Audi TT 7 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 1999 ➤

4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics

Engine ID

Edition 12.2005

AJQ APP ARY ATC AUM AUQ AWP BVP BVR

Service Department. Technical Information

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

Service

List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups

Re pa ir G ro up

00 - Technical data

10 - Removing and installing engine

13 - Crankshaft group

15 - Cylinder head, valve gear

17 - Lubrication

19 - Cooling

21 - Turbocharging/supercharging

26 - Exhaust system

Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi TT 1999 ➤

4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Contents

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

1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 Separating engine from manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.3 Separating engine from automatic gearbox 09A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.4 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.5 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.1 Checking adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.2 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1 Servicing work on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1.1 Poly V-belt drive - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.3 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1.4 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1.5 Toothed belt - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

1.6 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

1.7 Removing toothed belt from camshaft sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1.8 Positioning crankshaft at “TDC” with engine installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

1.9 Positioning crankshaft at “TDC” with engine removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2 Removing and installing sealing flanges and dual-mass flywheel/drive plate . . . . . . . . . . 63

2.1 Sealing flanges and dual-mass flywheel/drive plate - exploded view of components . . . . 63

2.2 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

2.3 Removing and installing sealing flange (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

2.4 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

2.5 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.1 Crankshaft - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.3 Removing and installing drive chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.1 Different versions of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.2 Pistons and conrods - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4.4 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1.1 Cylinder head - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1.4 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

2.1 Valve gear - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

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 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

2.2 Checking axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

2.3 Renewing exhaust camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

2.4 Renewing inlet camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

2.5 Removing and installing camshafts and hydraulic chain tensioner/camshaft adjuster . . . . 110

2.6 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

2.7 Renewing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

2.8 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

2.9 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

2.10 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

3 Checking variable valve timing - not on engine codes AJQ, APP, ATC . . . . . . . . . . . . . . . . 125

3.1 Checking function of variable valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

3.2 Checking inlet camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

1.1 Lubrication system - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

1.4 Oil filter and oil cooler - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

1.5 Checking oil pressure and oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

1.6 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

1.7 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

1.1 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

1.2 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

1.4 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

1.5 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

1.6 Removing and installing coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

1.7 Radiator and radiator fan - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . 156

1.8 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

1.9 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1.2 Test requirements for checking turbocharging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1.3 Diagram of connections for charge pressure control system and vacuum system . . . . . . 164

1.4 Effects of leaks in charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

1.5 Checking turbocharger and charge pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . 169

1.6 Checking mechanical air recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

1.7 Checking air recirculation valve for turbocharger N249 . . . . . . . . . . . . . . . . . . . . . . . . . . 175

1.8 Checking solenoid valve for charge pressure control N75 . . . . . . . . . . . . . . . . . . . . . . . . 180

1.9 Checking charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

2 Servicing charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

2.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

2.2 Turbocharger - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

2.3 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

2.4 Charge air cooler - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

2.5 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

1 Removing and installing parts of exhaust system - vehicles with front-wheel drive . . . . . . 202

1.1 Exhaust system - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

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 1999 ➤

4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

1.2 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

1.3 Removing and installing front exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . 206

1.4 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

1.5 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

2 Removing and installing parts of exhaust system - vehicles with four-wheel drive . . . . . . 213

2.1 Exhaust system - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

2.2 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

2.3 Removing and installing front exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . 216

2.4 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

2.5 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

2.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

3 Secondary air system - not applicable to engine code AJQ . . . . . . . . . . . . . . . . . . . . . . . . 225

3.1 Principle and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

3.2 Checking secondary air inlet valve N112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

3.3 Checking secondary air pump relay J299 and secondary air pump motor V101 . . . . . . . . 233

3.4 Checking combination valve for secondary air system for proper operation and leakage . . 238

3.5 Removing and installing combination valve for secondary air system . . . . . . . . . . . . . . . . 240

3.6 Removing and installing secondary air pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

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 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

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.

4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

00 – Technical data

1 Technical data

1.1 Engine number

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

be found at the front of the joint between engine and gearbox.

♦ Additionally there is a sticker on the toothed belt cover showing

the “engine code” and “serial number”.

♦ The engine code is also included on the vehicle data sticker.

Note

The engine code is additionally marked at the engine lifting eye (right-side).

Audi TT 1999 ➤

1.2 Engine data

Code letters AJQ APP ARY

Capacity ltr. 1.781 1.781 1.781 Power output kW at rpm 132/5500 132/5500 132/5500 Torque Nm at rpm 235/1950 … 4700 235/1950 … 4700 235/1950 … 4700 Bore ∅ in mm 81 81 81 Stroke mm 86.4 86.4 86.4 Compression

ratio RON at least

Injection/ignition system Motronic Motronic Motronic Firing order 1-4-3-2 1-4-3-2 1-4-3-2 Emissions standard EU2+D3 EU2+D4 EU3 Turbocharging/supercharging yes yes yes Catalytic converter yes yes yes Knock control yes yes yes Charge air cooling yes yes yes Lambda control 1 probe 2 probes 2 probes Variable valve timing no no yes Secondary air system no yes yes

1)

•

In exceptional circumstances, fuel with not less than 95 RON can also be used, but this will cause a

loss of power.

9.5 9.5 9.5

1)

98

1)

98

1)

Code letters ATC AUM AUQ

Capacity ltr. 1.781 1.781 1.781 Power output kW at rpm 132/5500 110/5700 132/5500 Torque Nm at rpm 235/1950 … 4700 210/1750 … 4600 235/1950 … 4700 Bore ∅ in mm 81 81 81 Stroke mm 86.4 86.4 86.4

1. Technical data 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 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Code letters ATC AUM AUQ

Compression

9.5 9.5 9.5

ratio RON at least

98

1)

95

2)

98

1)

Injection/ignition system Motronic Motronic Motronic Firing order 1-4-3-2 1-4-3-2 1-4-3-2 Emissions standard TLEV EU4 EU4 Turbocharging/supercharging yes yes yes Catalytic converter yes yes yes Knock control yes yes yes Charge air cooling yes yes yes Lambda control 2 probes 2 probes 2 probes Variable valve timing no yes yes Secondary air system yes yes yes

1)

•

In exceptional circumstances, fuel with not less than 95 RON can also be used, but this will cause a

loss of power.

2)

•

In exceptional circumstances, fuel with not less than 91 RON can also be used, but this will cause a

loss of power.

