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.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt D3E8020278E
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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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010
iv Contents
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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010
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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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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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010
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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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010
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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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010
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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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010
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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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010
♦ 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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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010
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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Audi TT 2007 ➤
5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010
– 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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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010
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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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010
– 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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Audi TT 2007 ➤
5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010
Caution
If a used belt runs in the opposite direction when it is refitted,
this can cause breakage.
♦ Before removing, mark direction of rotation of poly V-belt
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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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010
– 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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5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010
– 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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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.
5-cylinder direct petrol injection engine (2.5 ltr. 4-valve turbo), mechanics - Edition 12.2010
– 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
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
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
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.
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
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
– 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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