Audi TT 41 User Manual
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
Workshop Manual
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve
turbo TTS), mechanics
Engine ID
Edition 01.2008
CDLACDLBCDM
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 A005TT01820
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Procedure before opening high-pressure section of injection system . . . . . . . . . . . . . . . . 5
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Rules for cleanliness when working on fuel supply system, injection system and
turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Separating engine from manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Separating engine and S tronic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.1 Assembly mountings - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.2 Checking adjustment of assembly mountings (engine/gearbox mountings) . . . . . . . . . . . . 43
5.3 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.1 Poly V-belt drive, bracket for ancillaries - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.4 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.6 Sealing flange (pulley end) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.7 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.8 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.1 Dual-mass flywheel and sealing flange (gearbox end) - exploded view . . . . . . . . . . . . . . . . 63
2.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.3 Renewing sealing flange (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1 Crankshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.5 Extracting and driving in needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.6 Removing and installing drive chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.1 Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.3 Measuring axial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.4 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Contents i
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
1 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.1 Toothed belt drive - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.1 Cylinder head cover and cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.2 Removing and installing inlet camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . 92
2.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.1 Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.2 Measuring axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.3 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.4 Renewing exhaust camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.5 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.6 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.7 Renewing valve stem oil seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . 120
3.8 Renewing valve stem oil seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . 123
3.9 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.10 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.11 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1 Oil pump and sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.1 Sump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 131
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.4 Balance shaft assembly with oil pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.5 Removing and installing balance shaft assembly with oil pump . . . . . . . . . . . . . . . . . . . . . . 136
2 Oil filter bracket and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.1 Oil filter bracket and oil cooler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.2 Draining oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.3 Removing and installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
2.4 Removing and installing oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.5 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.6 Checking oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.7 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.8 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.9 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.1 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.2 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2 Coolant pump and coolant thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.1 Coolant pump and thermostat with housing - exploded view . . . . . . . . . . . . . . . . . . . . . . . . 160
2.2 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 161
2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.4 Removing and installing thermostat with housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3 Coolant pipes and continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . . . . . . . 164
3.1 Coolant pipes - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3.2 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 165
3.3 Removing and installing coolant pipes 1 and 2 (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.4 Removing and installing coolant pipe (front right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.5 Continued coolant circulation pump V51 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 170
ii Contents
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
3.6 Removing and installing continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . 171
4 Radiator and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.1 Radiator and radiator fans - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.3 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.4 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 174
4.5 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.1 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.2 Removing and installing air pipes and hoses with plug-in connectors . . . . . . . . . . . . . . . . 178
1.3 Turbocharger - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.4 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.5 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.6 Removing and installing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.7 Adjusting vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2 Charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.1 Charge air cooler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.2 Removing and installing charge air pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . 195
2.3 Removing and installing turbocharger air recirculation valve N249 . . . . . . . . . . . . . . . . . . 195
2.4 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1 Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.1 Silencers - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.2 Removing and installing front exhaust pipe with catalytic converter and front silencer . . . . 202
1.3 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1.4 Aligning tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3 Exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3.1 Checking vacuum unit for exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Contents iii
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
iv Contents
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
00 – Technical data
1 Engine number
♦ The engine number (“Engine code” and “Serial number”) can
be found on the left of the joint between engine and gearbox
-arrow-.
♦ The engine code letters are also stamped on the right of the
cylinder head -2- and on the cylinder block -1-.
♦ Additionally there is a sticker on the toothed belt cover with“En‐
gine 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.
Note
♦
The 4-character engine code can be found on the type plate
(in versions for some countries only) and on the vehicle data
sticker and the engine control unit.
♦
Fitting locations of the type plate (certain countries only) and
the vehicle data sticker ⇒ Maintenance ; Booklet 810 .