Code letters AWP BVP BVR

Capacity ltr. 1.781 1.781 1.781 Power output kW at rpm 132/5500 120/5700 140/5700 Torque Nm at rpm 235/1950 … 4700 225/1950 … 4700 240/1980 … 5400 Bore ∅ in mm 81 81 81 Stroke mm 86.4 86.4 86.4 Compression

9.5 9.5 9.5

ratio RON at least

98

1)

95

2)

98

1)

Injection/ignition system Motronic Motronic Motronic Firing order 1-4-3-2 1-4-3-2 1-4-3-2 Emissions standard LEV EU4 EU4 Turbocharging/supercharging yes yes yes Catalytic converter yes yes yes Knock control yes yes yes Charge air cooling yes yes yes Lambda control 2 probes 2 probes 2 probes Variable valve timing yes yes yes Secondary air system yes yes yes

1)

•

In exceptional circumstances, fuel with not less than 95 RON can also be used, but this will cause a

loss of power.

2)

•

In exceptional circumstances, fuel with not less than 91 RON can also be used, but this will cause a

loss of power.

2 Rep. Gr.00 - Technical data

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

10 – Removing and installing engine

1 Removing and installing engine

1.1 Removing engine

♦ Hose clamps for hoses up

to 25 mm Ø -3094-

♦ Drip tray for workshop hoist

-VAS 6208- or V.A.G 1306-

♦ Engine and gearbox jack -

V.A.G 1383 A-

♦ Hose clip pliers -V.A.G

1921-

♦ Stepladder -VAS 5085-

♦ Engine bracket -T10012-

Audi TT 1999 ➤

♦ Locking pin -T10060 A-

1. Removing and installing engine 3

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Procedure

Note

♦

The engine is removed from underneath together with the gearbox.

♦

All cable ties which are released or cut open when removing must be fitted in the same position when installing.

♦

Collect drained coolant in a clean container for re-use or dis‐ posal.

– Remove engine cover panel -1- and cover -2- in front of intake

manifold -arrows-.

– Remove covers -1- and -2- at lock carrier (left-side) and above

battery -arrows-.

– Remove covers -1- and -2- at lock carrier (right-side) and

above coolant expansion tank -arrows-.

4 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Caution

Observe notes on procedure for disconnecting the battery ⇒ Rep. Gr. 27 .

– With ignition switched off, disconnect battery earth cable

-arrow-.

WARNING

Hot steam or hot coolant can escape when expansion tank is opened; cover filler cap with cloth and open carefully.

– Open filler cap on coolant expansion tank.

– If fitted, unbolt bracket for headlight range control sender in

wheel housing (left-side) -arrows- and tie up sender to one side.

Audi TT 1999 ➤

– Remove centre noise insulation -1 ... 3-.

– Disconnect air pipe at bottom of right-hand longitudinal mem‐

ber -arrows- (air pipe leads to charge air cooler).

1. Removing and installing engine 5

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Remove left noise insulation -arrows-.

– Remove right noise insulation -arrows-.

– If fitted, detach power steering pipe from cross piece

-arrows-.

– Remove front cross piece -arrows-.

6 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Place drip tray for workshop hoist -VAS 6208- under engine.

– Turn drain plug -1- on radiator anti-clockwise and drain coolant

(attach hose to connection if necessary).

– Disconnect coolant hose from radiator by pulling off retaining

clip -2- at bottom.

– Disconnect bottom coolant hose from oil cooler -arrow-, and

drain off remaining coolant.

Audi TT 1999 ➤

– Remove cross piece -1- for suspension strut -arrows-, if fitted.

– Detach air hose -1- leading to secondary air pump at air clean‐

er housing.

– Release hose clip -2- and detach air intake hose from air mass

meter -G70- .

– Unplug electrical connector at air mass meter -G70-

-item 3-.

– Unscrew bolts -4- and -5- and remove air cleaner housing.

1. Removing and installing engine 7

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Vehicles with hoses routed according to version 1:

– Disconnect electrical connector -6- and hose -4- at solenoid

valve for charge pressure control -N75- .

– Pull solenoid valve for charge pressure control -N75- -5- out

of air intake hose.

– Pull mechanical air recirculation valve -3- and pressure control

valve for crankcase breather -8- out of air intake hose.

– Pull out locking clip at connection on turbocharger and dis‐

connect air intake hose -7-.

Note

Seal off opening in turbocharger intake system with a clean cloth.

– Disconnect hose -2- between coolant expansion tank and en‐

gine at bulkhead.

– Disconnect hose -1- between charge pressure control sole‐

noid valve -N75- and turbocharger at bulkhead.

Vehicles with hoses routed according to version 2:

– Disconnect electrical connector -5- and hose -3- at charge

pressure control solenoid valve -N75- .

– Pull solenoid valve for charge pressure control -N75- -4- out

of air intake hose.

– Pull mechanical air recirculation valve -2- and pressure control

valve for crankcase breather -1- out of air intake hose.

– Pull out locking clip at connection on turbocharger and detach

air intake hose -6-.

Note

Seal off opening in turbocharger intake system with a clean cloth.

All models:

– Detach coolant hoses going to to heat exchanger at bulkhead

-arrows- by releasing retaining clips.

8 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Open cover of main fuse box.

– Unclip protective cover -2- for electrical cables.

– Unscrew black wire -1- at fuse block.

– Remove battery.

Vehicles with battery tray (version 1):

– Remove battery tray -arrows-.

Audi TT 1999 ➤

Vehicles with battery tray (version 2):

– Lift off side wall -1- together with main fuse box.

– Remove battery tray -arrows-.

All models:

– Unscrew earth wire -1- at engine/gearbox connection.

– Detach electrical wiring -3- and -4- at starter.

– Detach electrical connector -2- from bracket and unplug.

– Disengage wiring from bracket on starter and move it clear to

the side.

1. Removing and installing engine 9

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Use screwdriver to pry off caps on wiper arms -arrows- and

slacken off nuts several turns.

– Loosen wiper arms -1- from wiper shafts by tilting slightly.

– Remove nuts completely and take off wiper arms.

– Pull off rubber seal -2- and plenum chamber cover -3-.

– Detach the washer hose and electrical connectors at wind‐

screen washer jets.

– Lay aside plenum chamber cover (towards windscreen).

– Unclip cover -2-.

– Detach multi-pin connector -1- at engine control unit.

– Release retaining tab -arrow- and pull engine control unit for‐

wards out of the bracket.

Note

The multi-pin connector -3- remains attached to the engine control unit.

– Open cable duct (left-side) in engine compartment -arrows-.

