Audi TT 45 User Manual
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
Workshop Manual
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail generation II), mechanics
Engine ID
Edition 05.2010
CFG
B
Service Department. Technical Information
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
26 - Exhaust system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt D3E8029FA9E
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
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 Working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Using testers and measuring instruments during a road test . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 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 for leaks in the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.5 Installing radiators, condensers and charge air coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.6 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Separating engine from manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 Assembly mountings - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Removing and installing engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3 Checking adjustment of assembly mountings (engine/gearbox mountings) . . . . . . . . . . . . 41
5.4 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.1 Poly V-belt drive without air conditioner compressor - exploded view . . . . . . . . . . . . . . . . 46
1.2 Removing and installing poly V-belt - vehicles without air conditioner compressor . . . . . . 47
1.3 Poly V-belt drive for vehicles with air conditioner compressor and tensioner - exploded
view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.4 Removing and installing poly V-belt - vehicles with air conditioner compressor and
tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.5 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.6 Poly V-belt drive for vehicles with air conditioner compressor and tensioning roller - exploded
view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.7 Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioning
roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.8 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.9 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.10 Sealing flange (pulley end) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.11 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.12 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.1 Dual-mass flywheel and sealing flange (gearbox end) - exploded view . . . . . . . . . . . . . . . . 65
2.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.3 Renewing sealing flange (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Contents i
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
3.1 Crankshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.5 Extracting needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.6 Pulling spur gear off crankshaft and shrink-fitting new spur gear . . . . . . . . . . . . . . . . . . . . 78
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.1 Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2 Measuring piston projection at “TDC” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.4 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.1 Toothed belt - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.1 Cylinder head cover - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.3 Renewing injector seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.4 Cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.5 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.1 Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.2 Measuring axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.3 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.4 Renewing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.5 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.6 Checking hydraulic valve compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.7 Renewing valve stem oil seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . 135
3.8 Renewing valve stem oil seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . 139
3.9 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.10 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.11 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.12 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1 Oil pump, sump, balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.1 Oil pump, sump, balance shaft assembly - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 147
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.5 Removing balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.6 Installing a new balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.7 Re-installing a used balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2 Oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.1 Oil filter bracket and engine oil cooler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.2 Removing and installing oil filter bracket with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . 160
2.3 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.4 Checking oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.5 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2.6 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.7 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
ii Contents
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.1 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.2 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2 Coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.1 Coolant pump and thermostat - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.3 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.4 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3 Coolant pipes, coolant temperature senders, coolant circulation pump . . . . . . . . . . . . . . . . 184
3.1 Coolant pipes, coolant temperature senders, coolant circulation pump - exploded view . . 184
3.2 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 185
3.3 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 187
3.4 Removing and installing pump for exhaust gas recirculation cooler V400 . . . . . . . . . . . . 188
3.5 Removing and installing coolant pipe (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3.6 Removing and installing coolant pipe (top front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.7 Removing and installing coolant pipe (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.8 Removing and installing coolant pipe (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4 Radiator and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4.1 Radiator and radiator fans - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4.2 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4.3 Removing and installing radiator fans V7 and V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1.1 Diagram of vacuum connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1.2 Turbocharger - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.3 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2 Charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.1 Charge air cooler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.2 Removing and installing charge pressure sender G31 / intake air temperature sender G42
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1 Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1.1 Silencers - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1.2 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
1.3 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.4 Aligning tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2 Exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.1 Exhaust gas temperature control - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.2 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 225
2.3 Removing and installing exhaust gas temperature sender 3 G495 . . . . . . . . . . . . . . . . . . 226
2.4 Removing and installing exhaust gas temperature sender 4 G648 . . . . . . . . . . . . . . . . . . 227
3 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3.1 Diagram of vacuum connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3.2 Exhaust gas recirculation with exhaust gas recirculation cooler - exploded view . . . . . . . . 229
3.3 Checking exhaust gas recirculation cooler change-over . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3.4 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 230
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 TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
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 TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
00 – Technical data
1 Engine number
♦ The engine number (“Engine code” and “Serial number”)
-arrow- can be found at the front of the joint between engine
and gearbox.
♦ There is also a sticker on the toothed belt cover showing the
“Engine code” and “Serial number”.
♦ Starting with the letter “C”, the engine codes consist of 4 let‐
ters.
