approx. 10 mm

from the lower edge, perpendicular to the piston pin axis.

• Maximum deviation from nominal dimension: 0.04 mm.

Nominal dimension

⇒ „4.2 Piston and cylinder dimensions“, page 77 .

Checking cylinder bore

– Use an internal dial gauge -VAS 6078- to take measurements

at 3 points in transverse direction -A- and in longitudinal di‐ rection -B-.

• Maximum deviation from nominal dimension: 0.08 mm.

Nominal dimension

⇒ „4.2 Piston and cylinder dimensions“, page 77 .

Installation position of bearing shells in conrods

– Insert bearing shells centrally in conrod/conrod bearing cap.

• Distance -a- = approx. 1.5 mm.

Separating parts of new conrod

It is possible that the two parts of a new conrod are not completely separated as intended. If it is not possible to take off the conrod bearing cap by hand, proceed as follows:

– To avoid any risk of damage, the conrod should only be clam‐

ped lightly in a vice using jaw covers as shown in illustration.

• The conrod is clamped in position below the dotted line.

– Unscrew bolts -arrows- approx. 5 turns.

76 Rep. gr.13 - Crankshaft group

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Using a plastic hammer, carefully knock conrod bearing cap

loose -arrow-.

Oil spray jet and pressure relief valve

1 - Bolt with pressure relief valve, 27 Nm

2 - Oil spray jet (for cooling of pistons)

• Installation position: align locating edge of oil spray jet with machined surface of cylinder block.

Note

Audi TT 2007 ➤

♦

Take care not to bend oil spray jets.

♦

Always renew bent oil spray jets.

4.2 Piston and cylinder dimensions

Honing dimension (in mm)

Basic dimension

1)

•

Dimensions not including coating (thickness 0.02 mm).

Diameter of piston Diameter of cylinder

bore

82.451

1)

82.510

The coating will wear down in service.

4.3 Measuring radial clearance of conrods

Special tools and workshop equipment required

♦ Plastigage

Procedure

– Remove conrod bearing cap. Clean bearing cap and bearing

journal.

– Place a length of Plastigage corresponding to the width of the

bearing on the bearing journal or in the bearing shell.

• The Plastigage must be positioned in the centre of the bearing shell.

– Fit conrod bearing cap and tighten bolts to 45 Nm (do not turn

further) without rotating crankshaft.

– Remove conrod bearing cap again.

– Compare width of Plastigage with measurement scale.

Radial clearance:

• New: 0.02 ... 0.06 mm.

• Wear limit: 0.09 mm.

– Renew conrod bolts.

4. Pistons and conrods 77

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

15 – Cylinder head, valve gear

1 Chain drive

Overview

♦ ⇒ „1.1 Timing chain covers - exploded view“, page 79

♦ ⇒ „1.2 Removing and installing timing chain cover (top)“, page

80

♦ ⇒ „1.3 Renewing oil seal in timing chain cover (top)“,

page 83

♦ ⇒ „1.4 Removing and installing timing chain cover (bottom)“,

page 84

♦ ⇒ „1.5 Camshaft timing chain - exploded view“, page 89

♦ ⇒ „1.6 Removing and installing camshaft timing chain“,

page 90

♦ ⇒ „1.7 Drive chain for valve gear - exploded view“, page 96

♦ ⇒ „1.8 Removing and installing drive chain for valve gear“,

page 97

78 Rep. gr.15 - Cylinder head, valve gear

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

1.1 Timing chain covers - exploded view

1 - Engine speed sender -G28-

❑ Removing and installing

⇒ Rep. gr. 28

2 - Crankshaft oil seal (gearbox end)

❑ Renewing ⇒ page 68

3 - Dowel sleeve

4 - Bolt

❑ Tightening torque and

sequence ⇒ page 80

5 - O-ring

❑ Renew

6 - Cylinder head gasket

7 - Centre hex stud

❑ Tightening torque and

sequence ⇒ page 80

8 - Nut

❑ 8 Nm

9 - Bracket

❑ For engine cover panel,

high-pressure line and exhaust gas tempera‐ ture sender 1 -G235-

10 - Bolt

❑ 8 Nm

11 - Nut

❑ 8 Nm

12 - Bracket

❑ For engine cover panel

and electrical connec‐ tors

13 - Centre hex stud

❑ Tightening torque and sequence ⇒ page 80

14 - Filler cap for oil filler neck

15 - Grommet

16 - Upper cover for timing chains

❑ Removing and installing ⇒ page 80 ❑ Apply sealant when installing; refer to ⇒ Electronic parts catalogue

17 - Bolt

❑ Tightening torque and sequence ⇒ page 80

18 - Seal

❑ Renewing ⇒ page 83

19 - Sealing sleeve

❑ Renew

20 - Timing chain cover (bottom)

❑ Removing and installing ⇒ page 84

Audi TT 2007 ➤

1. Chain drive 79

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

❑ Apply sealant when installing; refer to ⇒ Electronic parts catalogue

21 - Plug

22 - Dowel sleeve

23 - Bolt

❑ Tightening torque ⇒ Rep. gr. 28

Timing chain cover (top) - tightening torque and tightening se‐ quence

Note

Bolts -3, 4, 5, 6, 10, 11- are supplied as centre hex studs.