1. Engine number 1
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Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
2 Engine data
Code letters CDLA CDLB CDMA
Capacity ltr. 1.984 1.984 1.984
Power output kW at rpm 195/6000 199/6000 195/6000
Torque Nm at rpm 350/2500 … 5250 350/2500 … 5250 350/2500 … 5250
Bore ∅ in mm 82.5 82.5 82.5
Stroke mm 92.8 92.8 92.8
Compression ratio
RON not less than
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Emission standards EU4 EU4 EU4
Exhaust gas recirculation no no no
Turbocharging/supercharging Turbocharger Turbocharger Turbocharger
Knock control yes yes yes
Charge air cooling yes yes yes
Lambda control 2 probes 2 probes 2 probes
Variable valve timing Inlet Inlet Inlet
Intake manifold change-over no no no
Secondary air system no no no
Valves per cylinder 4 4 4
1)
•
Unleaded premium RON 95 can also be used, but results in reduced power
9.8 9.8 9.8
98
1)
98
1)
98
1)
2 Rep. Gr.00 - Technical data
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Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
3 Safety precautions
When working on the fuel system note the following warnings:
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.
♦ 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 ⇒ page 5 .
WARNING
Escaping fuel can cause a fire risk.
♦ The power supply for the fuel pump control unit -J538-
must be disconnected before opening the fuel system, as
the fuel system pressurisation pump -G6- will be activated
briefly when the driver's door is opened with the battery
still connected.
– Remove luggage compartment side trim (right-side) ⇒ Rep.
Gr. 70 .
3. Safety precautions 3
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
– Remove fuse 6 in fuse holder F -SF6- for fuel pump control
unit -J538- in fuse holder in luggage compartment (right-side).
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 if electrical connectors
have been unplugged:
– Connect vehicle diagnostic, testing and information system -
VAS 5051B- .
– Start “Guided Functions” mode.
– Generate readiness code in engine control unit.
Caution
To prevent damage to the electronic components when dis‐
connecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery.
– Disconnect battery ⇒ Rep. Gr. 27 .
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.
♦ Cover filler cap on expansion tank with a cloth and open
carefully to dissipate pressure.
4 Rep. Gr.00 - Technical data
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
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.
Injuries can also be caused if the passenger's airbag is trig‐
gered in a collision.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
TT Coupé:
Test equipment must always be secured on the rear seat with
a strap and operated from the rear seat by a second person.
TT Roadster:
♦ Move the passenger's seat back as far as it will go.
♦ Use only vehicle diagnosis and service information sys‐
tem -VAS 5052- or diagnosis system -VAS 5053- .
♦ The test equipment -1- must rest flat on the passenger's
thighs (as shown in illustration) and must be operated by
the passenger.
3.1 Procedure before opening high-pres‐
sure section of injection system
♦ The injection system consists of a high-pressure section (max‐
imum approx. 120 bar) and a low-pressure section (approx.
6 bar).
♦ Before removing a component in the high-pressure section of
the injection system, the fuel pressure in the high-pressure
section must be reduced to a residual pressure of approx.
6 bar; follow the procedure outlined below.
Special tools and workshop equipment required
♦ Vehicle diagnostic, testing and information system -VAS
5051B-
Procedure
Proceed as follows:
– With ignition switched off, connect vehicle diagnostic, testing
and information system -VAS 5051B- with diagnosis lead to
diagnosis connection.
– Start the engine and run at idling speed.
3. Safety precautions 5
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
Display on -VAS 5051B- :
– Select Vehicle self-diagnosis from the list -item 1-.
Display on -VAS 5051B- :
– From menu -1-, select vehicle system “Engine electronics” and
press → key to continue.
Display on -VAS 5051B- :
– From menu -1-, select function “Measured values” and press
→ key to continue.
Display on -VAS 5051B- :
– Press keys 1 4 0 on keypad -1- to select “Display group 140”
and confirm entry by pressing Q
key.
6 Rep. Gr.00 - Technical data
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Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
Display on -VAS 5051B- :
– Check display indicating fuel pressure in fuel rail in display
zone -3-.