♦ The first 3 characters of the engine code stand for the engine
capacity and the mechanical construction and design. They
are stamped on the cylinder block, together with the serial
number.
♦ The 4th character indicates the power output and torque of the
engine, and is determined by the engine control unit.
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
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
2 Engine data
Code letters CFGB
Capacity ltr. 1.968
Power output kW at rpm 125/4200
Torque Nm at rpm 350/1750 … 2500
Bore ∅ in mm 81.0
Stroke mm 95.5
Compression ratio
CN not less than 51
Firing order
Exhaust gas recirculation yes
Exhaust gas temperature control yes
Turbocharging/supercharging Turbocharger
Glow plugs Steel glow plugs
Charge air cooling yes
Lambda control 1 Lambda probe
Particulate filter yes
Valves per cylinder 4
16.5
1-3-4-2
Note
Audi TT models with a TDI engine (2.0 ltr. 4-valve common rail)
are always equipped with steel glow plugs.
2 Rep. Gr.00 - Technical data
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
3 Safety precautions
3.1 Working on the fuel system
When working on the fuel system note the following warnings:
WARNING
Risk of injury - fuel system operates under pressure.
♦ Wrap a clean cloth around the connection before opening
the fuel system. Then release pressure by carefully loos‐
ening the connection.
♦ Wear protective gloves.
♦ Wear safety goggles.
The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
Observe the following points to prevent personal injuries and
damage to the injection and glow plug system:
♦ Always switch off the ignition before connecting or discon‐
necting tester cables or electrical wiring for the injection or
glow plug system.
♦ Always switch off ignition before washing engine.
♦ Entries are stored in event memory of engine control unit if
electrical connectors were unplugged and engine was started:
Interrogate event memory in Vehicle self-diagnosis
⇒ vehicle diagnostic tester .
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 ⇒ Electrical system; Rep. Gr. 27 .
3. Safety precautions 3
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
3.2 Working on the cooling system
When working on the cooling system note the following:
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.
Risk of injury as the radiator fans may start up automatically.
♦ Unplug electrical connectors before starting to work in the
area of radiator cowl.
Caution
Overheating can occur if the filler cap is not fitted properly.
♦ Close filler cap on coolant expansion tank (make sure it
engages).
3.3 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
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
3.4 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.
3.5 Working on the exhaust system
When working on the exhaust system 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
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
4 General repair instructions
4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger
Even small amounts of dirt can cause malfunctions. For this rea‐
son, please observe the following rules when working on the fuel
supply system, injection system and turbocharger:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal off open pipes/lines and connections using engine bung
set -VAS 6122- .
♦ Place parts that have been removed on a clean surface and
cover them over. Do not use fluffy cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have not been stored in the proper packaging (e.g. in tool
boxes etc.).
♦ When the system is open: Do not work with compressed air.
Do not move the vehicle unless absolutely necessary.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
4.2 Checking for leaks in the fuel system
Procedure
– Allow engine to run for several minutes at moderate rpm.
– Switch off ignition.
– Check complete fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.
– Road-test vehicle and accelerate with full throttle at least once.
– Then inspect high-pressure section of fuel system again for
leaks.
4.3 Contact corrosion!
Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
used.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Note the following:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
6 Rep. Gr.00 - Technical data
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
♦ We recommend the use of Audi accessories.
♦ Damage caused by contact corrosion is not covered under
warranty.
4.4 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).
4.5 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, charge air cooler or condenser.
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.
– If a fault is stored in the event memory, check the vacuum lines
leading to the relevant component and also check the remain‐
ing 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. General repair instructions 7
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
10 – Removing and installing engine
1 Removing engine
Special tools and workshop
equipment required
♦ Removal lever -80 - 200-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Stepladder -VAS 5085-
♦ Engine bung set -VAS
6122-
♦ Drip tray for workshop hoist
-VAS 6208-
♦ Hose clip pliers -VAS 6362-
♦ Hook -2024 A /1- of lifting tackle -2024 A-
8 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.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
♦ Hose clamps for hoses up to 25 mm -3094-
♦ Engine bracket -T10012-
♦ Locking pin -T10060 A- for vehicles with air conditioner com‐
pressor and tensioner
♦ Safety goggles
♦ Protective gloves
Procedure
Note
♦
The engine is removed from underneath together with the
gearbox.