– Tighten bolts in 2 stages in the sequence shown:

Stage Bolts Tightening torque

1. -1 … 12- Screw in bolts by hand until they make contact

2. -1 … 12- 9 Nm

Timing chain cover (bottom) - tightening torque and tightening sequence

Note

Renew the bolts tightened with specified tightening angle.

– Tighten bolts in 6 stages:

Stage Bolts Tightening torque

1. -1 ... 6- and

2. -arrows- 5 Nm

3. -1 … 6- 8 Nm in diagonal sequence

4. -arrows- 8 Nm

5. -1 … 6- 20 Nm in diagonal sequence

6. -arrows- turn 90° further

Screw in bolts by hand until they make

-arrows-

contact

1.2 Removing and installing timing chain cover (top)

Special tools and workshop equipment required

80 Rep. gr.15 - Cylinder head, valve gear

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

♦ Hose clip pliers -VAS 6362-

♦ Electric drill with plastic brush attachment

♦ Safety goggles

♦ Sealant ⇒ Electronic parts catalogue

Removing

Note

Audi TT 2007 ➤

Routing and attachment of pipes, hoses and wiring in engine compartment ⇒ page 7 .

– Remove air cleaner housing ⇒ Rep. gr. 24 .

– Unplug electrical connectors -1- and -2-.

– Unscrew nuts and bolt -arrows- and move bracket for connec‐

tors to one side.

– Remove front coolant pipes ⇒ page 187 .

– Remove coolant pipe (left-side) ⇒ page 184 .

– Unplug electrical connector -2- at coolant temperature sender

-G62- .

– Release hose clip -3- and detach coolant hose.

– Unscrew nuts -arrows- and move coolant connection to side

with coolant hose -1- connected.

1. Chain drive 81

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Remove nuts -arrows- and detach bracket -1-.

– Remove bolts in the sequence -12 ... 1- and carefully release

timing chain cover (top) from bonded joint.

– Drive out oil seal in timing chain cover (top) ⇒ page 83 .

Installing

Caution

Protect lubrication system against contamination.

♦ Cover exposed parts of the engine.

WARNING

Protect eyes against injuries.

♦ Wear safety goggles.

– Remove remaining sealant on timing chain cover, cylinder

block and cylinder head using rotating plastic brush or similar.

– Press in new oil seal in timing chain cover (top) ⇒ page 83 .

– Clean sealing surfaces; they must be free of oil and grease.

Note

Note the use-by date of the sealant.

– Cut off nozzle of tube at front marking (nozzle ∅ approx. 1.5

mm).

82 Rep. gr.15 - Cylinder head, valve gear

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Caution

Make sure lubrication system is not clogged by excess sealant.

♦ The bead of sealant must not be thicker than specified.

– Apply sealant bead -A- onto the clean sealing surface of the

timing chain cover (top) as illustrated.

• Thickness of sealant bead: 1.5 ... 2.0 mm

Note

The timing chain cover (top) must be installed within 5 minutes after applying the sealant.

– Install timing chain cover (top) and tighten bolts ⇒ page 80 .

Remaining installation steps are carried out in reverse sequence; note the following:

– Install coolant connection ⇒ page 182 .

– Install coolant pipe (left-side) ⇒ page 184 .

– Install coolant pipes (front) ⇒ page 187 .

Audi TT 2007 ➤

1.3 Renewing oil seal in timing chain cover (top)

Special tools and workshop equipment required

♦ Punch -VW 195-

1. Chain drive 83

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

♦ Tube -VW 415 A-

♦ Fitting sleeve -3241/4-

Procedure

– Remove timing chain cover (top) ⇒ page 80 .

– Use punch -VW 195- to drive out oil seal -arrow-.

– Remove any sealant residue from timing chain cover (top),

place cover on a fixed surface with lugs on casting -arrowsfacing downwards and press in new seal until it makes contact using fitting sleeve -3241/4- .

– Install timing chain cover (top) ⇒ page 80 .

1.4 Removing and installing timing chain cover (bottom)

Special tools and workshop equipment required

♦ Electric drill with plastic brush attachment

♦ Safety goggles

84 Rep. gr.15 - Cylinder head, valve gear

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

♦ Sealant ⇒ Electronic parts catalogue

Removing

• Gearbox removed ⇒ Rep. gr. 34 .