• With engine idling the figure displayed will be 35 ... 45 bar. The
display shows the actual pressure in the fuel rail which is being
generated by the high-pressure pump.
– Remove luggage compartment side trim (right-side) ⇒ Rep.
Gr. 70 .
– Remove fuse 6 in fuse holder F -SF6- for fuel pump control
unit -J538- in fuse holder in luggage compartment (right-side).
3. Safety precautions 7
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Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
Display on -VAS 5051B- :
– With engine still running, check display zone -3- for fuel pres‐
sure in fuel system:
• The fuel pressure will decrease very quickly because the me‐
chanical high-pressure pump is no longer being supplied with
fuel from the fuel tank by the electric fuel pump.
– Switch off ignition as soon as fuel pressure has dropped to just
below 8 bar.
Note
Fuel pressure must not fall below 6 bar, otherwise the engine will
stall (this could damage the catalytic converter).
The fuel rail is still filled with fuel, however it is no longer under
high pressure.
WARNING
There is a risk of injury: avoid skin contact with fuel.
♦ Wear safety goggles and protective clothing when open‐
ing the fuel system.
♦ Before opening the high-pressure section of the fuel sys‐
tem, place a clean cloth around the connection to catch
escaping fuel.
– Disconnect a fuel line connection without delay.
Note
The pressure will increase again due to the effect of residual heat
if the high-pressure system is not opened immediately.
Additional steps required
– Re-fit fuse 6 in fuse holder F -SF6- .
– With ignition switched off, connect vehicle diagnostic, testing
and information system -VAS 5051B- .
– Start “Guided Functions” mode.
– Generate readiness code in engine control unit ⇒ Vehicle di‐
agnosis, testing and information system VAS 5051.
8 Rep. Gr.00 - Technical data
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Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
4 General repair instructions
4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger
Even small amounts of dirt can cause malfunctions. For this rea‐
son, please observe the following rules when working on the fuel
supply system, injection system and turbocharger:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal off open lines and connections with clean plugs or sealing
caps immediately.
♦ 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 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.
4.3 Routing and attachment of pipes, hoses and wiring
Mark hydraulic lines, vacuum lines and electrical wiring before
removal so they can be re-installed in the original positions and
correctly connected. Make sketches or take photographs if nec‐
essary.
4. General repair instructions 9
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
10 – Removing and installing engine
1 Removing engine
Special tools and workshop
equipment required
♦ Drip tray for workshop hoist
-VAS 6208-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Hose clip pliers -V.A.G
1921-
♦ Stepladder -VAS 5085-
♦ Engine bracket -T10012-
♦ Removal lever -80 - 200-
♦ Lambda probe open ring spanner set -3337-
10 Rep. Gr.10 - Removing and installing engine
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
♦ Locking pin -T10060A-
♦ Tool set for wiper arms -T10369-
♦ Engine bung set -VAS 6122-
Procedure
Proceed as follows:
Note
♦
The engine is removed from underneath together with the
gearbox.
♦
Fit cable ties in the original positions when installing.
♦
Collect drained coolant in a clean container for re-use or dis‐
posal.
WARNING
The fuel system operates at extremely high pressure. This can
cause injury.
♦ Do not open the high-pressure section of the injection
system when removing the engine.
♦ However, if the engine has to be removed for repair pro‐
cedures which necessitate opening the high-pressure
section, the fuel pressure in the high-pressure section
must be reduced in a controlled manner to a residual pres‐
sure prior to opening.
– Reduce fuel pressure in high-pressure section of injection sys‐
tem ⇒ page 5 .
1. Removing engine 11
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
Caution
To prevent damage to the electronic components when dis‐
connecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
– Take out luggage compartment floor covering.
– Remove rear cross panel trim if cover for negative terminal of
battery is located under rear cross panel trim ⇒ Rep. Gr. 70 .
– Release retaining clips -arrows- and detach cover for negative
terminal.
– Slacken nut a few turns and disconnect battery clamp on earth
cable -arrow- from battery terminal.