– Unplug electrical connector in cable duct.

10 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Take electrical connector out of bracket and unplug it

-arrow-.

Note

Illustration shows electrical connector on vehicle with gas dis‐ charge headlights.

– Release wiring harness leading to engine control unit.

– Place engine control unit with wiring harness on top of engine.

– Secure the engine control unit to prevent it falling.

– Unbolt cable support bracket from gearbox and unclip hose

going to clutch slave cylinder -arrows-.

Audi TT 1999 ➤

Vehicles to 06.2001:

– Press locking sleeve in direction of -arrow 1- as far as stop and

lock by turning anti-clockwise in direction of -arrow 2- to re‐ lease cable end-piece for gate selector cable and gear selec‐ tor cable.

– Disengage cables from cable end-piece.

Vehicles from 07.2001:

– Unclip retaining clip -1- from gear selector cable and retaining

clip -2- from gate selector cable.

– Pull selector cable end-pieces with selector cables off selector

shaft lever and relay lever.

1. Removing and installing engine 11

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Vehicles with front-wheel drive:

– Detach gearbox strut -arrows A- from gearbox.

– Remove clutch slave cylinder -arrows- and use a piece of wire

to secure in position (do not open pipes).

Caution

Do not operate clutch pedal with slave cylinder removed.

Vehicles with automatic gearbox 09A:

– Remove bracket -arrow-, if fitted.

– Move selector lever to position “P” and pry selector lever cable

-1- off selector shaft lever -4- using a screwdriver.

Note

Do not loosen bolt -2-.

– Unclip retaining clip -3- at support bracket.

– Detach selector lever cable and move to one side.

– Unplug electrical connectors:

1 - At multi-function switch -F125-

2 - At gearbox wiring harness (turn locking lever)

Note

Disregard -item 3-.

12 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Unscrew earth cable -1- from bracket.

– Unbolt power steering line -arrows-.

– Unscrew bracket -3-.

– Detach rear power steering line from gearbox and tie up to

side.

Vehicles with four-wheel drive:

– Clamp off hydraulic line leading to clutch slave cylinder using

a hose clamp -3094- .

– Pull out retainer towards the top -arrow- and disconnect hy‐

draulic line -1- from hose connector.

Caution

Audi TT 1999 ➤

Do not press clutch pedal after disconnecting hydraulic line.

Vehicles with hoses routed according to version 1:

– Detach vacuum line -arrow- going to brake servo at intake

manifold.

Vehicles with hoses routed according to version 2:

– Detach vacuum line -arrow- going to brake servo.

1. Removing and installing engine 13

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

All models:

– Remove coolant hose -1- between engine and radiator.

– Detach pipe for secondary air system from brackets on engine

-arrows-.

– Remove bolts -2- and -3- and detach bracket for dipstick guide

tube -4-.

– Unplug electrical connectors -1- for turbocharger air recircu‐

lation valve -N249- and secondary air inlet valve -N112- on underside of retainer.

– Detach vacuum hose going to electrical change-over valves

at intake manifold.

– Unplug electrical connector -2-.

– Detach coolant hose -1-.

14 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Vehicles with hoses routed according to version 1:

– Disconnect vacuum line -1- leading to activated charcoal filter

from throttle valve module -J338- .

– Disconnect air intake hose -2- from throttle valve module -

J338- .

– Disconnect hose -arrow- leading to non-return valve.

– Release hose from retainers, etc.

Audi TT 1999 ➤

The fuel system is pressurised. Before opening the system

WARNING

place a clean cloth around the connection. Then release pres‐ sure by carefully unfastening the connection.

– Disconnect fuel supply pipe -1- and fuel return pipe -2- by

pressing release tabs.

Vehicles with hoses routed according to version 2:

– Detach vacuum line -1- leading to activated charcoal filter.

– Disconnect air intake hose -2- from throttle valve module -

J338- .

1. Removing and installing engine 15

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

WARNING

The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pres‐ sure by carefully unfastening the connection.

– Disconnect fuel supply pipe -1- and fuel return pipe -2- by

pressing release tabs.

– Disconnect coolant hose -3- from coolant expansion tank.

Rest-of-world vehicles with halogen headlights:

– Remove nut -1-.

– Lift off activated charcoal filter -2- and release hoses from re‐

tainers, etc.

– Move activated charcoal filter aside.

USA models with halogen headlights:

– Remove nut -1-.

– Lift off vacuum reservoir -2- and release hoses from retainers,

etc.

– Move vacuum reservoir to side.

Vehicles with gas discharge headlights:

– Remove front bumper ⇒ Rep. Gr. 63 .

– Remove right headlight ⇒ Rep. Gr. 94 .

All models:

– Unplug electrical connector at charge pressure sender -G31-

-arrow-.

16 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Detach coolant hoses (right-side) from engine -arrows-.

Note

Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.

– Turn the tensioner in the direction of the -arrow- to slacken the

poly V-belt.

– Remove poly V-belt.

Audi TT 1999 ➤

– Lock tensioner in position with locking pin -T10060 A- .

– Loosen bolts -arrows- of assembly mounting for engine ap‐

prox. 2 turns.

1. Removing and installing engine 17

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Loosen bolts -arrows- of assembly mounting for gearbox ap‐

prox. 2 turns.

– Unscrew bolts for radiator cowl which are accessible from

above.

– Unbolt pulley for power steering pump.

– Unplug electrical connector -1- at power assisted steering

pressure switch -F88- .

– Unbolt power steering pump -arrows-; hydraulic lines remain

attached.

– Detach power steering cooling pipe from gearbox -arrows-.

Vehicles with manual gearbox:

– Unplug electrical connector -arrow- at reversing light switch -

F4- on gearbox.

18 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Vehicles with secondary air system:

– Unplug electrical connector at secondary air pump motor -

V101- , detach hoses and remove nuts -arrows-.

– Detach secondary air pump.

– Release wiring harness leading to body from retainers, etc.

All models:

– Detach electrical connectors -arrows- for radiator fan on bot‐

tom left of radiator cowl.

– Unscrew bolts on radiator cowl (accessible from below) and

remove radiator cowl with both fans from below.

– Tie up power steering pump together with hydraulic line onto

lock carrier on left side.

Audi TT 1999 ➤

Vehicles with air conditioning:

– Unplug electrical connector -1- for magnetic clutch of air con‐

ditioner compressor.

WARNING

The air conditioner refrigerant circuit must not be opened.

– Unscrew bolts -arrow- for air conditioner compressor.