Note

Fit all cable ties in the original positions when installing.

– Remove dual-mass flywheel ⇒ page 67 .

– Remove timing chain cover (top) ⇒ page 80 .

– Remove vacuum pump for brake servo ⇒ Rep. gr. 47 .

– Remove engine speed sender -G28- ⇒ Rep. gr. 28 .

– First remove bolts -arrows-, then -1 ... 6-.

Audi TT 2007 ➤

– Carefully release timing chain cover (bottom) -1- from bonded

joint; to do so, apply screwdriver -A- at the correct positions at top and bottom.

2 - Cylinder block

3 - Sump (top section)

– Always start to release cover in area of dowel sleeves

-arrows-.

– Press crankshaft oil seal (gearbox end) out of timing chain

cover (bottom).

1. Chain drive 85

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Installing

– Drive back dowel sleeves -arrows- in timing chain cover (bot‐

tom) that they do not protrude beyond sealing surface.

Note

Renew gaskets, seals and O-rings.

Caution

Protect lubrication system against contamination.

♦ Cover exposed parts of the engine.

WARNING

Protect eyes against injuries.

♦ Wear safety goggles.

– Remove remaining sealant on timing chain cover (bottom),

cylinder block and sump (top section) using rotating plastic brush or similar.

– Clean sealing surfaces; they must be free of oil and grease.

86 Rep. gr.15 - Cylinder head, valve gear

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Clean old sealant from holes -arrow- in cylinder head gasket.

Note

With the cylinder head installed the holes in the cylinder head gasket are only half visible.

Caution

Audi TT 2007 ➤

Avoid damage to cylinder head gasket.

♦ Only bend the end of the cylinder head gasket slightly and

do not kink.

Note

If the cylinder head gasket has been bent and kinked it must be renewed.

– Carefully bend the end of the cylinder head gasket down very

slightly -arrows-, just far enough to be able to clean the upper sealing surface on the cylinder head gasket and cylinder head.

– Clean cylinder head gasket (top and bottom); it must be free

of oil and grease.

Note

Note the use-by date of the sealant.

– Cut off nozzle of tube at front marking (nozzle ∅ approx. 2

mm).

1. Chain drive 87

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Apply a small amount of sealant to sealing surface of cylinder

head gasket (top and bottom). To do so, you again have to bend cylinder head gasket down very slightly -arrows-.

– Use a flat object (e.g. a feeler gauge) to apply sealant to the

area between cylinder head and gasket.

– Clean holes -arrow- in cylinder head gasket and fill them with

sealant.

Caution

Make sure lubrication system is not clogged by excess sealant.

♦ The bead of sealant must not be thicker than specified.

– Apply sealant bead -arrow- onto the clean sealing surface of

the timing chain cover (bottom) as illustrated.

• Thickness of sealant bead: 1.5 ... 2.0 mm

Note

The timing chain cover (bottom) must be installed within 5 minutes after applying the sealant.

– Fit dowel sleeve -1- and O-ring -2-.

– Fit timing chain cover (bottom), guiding it towards the sealing

surface on cylinder block and cylinder head at an angle and from below.

– Take care not to damage the cylinder head gasket when fitting

the cover.

88 Rep. gr.15 - Cylinder head, valve gear

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Initially screw in bolts for timing chain cover (bottom) by hand

until they make contact.

– Drive in dowel sleeves from timing chain cover (bottom) into

cylinder block in each case until they make contact.

– Tighten bolts for timing chain cover (bottom) ⇒ page 80 .

Remaining installation steps are carried out in reverse sequence; note the following:

– Install engine speed sender -G28- ⇒ Rep. gr. 28 .

– Install vacuum pump for brake servo ⇒ Rep. gr. 47 .

– Install timing chain cover (top) ⇒ page 80 .

– Install crankshaft oil seal (gearbox end) ⇒ page 68 .

– Install dual-mass flywheel ⇒ page 67 .