♦
Fit all cable ties in the original positions when installing.
♦
Fit heat insulation sleeves in the original positions when in‐
stalling.
1. Removing engine 9
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
Caution
To prevent damage to the electronic components when dis‐
connecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
– Disconnect earth cable -arrow- from battery terminal ⇒ Elec‐
trical system; Rep. Gr. 27 .
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.
– Open filler cap on coolant expansion tank.
– Remove engine cover panel -arrows-.
– Pull cover off air duct (release clips on sides) -arrows-.
10 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.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
– Release clips on left and right -arrow A- and unclip air duct at
bottom -2-.
– Swivel air duct (bottom) slightly to the rear and detach air duct
(bottom) from retainers -3-.
– Detach air pipe -1- from air duct (bottom) -arrow B-.
– Unplug electrical connector -1- from air mass meter -G70- .
– Detach hose -4-.
– Release hose clip -2- and detach air hose.
– Unscrew bolt -3- and remove air cleaner housing.
– Remove bolts -arrows- and detach air duct -1- from lock car‐
rier.
1. Removing engine 11
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
– Remove bolts -top arrows- for radiator cowl.
Note
The bolts -bottom arrows- are removed at a later stage.
– Remove both front wheels.
– Remove noise insulation ⇒ Rep. Gr. 66 .
– Remove bottom sections of wheel housing liners (left and
right) ⇒ Rep. Gr. 66 .
– TT Roadster: Remove noise insulation frame -arrow- ⇒ Rep.
Gr. 50 .
12 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.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
– Release hose clips -1- and -2- and remove air hose.
– Release hose clips -1- and -2- and remove air hose.
– Seal off open pipes/lines and connections with clean plugs
from engine bung set -VAS 6122- .
– Unplug electrical connector -1-.
– Remove bolts -bottom arrows- and take out air cowl down‐
wards.
Note
Collect drained coolant in a clean container for re-use or disposal.
– Place drip tray for workshop hoist -VAS 6208- beneath engine.
– Lift retaining clip -arrow-, disconnect coolant hose (bottom
right) from radiator and drain off coolant.
1. Removing engine 13
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
– Open hose clip -arrow-, disconnect coolant hose (bottom)
leading to pump for exhaust gas recirculation cooler -V400and drain off coolant.
– Release hose clip -arrow-, disconnect coolant hose at oil filter
housing and drain off remaining coolant.
– Remove bolts -bottom arrows- on rear side of radiator.
Note
The bolts -top arrows- are removed at a later stage.
– Remove bolts -arrows- and detach bracket -1- for air cleaner
housing.
14 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.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
– Press release tabs and disconnect crankcase breather hose
-1- from cylinder head cover.
– Move clear vacuum hoses -arrows- at air pipe.
– Remove bolt -2-, swivel air pipe with connection to rear and
detach from turbocharger.
– Detach vacuum hose -2- from vacuum unit of turbocharger.
– Disconnect vacuum hose -3-.
Note
Disregard -item 1-.
– Detach vacuum hose -arrow- from brake servo.
Note
Place a cloth underneath heat exchanger to catch escaping cool‐
ant.
– Lift retaining clips -arrows- and detach coolant hoses from
heat exchanger.
1. Removing engine 15
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
– Detach electrical connector -1- from bracket and unplug.
– Move clear electrical wiring.
Note
Disregard -items 2, 3, 4-.
– Slacken bolt -2- and remove clamp.
Note
Disregard -items 1, 3-.
– Remove top bolt -1- at bracket for particulate filter.
– Unplug electrical connector -2- at pressure differential sender
-G505- .
– Remove bolt -1-.
Note
Disregard -arrows-.
16 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.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
– Unplug electrical connector -2- on fuel temperature sender -
G81- .
WARNING
The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
– Release hose clips -1- and -3- and disconnect fuel supply hose
and fuel return hose.
Note
Disregard -item 4-.
– Release hose clip -arrow- and detach coolant hose.
Note
Disregard -item 1-.
– Disengage fuel hose -3- at bracket.
– Pull off bracket for fuel lines towards right -arrow- and move
clear to one side.
– Unplug electrical connector -1- at supplementary fuel pump -
V393- .
– Remove bolts -2- and -4-, detach bracket with supplementary
fuel pump -V393- and move clear to one side.