– Tie up air conditioner compressor together with refrigerant ho‐

ses to bonnet lock (refrigerant hoses remain connected).

– Remove cross piece (rear) -arrows-.

1. Removing and installing engine 19

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Vehicles with front-wheel drive:

– Unbolt heat shield for drive shaft (right-side) from cylinder

block -arrows-.

Vehicles with four-wheel drive:

– Unscrew heat shield for drive shaft (right-side) from bevel box

-arrows-.

– Mark position of flexible coupling on bevel box.

– Unscrew propshaft with flexible coupling from bevel box

-arrows- (counter-hold using a suitable lever at the triangular flange).

Caution

Avoid damaging the seal -arrow- in the propshaft flange when removing. If a seal is damaged the propshaft must be renewed.

– Push propshaft horizontally as far back as possible.

20 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

All models:

Caution

After unscrewing the bolts -A-, the engine/gearbox assembly swings slightly forward.

– First remove bolts -A-, then bolts -B- and remove pendulum

support.

– Unbolt protective cover -2- -arrows-.

– Unplug electrical connectors and release wiring for Lambda

probes -1- and -3- from retainers, etc.

Audi TT 1999 ➤

Note

To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°.

– Unscrew nuts -arrows- securing front exhaust pipe to turbo‐

charger.

– Separate exhaust system at clamp -arrows-.

– Push clamp back and remove front exhaust pipe with catalytic

converter.

1. Removing and installing engine 21

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Unbolt coupling rod from anti-roll bar -arrow- on left and right

side of vehicle.

– Unbolt drive shafts (left and right) from gearbox flange shafts.

– Push engine forward. At the same time swivel right drive shaft

towards front and tie up with wire.

– Tie up left-side drive shaft with wire.

Note

Take care not to damage the surface coating of the drive shafts.

– Remove bracket for secondary air pump -arrows-.

– Attach engine bracket -T10012- with nut and bolt to cylinder

block: approx. 20 Nm.

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

bracket -T10012- and raise engine/gearbox assembly slightly.

– Remove bolts -arrows- of assembly mounting on engine.

Note

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

22 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Remove bolts -arrows- of assembly mounting on gearbox.

Note

Check that all hoses, pipes and wiring connections between en‐ gine, gearbox and body have been detached.

– Pull engine/gearbox assembly as far forward as possible, and

lower gradually using engine and gearbox jack -V.A.G 1383 A- .

Note

♦

Carefully guide engine/gearbox assembly when lowering to avoid damage.

♦

Make sure there is sufficient clearance for vacuum unit of charge pressure control system on turbocharger.

1.2 Separating engine from manual gear‐ box

Audi TT 1999 ➤

Procedure

• Engine/gearbox assembly removed and attached to engine

bracket -T10012- .

– Disengage heat protection sleeve at speedometer sender -

G22- .

– Unplug electrical connector -arrow- at speedometer sender -

G22- on gearbox and release wiring from retainers, etc.

Vehicles with four-wheel drive and cast bracket for bevel box:

– Remove bolts -A ... C- on bracket for bevel box.

Note

Leave bracket in position. It cannot be removed at this stage.

1. Removing and installing engine 23

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Vehicles with four-wheel drive and pressed steel bracket for bevel box:

– Remove bolts -A ... C- on bracket for bevel box.

Note

Leave bracket in position. It cannot be removed at this stage.

All models:

Note

On vehicles with four-wheel drive, the small cover plate -2- for the flywheel is located behind the bevel box and is not visible with the bevel box installed. Shown in illustration with gearbox removed.

– Unscrew bolt -1- and lift out cover plate.

– Remove bottom engine/gearbox securing bolts -1 ... 8-.

– Separate gearbox from engine.

Note

Second mechanic is required to separate engine/gearbox as‐ sembly.

24 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

1.3 Separating engine from automatic gearbox 09A

Special tools and workshop equipment required

♦ Hooks -10 - 222 A /2-

♦ Shackle -10 - 222 A /12-

♦ Workshop hoist -VAS

6100-

♦ Socket, 15 mm Matra V175

Audi TT 1999 ➤

Procedure

• Engine/gearbox assembly removed and attached to engine

bracket -T10012- .

– Unplug electrical connectors on gearbox if necessary and re‐

lease wiring from retainers, etc.

– Disconnect coolant hose at ATF cooler.

– Remove plug from opening in cover plate for torque converter.

– Unscrew 3 nuts for torque converter -arrow- using socket

(15 mm Matra V175); turn crankshaft 1/3 turn each time and counterhold at central bolt on vibration damper.

1. Removing and installing engine 25

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Remove starter.

– Secure shackle -10 - 222 A /12- to gearbox housing and con‐

nect shackle to hook -10 - 222 A /2- .

– Attach hook -10 - 222 A /2- to workshop hoist -VAS 6100- .

WARNING

The support hooks and retaining pins on the lifting tackle must be secured with locking pins -arrows-.

– Remove remaining engine/gearbox securing bolts.

– Separate gearbox from engine.

– Secure the torque converter in the gearbox using wire or sup‐

port bridge -30 - 211 A- to prevent it falling out.

26 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

1.4 Securing engine to assembly stand

Special tools and workshop equipment required

♦ Support clamp -VW 313-

♦ Engine and gearbox sup‐

port -VW 540-

♦ Lifting tackle -2024 A-

♦ Workshop hoist -VAS

6100- or -V.A.G 1202 A-

Audi TT 1999 ➤

Procedure

– Hook lifting tackle -2024 A- onto engine and workshop hoist -

VAS 6100- .

Note

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

WARNING

The support hooks and retaining pins on the lifting tackle must be secured with locking pins -arrows-.

– Lift engine off engine and gearbox jack -V.A.G 1383 A- using

workshop hoist -VAS 6100- .

1. Removing and installing engine 27

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– When carrying out repairs, secure engine to assembly stand

with engine and gearbox support -VW 540- .

1.5 Installing engine

Note

♦

On assembly, renew oil seals and gaskets as well as selflocking nuts and bolts that are tightened by turning through to a specified angle.

♦

Hose connections and hoses for charge air system must be free of oil and grease before assembly.

♦

Fit all heat insulation sleeves in the original position when in‐ stalling.

♦

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

♦

Fit all cable ties in the original positions when installing.

– Check whether dowel sleeves for centring the engine/gearbox

assembly are fitted in the cylinder block; install dowel sleeves if necessary.

– Engage intermediate plate on sealing flange and slip onto

dowel sleeves -arrows-.

– Check that clutch plate is correctly centred.