1.5 Camshaft timing chain - exploded view

Audi TT 2007 ➤

1 - Chain sprocket for camshaft timing chain

2 - Guide rail

3 - Bolt

❑ Renew ❑ 60 Nm + turn 90° further

4 - Camshaft adjuster for inlet camshaft

❑ Identification: „IN“ ❑ Removing and installing

⇒ „1.6 Removing and in‐ stalling camshaft timing chain“, page 90

5 - Bolt

❑ 9 Nm

6 - Chain tensioner for cam‐ shaft timing chain

7 - Oil strainer

❑ Inserted into cylinder

head

8 - Gasket

❑ Renew

9 - Camshaft adjuster for ex‐ haust camshaft

❑ Identification: „EX“ ❑ Removing and installing

⇒ „1.6 Removing and in‐ stalling camshaft timing chain“, page 90

10 - Camshaft timing chain

❑ Before removing, mark

running direction with paint

❑ Removing and installing ⇒ page 90

1. Chain drive 89

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

11 - Bearing mounting

❑ 40 Nm

12 - Tensioning rail

1.6 Removing and installing camshaft timing chain

Special tools and workshop equipment required

♦ Torque wrench -V.A.G

1332-

♦ Open ring spanner insert -

V.A.G 1332/9-

♦ Socket -T03003-

♦ Locking pin -T03006-

♦ Locking pin -T40069-

♦ Camshaft clamp -T40070-

♦ Key -T40079-

90 Rep. gr.15 - Cylinder head, valve gear

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

Removing

– Remove noise insulation panel -1- and -2- ⇒ Rep. gr. 66 .

– Remove vacuum pump for brake servo ⇒ Rep. gr. 47 .

– Remove cylinder head cover ⇒ page 103 .

– Remove timing chain cover (top) ⇒ page 80 .

– Turn crankshaft with socket -T03003- in normal direction of

rotation -arrow- to „TDC position“.

• Notch -1- in socket -T03003- must be perpendicular to sealing surface of sump.

• Marking -2- on vibration damper must be opposite marking

-3- on sealing flange.

Audi TT 2007 ➤

• The threaded holes -arrows- in the camshafts must face up‐ wards.

Note

Turn crankshaft by 360° if the threaded holes do not point up‐ wards.

– Fit camshaft clamp -T40070- onto cylinder head and tighten

bolts -arrows- to 25 Nm.

• The camshaft clamp -T40070- is positioned correctly if the holes for the cylinder head bolts remain free.

1. Chain drive 91

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Unscrew plug -arrow- for „TDC“ marking from cylinder block.

– Screw locking pin -T40069- into locating groove and tighten to

15 Nm. If necessary, turn crankshaft backwards and forwards slightly to fully centralise locking pin.

– Press guide rail of chain tensioner for camshaft timing chain

inwards as far as the stop using a screwdriver. Then lock chain tensioner by inserting locking pin -T03006- .

Caution

If a used timing chain rotates in the opposite direction when it is refitted, this can cause breakage.

♦ Mark running direction of timing chain with coloured ar‐

rows for re-installation. Do not mark timing chain by means of centre punch, notch or the like.

Risk of irreparable damage to engine.

♦ Block off the opening in the valve timing housing with a

clean cloth to prevent small items from dropping into the engine.

– Unscrew bolts -1- and -2- and detach both camshaft adjusters.

92 Rep. gr.15 - Cylinder head, valve gear

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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Detach camshaft timing chain from drive sprocket -arrow- for

camshaft timing chain.

Installing

• Tightening torques

⇒ „1.5 Camshaft timing chain - exploded view“, page 89

Note

Renew the bolts tightened with specified tightening angle.

Caution

Avoid damage to valves and piston crowns.

♦ The crankshaft must not be at „TDC“ at any cylinder when

the camshafts are turned.

Audi TT 2007 ➤

• Drive chain for valve gear installed ⇒ page 97

• Crankshaft locked in position with locking pin -T40069- .

• Camshaft clamp -T40070- installed and tightened to 25 Nm

-arrows-.

– Fit camshaft timing chain onto drive sprocket -arrow- for cam‐

shaft timing chain.

1. Chain drive 93

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Audi TT 2007 ➤ 5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010

– Install camshaft adjusters according to marks applied when

removing ⇒ Item 4 (page 89) and ⇒ Item 9 (page 89) .

– Attach camshaft adjusters with camshaft timing chain fitted, fit

bolts -1- and -2- without tightening.

• It should just be possible to turn both camshaft adjusters on the camshaft without axial movement.

– Remove locking pin -T03006- .

Note

A second mechanic is required for the following work steps.

– Fit key -T40079- onto camshaft adjuster of exhaust camshaft.

– Apply torque wrench -V.A.G 1332- with open ring spanner in‐

sert -V.A.G 1332/9- to key -T40079- .

– Have a 2nd mechanic apply a torque of 25 Nm to camshaft

adjuster in clockwise direction -arrow-.

– Tighten bolts as follows while keeping camshaft adjuster un‐

der tension:

Stage Bolt Tightening torque

1. -1- on inlet camshaft 60 Nm

1. -2- on exhaust camshaft 60 Nm

– Remove key -T40079- .

– Remove camshaft clamp -T40070- -arrows-.

– Tighten bolts for camshaft adjusters in the following sequence:

Stage Bolt Angle to turn bolts

2. -1- 90°

2. -2- 90°

94 Rep. gr.15 - Cylinder head, valve gear