1. Removing engine 17
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
– Release hose clip -1-, detach coolant hose from coolant ex‐
pansion tank and move coolant hose clear -arrow-.
– Lift retaining clip -arrow- and disconnect coolant hose (top left)
from radiator.
– Unplug electrical connector -A- at high-pressure sender -G65-
-item B-.
Note
Disregard -item C-.
– Detach sealing lip at lock carrier (top).
18 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.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
– Remove bolts -top arrows- at rear and lift out radiator.
– Release electrical connector -1- for engine wiring harness
-arrow- and detach ⇒ Rep. Gr. 23 ; Removing and installing
engine control unit -J623- .
– Release wiring protector -1- for engine wiring harness
-arrow- and lift off.
– Move clear and unplug electrical connector -1-.
– Open wiring duct bracket -arrows-, use removal lever -80 -
200- to unclip wiring and press wiring to side.
– Unclip wiring duct.
– 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.
1. Removing engine 19
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
– 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.
– Unplug electrical connector -1-.
Note
Disregard -arrows-.
– Unplug electrical connector -7- (push retainer to the rear and
press down release catch).
– Push back protective sleeve -6-.
– Remove nut -1- and detach B+ wire -item 2- from starter sol‐
enoid switch.
– Remove nut -5- and detach earth wire -4-.
Note
Disregard -item 3-.
20 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.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
– Lift clip and detach retaining clip -3- for gear selector cable
from gearbox selector lever -1-.
– Detach gear selector cable -2- from pin -arrow-.
• To prevent damage to gate selector cable, cable end-piece
must be detached from gate selector cable before removing.
– Pull locking device forwards onto stop -arrow 1- and lock by
turning anti-clockwise -arrow 2-.
– Press selector relay lever towards front -arrow 3-.
– Remove nut -1- and bolts -2-, detach cable support bracket
and place to one side (selector cables remain fitted).
– Vehicles with plastic pipe between clutch master cylinder and
slave cylinder: clamp off supply hose at brake fluid reservoir
using hose clamp -3094- .
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 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
– Vehicles with pipe/hose assembly between clutch master cyl‐
inder and slave cylinder: clamp off hose -A- at pipe/hose
assembly using hose clamp -3094- .
Note
Disregard -arrow-.
Note
Make sure brake fluid does not come into contact with starter or
gearbox when performing the following operations. If it does,
clean affected area thoroughly.
– 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.
Note
Disregard -item B-.
– Seal off open pipes/lines and connections with clean plugs
from engine bung set -VAS 6122- .
Caution
Risk of contamination by escaping brake fluid.
♦ Do not operate clutch pedal after detaching pipe from
bleeder screw on clutch slave cylinder.
Vehicles with start/stop system:
– Unplug electrical connector -3- for gearbox neutral position
sender -G701- .
All vehicles (continued):
– Unplug electrical connector -2- at reversing light switch -F4- .
– Unscrew nut -1- and detach bracket for electrical connectors.
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.
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
– Unscrew bolts -arrows- at engine mounting approx. 2 turns.
– Loosen bolts -arrows- at gearbox mounting approx. 2 turns.
Vehicles with air conditioner compressor and tensioner:
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.
Vehicles with air conditioner compressor and tensioning roller:
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.
– Remove bolt -arrow- and detach tensioner to slacken poly V-
belt.
– Take off poly V-belt.
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 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
All vehicles with air conditioner compressor (continued):
– Unplug electrical connector -2- on air conditioner compressor
regulating valve -N280- .
Caution
Make sure that air conditioner compressor and refrigerant
pipes and hoses are not damaged.
♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Remove bolts -arrow-, detach air conditioner compressor -1-
with refrigerant lines connected and tie up to front.
All vehicles (continued):
– Unplug electrical connector -1- at oil level and oil temperature
sender -G266- .
– Unclip bracket -2- for wire to oil level and oil temperature
sender -G266- from subframe.
– Remove bolts -arrows- and detach heat shield for drive shaft
(right-side).
– Detach drive shaft (left-side) from flange shaft of gearbox and
tie up.
– Detach drive shaft (right-side) from flange shaft of bevel box.
– Remove bolts -1, 2, 3- and remove pendulum support.
24 Rep. Gr.10 - Removing and installing engine
Loading...