– Check clutch release bearing for wear, renew if necessary.

– Lightly grease clutch release bearing, release bearing guide

sleeve and splines on input shaft with grease for clutch plate splines -G 000 100- .

– Bolt gearbox onto engine. Use new securing bolts on vehicles

with gearbox 02M.

Note

♦

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

♦

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

♦

Do not use degreased parts.

♦

Tolerance for tightening torques ± 15 %.

Vehicles with four-wheel drive:

– Fit bracket for bevel box before installing engine/gearbox se‐

curing bolts.

28 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Vehicles with manual gearbox 02J:

Securing engine to gearbox

Item Bolt Nm

1, 2 1), 8

3 1), 4

M12x55 80

M12x150 80

5, 7 M10x50 45

6 M10x70 45 A Dowel sleeves for centralising

1)

•

Bolt with M8 stud

Vehicles with manual gearbox 02M:

Securing engine to gearbox

Audi TT 1999 ➤

Item

1, 2

3 1), 4

1)

Bolt

2

Nm

M12x55 80

M12x165 80

5 M10x105 40

6, 7 M10x50 40

8 M12x70 80 A Dowel sleeves for centralising

1)

•

Bolt with M8 stud

2)

•

Renew bolts.

All models:

– Push in small cover plate -2- for flywheel in such a way that

lug at bottom engages into the cylinder block and secure with bolt -1-.

Note

Shown in illustration with gearbox removed.

Vehicles with four-wheel drive and cast bracket for bevel box:

– Fit bolts -A ... C- of bevel box bracket. Note tightening se‐

quence:

1. Initially tighten bolts -A- to 3 Nm.

2. Tighten bolts -B- and -C- to 35 Nm.

3. Tighten bolts -A- to 45 Nm.

1. Removing and installing engine 29

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Vehicles with four-wheel drive and pressed steel bracket for bevel box:

– Fit bolts -A ... C- for bevel box bracket. Note tightening se‐

quence:

1. Initially tighten bolts -A- to 3 Nm.

2. Tighten bolts -B- to 35 Nm.

3. Tighten bolt -C- to 22 Nm.

4. Tighten bolts -A- to 45 Nm.

Vehicles with automatic gearbox 09A:

If the torque converter is correctly installed, the depth -a- between the contact surfaces at the bottom of the studs on the torque con‐ verter and the contact surface of the torque converter bell housing is about 22 mm.

If the torque converter has not been completely inserted, this dis‐ tance will be approx. 10 mm.

Caution

If the torque converter is not installed correctly, the drive lugs of the torque converter and the ATF pump will be seriously damaged when the gearbox is joined to the engine.

– To secure torque converter on drive plate, use only genuine

nuts (same as original equipment) as specified in ⇒ Parts catalogue .

– Before installing engine, rotate torque converter and drive

plate so that one hole and one stud are level with aperture for starter motor.

– Bolt gearbox to engine.

Note

♦

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

♦

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

♦

Do not use degreased parts.

♦

Tolerance for tightening torques ± 15 %.

30 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Securing engine to automatic gearbox 09A

Item Bolt Nm

1 M12x40 80

2

1)

M12x60 80

3 M12x70 80 4 M10x70 45 5 M10x55 45

A, B Dowel sleeves for centralising

1)

•

Bolts on left of illustration with M8 stud.

All models:

– Guide engine/gearbox assembly into the body.

– Tighten bolts securing engine mounting to engine support

-arrows- initially hand-tight.

Audi TT 1999 ➤

– Tighten bolts securing gearbox mounting to gearbox support

-arrows- initially hand-tight.

– Use new securing bolts.

Note

The bolts are tightened to final torque only after adjusting the en‐ gine mountings ⇒ page 36 .

– Remove engine bracket -T10012- from engine.

– Bolt drive shafts to flange shafts of gearbox ⇒ Rep. Gr. 40 .

Note

Drive shafts must be installed prior to further assembly.

– Secure pendulum support at gearbox -arrows B-.

– Use new securing bolts.

1. Removing and installing engine 31

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Vehicles with four-wheel drive:

– Secure front exhaust pipe to turbocharger.

Caution

Avoid damaging the seal -arrow- in the propshaft flange when installing. If a seal is damaged the propshaft must be renewed.

– Push engine/gearbox assembly towards bulkhead; the journal

of the bevel box must be simultaneously inserted horizontally and carefully into the flange of the propshaft.

All models:

– Secure pendulum support to subframe -arrows A-.

– Use new securing bolts.

– Install cross piece; note marking “L” or “Links” for left side of

vehicle.

Vehicles with four-wheel drive:

– Secure propshaft with flexible coupling to bevel box -arrows-

⇒ Rep. Gr. 39 .

All models:

– Install exhaust system and align it free of stress ⇒ page 210

or ⇒ page 222 .

– Knock back bushes for securing bolts slightly to facilitate in‐

stallation of power steering pump and air conditioner com‐ pressor.

– Install power steering pump ⇒ Rep. Gr. 48 .

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

– Install secondary air pump ⇒ page 241 .

Vehicles with front-wheel drive:

Caution

The clutch pedal must not be operated before installing slave cylinder.

– Install clutch slave cylinder -arrows- ⇒ Rep. Gr. 30 .

32 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Install gearbox strut -arrows A-.

Audi TT 1999 ➤

1. Removing and installing engine 33

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Vehicles with four-wheel drive:

– Push the hydraulic line -1- for clutch slave cylinder into the

hose connector and lock it with the catch.

Caution

The clutch pedal must not be operated before the clutch sys‐ tem has been bled.

– Detach hose clamp -3094- .

– Bleed clutch hydraulics ⇒ Rep. Gr. 30 .

All models:

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

– Install cable support bracket and selector cables ⇒ Rep. Gr.

34 .

– Adjust selector cables ⇒ Rep. Gr. 34 .

– Install battery tray and battery; follow procedure required after

connecting battery ⇒ Rep. Gr. 27 .

– Install poly V-belt ⇒ page 41 .

– Adjust assembly mountings ⇒ page 36 .

– Connect vacuum hoses ⇒ page 164 .

– Install cross piece for suspension strut ⇒ Rep. Gr. 40 .

– Electrical connections and routing ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations.

– Observe notes on procedures required after connecting bat‐

tery ⇒ Rep. Gr. 27 .

– Install and adjust wiper arms ⇒ Rep. Gr. 92 .

Vehicles with gas discharge headlights:

– Install headlight (right-side) ⇒ Rep. Gr. 94 .

– Install front bumper ⇒ Rep. Gr. 63 .