WARNING
Hot steam/hot coolant can escape - risk of scalding.
♦ The cooling system is under pressure when the engine is
hot.
♦ Cover filler cap on expansion tank with a cloth and open
carefully to dissipate pressure.
– Open filler cap on expansion tank.
– Remove both front wheels.
– Remove front noise insulation -1- ⇒ Rep. Gr. 66 .
12 Rep. Gr.10 - Removing and installing engine
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
– Remove noise insulation on left and right sides -arrows-.
– Remove noise insulation frame -arrow- together with rear
noise insulation ⇒ Rep. Gr. 66 .
– Place drip tray for workshop hoist -VAS 6208- beneath engine.
– Lift retaining clip, disconnect coolant hose (bottom) -arrow-
from radiator and drain off coolant.
– Disconnect bottom coolant hose leading to continued coolant
circulation pump -V51- -arrow- and drain off coolant.
1. Removing engine 13
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
– Release hose clips -1- and -2- and remove air hose.
– Unplug electrical connector -2-.
– Remove bolts -3-.
– Remove engine cover panel -arrows-.
– Detach coolant hoses -1- and -2-.
14 Rep. Gr.10 - Removing and installing engine
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Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
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
Observe rules for cleanliness when working on the fuel supply
system ⇒ page 9 .
– Remove protective sleeve -2- and disconnect fuel hose by
pressing release ring.
– Detach hose -1-.
– Release activated charcoal filter -arrow B-, lift off -arrow A- and
move clear to one side.
– Unscrew bolts -arrows- and remove air duct.
– Remove bolts -1- and lift out radiator cowl.
1. Removing engine 15
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– Lift retaining clip and disconnect coolant hose (top) -arrow-
from radiator.
– Remove bolts -arrows- on reverse side of radiator.
– Remove radiator upwards.
Vehicles with air conditioning:
Caution
If a used belt runs in the opposite direction when it is refitted,
this can cause breakage.
♦ Before removing, mark direction of rotation of poly V-belt
with chalk or felt-tipped pen for re-installation.
– To slacken poly V-belt turn tensioner in clockwise direction
-arrow-.
– Lock tensioner with locking pin -T10060 A-
– Take off poly V-belt.
16 Rep. Gr.10 - Removing and installing engine
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
– Remove bolts -arrows- and detach alternator from bracket for
ancillaries.
Note
♦
If alternator sticks in its bracket, screw bolt back in again down
to the last 2 turns.
♦
Tap carefully on bolt heads with flat side of hammer to release
bushes of alternator mountings.
– Swivel alternator towards right side of vehicle with electrical
wiring connected.
– Unplug electrical connector -2-.
– Unscrew electrical wiring -1- and clamp -3- and remove from
alternator.
– Lift out alternator.
– Unplug electrical connector -1- for magnetic clutch on air con‐
ditioner compressor.
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.
All vehicles (continued):
– Release hose clip -1- and detach air hose.
– Unplug electrical connector -2- for air mass meter -G70- .
– Unscrew top section of air cleaner housing -arrow- and re‐
move air filter element.
1. Removing engine 17
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
– Remove bolts -arrows- and detach bottom section of air clean‐
er housing.
– Remove bolts -arrows- and detach bracket for air cleaner
housing.
– Take electrical connector -arrow- for Lambda probe -G39- out
of bracket, unplug and move clear.
– Unscrew Lambda probe -G39- -arrow- using tool from Lambda
probe open ring spanner set -3337- .
18 Rep. Gr.10 - Removing and installing engine
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
– Remove bolt -arrow-.
– Release hose clip -1- and lay air pipe on engine (hose -2- re‐
mains attached).
Note
Disregard item -3-.
– Unscrew bolts -arrows- and nuts -1- and detach heat shield.
– Working from above, unscrew nuts -arrows- securing front ex‐
haust pipe to turbocharger.
– Detach coolant hoses -arrows- leading to heat exchanger.