– Check headlight adjustment ⇒ Maintenance ; Booklet 807 .

All models:

– Check oil level ⇒ page 141 .

– Fill cooling system ⇒ page 146 .

Note

♦

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

♦

Contaminated or dirty coolant must not be used again.

Caution

Never use battery charging equipment for boost starting. There is danger of damaging the vehicle's control units.

34 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Tightening torques

Component Nm

Bolts/nuts M6 9

M8 20 M10 45 M12 65

Except for the following: Front exhaust pipe to turbocharger 40 Pendulum support to: Gearbox

Subframe

Heat shield for drive shaft to:

Cylinder block 35 Bevel box 25

40 + 90°

20 + 90°

Gearbox strut 25 Rear cross piece to subframe

30 + 90° Cross piece to longitudinal member 20 Hose clips for air hoses 3.5

1)

•

Renew bolts.

2)

•

90° = one quarter turn.

3)

•

Install using locking fluid; locking fluid ⇒ Parts catalogue .

Audi TT 1999 ➤

1)2)

1)2)3)

1. Removing and installing engine 35

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

2 Adjusting assembly mountings

2.1 Checking adjustment

Procedure

– Unscrew bolt -1- and remove cover over coolant expansion

tank -arrow-.

– Disengage coolant hose from retainer -arrow-.

– Detach power steering reservoir above engine mounting

(right-side) and move to side.

• Both bolt heads -b- must be flush with the edge of the support arm -2-.

• The distance -a- between engine mounting -1- and support arm -2- must be 13 mm.

– Check gap -a- with 12 mm iron bar (or support bridge -2011- ).

• The bar must be easy to insert.

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

2.2 Adjusting assembly mountings

Special tools and workshop equipment required

36 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

♦ Support bracket -10 - 222 A-

Procedure

If the distance measured is too small or too great, proceed as follows:

– Remove engine cover panel -1- -arrows-.

Note

Audi TT 1999 ➤

Disregard -item 2-.

– Remove front left cover -arrows-.

– Detach air hose -1- leading to secondary air pump at air clean‐

er housing.

– Release hose clip -2- and detach air intake hose from air mass

meter -G70- .

– Unplug electrical connector at air mass meter -G70-

-item 3-.

– Unscrew bolts -4- and -5- and remove air cleaner housing.

2. Adjusting assembly mountings 37

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Set up support bracket -10 - 222 A- on top surface of panel

flange.

• The spindles face forwards.

– Attach hooks of spindles to engine lifting eyes.

– Lift the engine evenly a short distance with both spindles.

– Remove bolts -arrows- of assembly mounting on engine.

– Remove bolts -arrows- of assembly mounting on gearbox.

– Renew all 4 bolts one after the other and hand-tighten.

– Loosen bolts -b- for support arms on right and left sides ap‐

prox. 2 turns.

– Use lever to adjust engine until distance -a- between engine

mounting -1- and support arm -2- is 13 mm.

• It should be possible to insert the 12 mm iron bar (or support bridge -2011- ) easily.

• Both bolt heads -b- must be flush with the edge of the support arm.

– Tighten the bolts -b- for engine assembly mounting.

38 Rep. Gr.10 - Removing and installing engine

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Ensure that the edges of the support arm (on the gearbox as‐

sembly mounting) -a- and gearbox mounting -b- are parallel.

– Tighten the bolts for gearbox assembly mounting.

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

Note

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

Tightening torques

Component Nm

Support arm to: Gearbox support

Engine support

60 + 90°

1)2)

Hose clips for air hoses 3.5

1)

•

Renew bolts.

2)

•

90° = one quarter turn.

Audi TT 1999 ➤

2. Adjusting assembly mountings 39

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

13 – Crankshaft group

1 Servicing work on pulley end

1.1 Poly V-belt drive - exploded view of components

Note

The illustration shows the poly V-belt drive on vehicles with air conditioner.

1 - Poly V-belt

❑ Routing of belt on vehi‐

cles without air condi‐ tioner ⇒ page 41

❑ Routing of belt on vehi‐

cles with air conditioner

⇒ page 41

❑ Double-sided poly V-

belt on vehicles with air conditioner

❑ Before removing, mark

direction of rotation with chalk or felt-tipped pen. If the belt runs in the op‐ posite direction when it is refitted, this can

cause breakage. ❑ Check for wear ❑ Do not kink ❑ Removing and installing

⇒ page 41

2 - 23 Nm

3 - Poly V-belt tensioner

❑ Turn with open-end

spanner to slacken poly

V-belt ⇒ page 42

4 - Vibration damper

❑ With pulley for poly V-

belt ❑ Removing and installing

⇒ page 43

5 - 45 Nm

6 - 23 Nm

7 - Alternator

❑ Removing and installing ⇒ Rep. Gr. 27 ❑ To facilitate attachment of alternator, knock back threaded bushes for alternator securing bolts slightly

8 - Air conditioner compressor

❑ Removing and installing ⇒ Rep. Gr. 87 ❑ After detaching, secure compressor to lock carrier using wire or similar. Do not leave it suspended from

refrigerant pipes. ❑ Do not unscrew or disconnect refrigerant hoses or pipes.

40 Rep. Gr.13 - Crankshaft group

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Audi TT 1999 ➤

4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

❑ To facilitate attachment of air conditioner, knock back threaded bushes for securing bolts slightly

9 - Spacer bush

10 - Bracket for ancillaries

❑ Removing and installing ⇒ page 44

11 - 45 Nm

12 - 23 Nm

13 - 23 Nm

14 - Power steering pump

❑ Removing and installing ⇒ Rep. Gr. 48 ❑ To facilitate positioning of power steering pump, drive back threaded bush for securing bolt slightly at

bracket

15 - Pulley for power steering pump

16 - 23 Nm

17 - Special bolt

❑ For correct version refer to ⇒ Parts catalogue ❑ If bolt strength rating is 8.8, renew bolt and tighten to 10 Nm + 90° further ❑ If bolt strength rating is 10.9, tighten to 40 Nm

Routing of poly V-belt on vehicles without air conditioner

Routing of poly V-belt on vehicles with air conditioner

Note

A double-sided poly V-belt is fitted on engines with A/C compres‐

sor.

1.2 Removing and installing poly V-belt

Special tools and workshop equipment required

1. Servicing work on pulley end 41

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

♦ Locking pin -T10060 A-

Removing

– Remove covers -1- and -2- (right-side) on lock carrier and

above expansion tank -arrows-.

– Detach air intake hose from intake manifold.

Note

Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.

– Turn the tensioner in the direction of the -arrow- to slacken the

poly V-belt.

– Remove poly V-belt.

42 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Lock tensioner in position with locking pin -T10060 A- .

Installing

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

Note

♦

Before fitting poly V-belt, make sure all mechanical units (al‐ ternator, air conditioner compressor, power steering pump) are firmly in position.

♦

Hose connections and hoses for charge air system must be free of oil and grease before assembly.

♦

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

– Fit poly V-belt onto crankshaft pulley, power steering pump

pulley and then onto alternator pulley.

– Release pressure from tensioner and remove locking pin -

T10060 A- .

– Check poly V-belt for proper seating.

• Routing of poly V-belt on vehicles without air conditioner

⇒ page 41 .

• Routing of poly V-belt on vehicles with air conditioner

⇒ page 41 .

– Start engine and check that belt runs properly.

1.3 Removing and installing vibration damp‐

er

Audi TT 1999 ➤

Removing

– Remove poly V-belt ⇒ page 41 .

– Remove centre noise insulation -1 ... 3-.

– Disconnect air pipe at bottom of right-hand longitudinal mem‐

ber -arrows- (air pipe leads to charge air cooler).

1. Servicing work on pulley end 43

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Remove right noise insulation -arrows-.

– Unbolt vibration damper; counterhold on centre bolt with ring

spanner.

Installing

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

– When installing the vibration damper, use only genuine bolts

(same as original equipment): ⇒ Parts catalogue .

• The vibration damper can only be installed in one position. The hole -arrow- in the vibration damper must be located over the projection on the toothed belt sprocket.

Tightening torque

Component Nm

Vibration damper to crankshaft

1)

•

Renew bolts.

Bolt strength rating 8.8

Bolt strength rating 10.9 40

• 90° = one quarter turn.

10 + 90°

1)2)

1.4 Removing and installing bracket for an‐

cillaries

Removing

– Remove engine cover panel -1- and cover -2- in front of intake

manifold -arrows-.

44 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Remove covers -1- and -2- at lock carrier (left-side) and above

battery -arrows-.

– Remove covers (right-side) -1- and -2- at lock carrier and

above expansion tank -arrows-.

Caution

Observe notes on procedure for disconnecting the battery ⇒ Rep. Gr. 27 .

Audi TT 1999 ➤

– Disconnect earth wire at battery with ignition switched off.

– Remove poly V-belt ⇒ page 41 .

– Remove centre noise insulation -1 ... 3-.

– Remove left noise insulation -arrows-.

1. Servicing work on pulley end 45

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Remove right noise insulation -arrows-.

– If fitted, detach power steering pipe from cross piece

-arrows-.

– Remove front cross piece -arrows-.

– Unbolt pulley for power steering pump.

– Unplug electrical connector -1- at power assisted steering

pressure switch -F88- .

– Detach power steering pump from bracket for ancillaries

-arrows-.

– Tie up power steering pump to one side; hydraulic lines remain

connected.

46 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Unplug electrical connector at secondary air pump motor -

V101- , detach hoses and remove nuts -arrows-.

– Detach secondary air pump.

– Detach pipe for secondary air system from brackets on engine

-arrows-.

Audi TT 1999 ➤

– Remove bolts -2- and -3- and detach bracket for dipstick guide

tube -4-.

– Unplug electrical connectors -1- for turbocharger air recircu‐

lation valve -N249- and secondary air inlet valve -N112- on underside of retainer.

– Disconnect vacuum hose going to electrical change-over

valves at intake manifold and lay aside bracket with hoses connected.

– Unplug electrical connector -2-.

– Unscrew electrical wire -1- from alternator.

– Unscrew clamp and move electrical wiring clear.

1. Servicing work on pulley end 47

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Unscrew bolts -arrows-.

– Detach alternator and guide it towards left out of engine com‐

partment.

– Unscrew radiator fan (right-side) from radiator cowl, take out

downwards and tie up to body (wiring remains connected).

Vehicles with air conditioning:

– Unplug electrical connector -1- for magnetic clutch of air con‐

ditioner compressor.

WARNING

The air conditioner refrigerant circuit must not be opened.

– Unscrew bolts -arrow- for air conditioner compressor.

Note

To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent.

– Lower air conditioner compressor and tie up to lock carrier.

All models:

– Remove poly V-belt tensioner -arrows-.

48 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Remove bolts -1 ... 7-.

– Take out support for intake manifold -arrow- and bracket for

ancillaries.

Installing

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

– Drive back the respective bushes for securing bolts slightly to

facilitate installation of alternator, power steering pump and air conditioner compressor.

– Install power steering pump ⇒ Rep. Gr. 48 .

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

– Install alternator ⇒ Rep. Gr. 27 .

– Observe notes on procedures required after connecting bat‐

tery ⇒ Rep. Gr. 27 .

– Install poly V-belt ⇒ page 41 .

Tightening torques

Component Nm

Bracket for ancillaries to cylinder block 45 Support for in‐

take manifold to:

Intake manifold 20 Bracket for ancillaries 45

Radiator fan to radiator cowl 10 Tensioner for poly V-belt to bracket for ancilla‐

ries Pulley to power steering pump 23

23

Front cross piece to longitudinal member 20

Audi TT 1999 ➤

1. Servicing work on pulley end 49

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

1.5 Toothed belt - exploded view of components

1 - Engine support

2 - 45 Nm

3 - Toothed belt cover (top)

❑ To remove toothed belt

cover, it may be neces‐ sary to unbolt bracket for coolant return line (for turbocharger).

❑ Engage carefully in cen‐

tre toothed belt cover when installing

4 - Toothed belt

❑ Before removing, mark

direction of rotation with chalk or felt-tipped pen. If the belt runs in the op‐ posite direction when it is refitted, this can

cause breakage ❑ Check for wear ❑ Removing ⇒ page 52 ❑ Installing (adjusting

valve timing)

⇒ page 55

5 - Idler roller

6 - 27 Nm

7 - 65 Nm

❑ Use counterhold tool

-3036- when loosening

and tightening

⇒ page 51

8 - Camshaft sprocket for ex‐ haust camshaft

❑ Remove toothed belt prior to removing and installing ⇒ page 52 ❑ Installation position ⇒ page 51

9 - Tensioning roller

10 - Washer

11 - Tensioner for toothed belt

12 - O-ring

❑ Renew ❑ Lubricate with coolant additive Plus -G 012 A8F A1- prior to installing

13 - Coolant pump

❑ Removing and installing ⇒ page 149

14 - 15 Nm

15 - Crankshaft sprocket

❑ Contact surface between sprocket and crankshaft must be free of oil ❑ Can only be installed in one position

16 - 90 Nm + 90° (1/4 turn) further

❑ Renew

50 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

❑ Do not lubricate with oil ❑ Use counterhold tool -3415- when loosening and tightening ⇒ page 51

17 - 15 Nm

18 - 25 Nm

19 - Toothed belt cover (centre)

20 - Toothed belt cover (bottom)

21 - 10 Nm

❑ Install using locking fluid; for locking fluid refer to ⇒ Parts catalogue

Loosening and tightening bolt for camshaft sprocket

– Use counterhold tool -3036- when loosening and tightening

central bolt.