1. Removing engine 19
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
– Disconnect vacuum hose -1- coming from non-return valve.
– Pull non-return valve -arrow- off brake servo.
– Pry off caps on windscreen wiper arms with a screwdriver.
– Loosen nuts -arrows- several turns.
– Apply puller -T10369/1- to wiper arm -1- as shown in illustra‐
tion.
– Apply thrust piece -2- onto wiper shaft.
– Turn bolt -3- in clockwise direction until wiper arm is pulled off
wiper shaft.
– Remove nuts and detach windscreen wiper arms.
– Remove seal -1-.
Caution
Risk of damage to plenum chamber cover.
♦ Apply a small quantity of soap solution to transition be‐
tween windscreen and plenum chamber cover -2-. Then,
starting at edge of windscreen, carefully pull plenum
chamber cover upwards off retainer at windscreen.
– Detach plenum chamber cover -2- by pulling it carefully off re‐
tainer at windscreen.
– Detach engine wiring harness (rear) at plenum chamber par‐
tition panel.
20 Rep. Gr.10 - Removing and installing engine
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
– Remove engine control unit ⇒ Rep. Gr. 24 .
– Unplug electrical connector -1- for engine wiring harness
-arrow-.
– Release wiring protector -1- for engine wiring harness
-arrow- and lift off.
– Slide the two clips in the direction of the -arrows- and remove
cover from electronics box in engine compartment.
– Open wiring duct brackets -arrows-.
1. Removing engine 21
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
– Unclip electrical connector -1- from bracket and unplug.
– Open wiring duct bracket located underneath.
– Unclip wiring harness for engine control unit from wiring duct.
– Place engine wiring harness with engine control unit on top of
engine.
– Secure engine control unit to prevent it falling.
– Unclip electrical connector -2- from bracket and unplug.
– Unscrew terminal 30 wire -arrow- from electronics box in en‐
gine compartment and move it clear.
Note
Use removal lever -80 - 200- to lever out the wiring clips.
Vehicles with manual gearbox:
– Cut open cable tie -arrow- for protective cover -3-.
– Unplug electrical connector -2-.
– Push back protective cover and unscrew B+ cable at starter
solenoid switch
– Remove nut -1- for earth wire.
– Remove top starter bolt.
22 Rep. Gr.10 - Removing and installing engine
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
– Detach cable support bracket from gearbox -arrows-.
– Unclip circlip -1- from gear selector cable and circlip -2- from
gate selector cable.
– Pull selector cable end-pieces with selector cables off selector
shaft lever and relay lever.
– Tie selector cables with cable support bracket to one side.
– Clamp off pressure hose to clutch slave cylinder using a hose
clamp -3094- .
– Pull securing clip upwards -arrow- and detach pipe/hose as‐
sembly -1- from bleeder connection on clutch slave cylinder.
Caution
Risk of contamination by escaping brake fluid.
♦ Do not operate clutch pedal after detaching pipe/hose as‐
sembly from bleeder connection on clutch slave cylinder.
1. Removing engine 23
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4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
Vehicles with S tronic gearbox:
– Cut open cable tie -arrow- for protective cover -1-.
– Unplug electrical connector -2-.
– Push back protective cover and unscrew B+ cable at starter
solenoid switch
– Unscrew earth wire -3-.
Caution
Risk of damage to control unit (mechatronic unit) by static dis‐
charge.
♦ Do NOT touch connector contacts in gearbox connector
with your hands.
– Touch vehicle earth with bare hands to discharge any static
charge.
– Turn retainer catch anti-clockwise and unplug electrical con‐
nector -4- at gearbox.
– Unplug electrical connector -1-.
Note
Disregard -arrows-.
All vehicles (continued):
– Loosen bolts -arrows- for assembly mounting (engine end)
approx. 2 turns.
– Loosen bolts -arrows- for assembly mounting (gearbox end)
approx. 2 turns.
24 Rep. Gr.10 - Removing and installing engine
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