Audi TT 1999 ➤

Installation position of camshaft sprocket

• The thinner web of the camshaft sprocket faces outwards

-arrows- and the marking “OT” for TDC is visible from the front.

Removing and installing crankshaft sprocket

– Use counterhold tool -3415- when loosening and tightening

central bolt.

1. Servicing work on pulley end 51

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

1.6 Removing and installing toothed belt

Special tools and workshop equipment required

♦ Support bracket -10 - 222

A-

♦ Tensioning bolt -T10092-

♦ Locking pin -T40011-

Removing

– Remove engine cover panel -1- -arrows-.

Note

Disregard -item 2-.

– Remove poly V-belt ⇒ page 41 .

52 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Remove poly V-belt tensioner -arrows-.

Rest-of-world vehicles with hose routing version 1:

– Detach hose -3-.

– Press release tab and disconnect vacuum line -2- leading to

activated charcoal filter.

– Detach solenoid valve 1 for activated charcoal filter system -

N80- -4- from activated charcoal filter.

– Unscrew nut -arrow- and move activated charcoal filter to one

side; hoses remain connected.

– Detach coolant expansion tank -1- and power steering reser‐

voir -5-. Hoses remain connected.

Audi TT 1999 ➤

Rest-of-world vehicles with hose routing version 2:

– Detach hose -3-.

– Press release tab and disconnect vacuum line -2- leading to

activated charcoal filter.

– Unplug electrical connector -4- at solenoid valve 1 for activa‐

ted charcoal filter system -N80- .

– Remove nut -arrow- and detach activated charcoal filter.

– Detach coolant expansion tank -1- and power steering reser‐

voir -5-. Hoses remain connected.

USA models:

– Detach hose -3-.

– Press release tab and disconnect vacuum hose -2- leading to

solenoid valve 1 for activated charcoal filter system -N80- .

– Unplug electrical connector -4- at solenoid valve 1 for activa‐

ted charcoal filter system -N80- .

– Remove nut -arrow- and detach vacuum reservoir.

– Detach coolant expansion tank -1- and power steering reser‐

voir -5-. Hoses remain connected.

1. Servicing work on pulley end 53

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

All models:

– Turn crankshaft to “TDC”: With engine installed ⇒ page 58 ,

with engine removed ⇒ page 61 .

– Unbolt vibration damper; counterhold on centre bolt with ring

spanner.

– Unbolt lower and centre toothed belt covers -arrows-.

– Set up support bracket -10 - 222 A- on top surface of panel

flange.

• The spindle is located at the front.

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

– Lift engine slightly with spindle of support bracket -10 - 222

A- .

– Unbolt engine mounting and connecting bracket from body

and from engine support -arrows-.

– Remove engine mounting.

54 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Remove bolts for engine support -arrows- but do not take out

the engine support.

Note

To remove the bolts for the engine support, raise or lower the

engine slightly as necessary via the spindle on support bracket

-10 - 222 A- .

– Screw tensioning bolt -T10092- into toothed belt tensioner.

– Compress piston of tensioner just far enough so that the piston

can be locked with locking pin -T40011- .

Note

Bend locking pin -T40011- approx. 90° so it can be inserted more

easily.

Audi TT 1999 ➤

– Mark the rotation direction of toothed belt with chalk or a felt-

tipped pen.

– Pull out toothed belt through space between engine support

and cylinder block.

Installing (adjusting valve timing)

Caution

When turning the camshaft, the crankshaft must not be at “TDC”. Otherwise, there is a risk of damage to valves and pis‐ ton crowns.

– Check that marking on camshaft sprocket is aligned with mark‐

ing on cylinder head cover -arrows-.

– Check that crankshaft is still positioned at TDC -arrow-.

• Vehicles with manual gearbox

1. Servicing work on pulley end 55

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

• Vehicles with automatic gearbox

– Fit toothed belt onto crankshaft sprocket, noting direction of

rotation.

– Fit toothed belt onto remaining sprockets in the sequence:

coolant pump, tensioning roller, camshaft sprocket.

– Remove tensioning bolt -T10092- .

– Remove locking pin -T40011- from tensioner.

• Piston of toothed belt tensioner is released.

– Turn crankshaft at central bolt on toothed belt sprocket two

revolutions in direction of engine rotation and check whether camshaft and crankshaft markings align with their respective reference points.

– Install toothed belt cover.

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

Note

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

– Install vibration damper ⇒ page 43 .

– Install engine support -arrows-.

– Adjust assembly mountings ⇒ page 36 .

– Install poly V-belt ⇒ page 41 .

– Install coolant expansion tank, power steering reservoir and

activated charcoal filter.

Tightening torques

Component Nm

Toothed belt cover (bottom) to cylinder block

Toothed belt cover (centre) to cylinder block

1)

10

1)

10 Engine support to cylinder block 45 Connecting bracket to body/engine mounting 25 Engine mounting to body

Tensioner for poly V-belt to bracket for ancilla‐

40 + 90°

2)3)

23

ries

1)

•

Install using locking fluid; locking fluid ⇒ Parts catalogue .

2)

•

Renew bolts.

3)

•

90° = one quarter turn.

56 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

1.7 Removing toothed belt from camshaft sprocket

Special tools and workshop equipment required

♦ Stud M5x55, nut and large washer

Removing

– Turn crankshaft to “TDC”: With engine installed ⇒ page 58 ,

with engine removed ⇒ page 61 .

– Screw stud M5x55 -item 1- into toothed belt tensioner.

– Screw nut -3- with large washer -2- onto stud.

– Carefully tension piston of tensioner until it is just possible to

detach toothed belt from camshaft sprocket.

Note

Take care not to compress tensioner too far.

– Remove toothed belt from camshaft sprocket.

Audi TT 1999 ➤

Fitting (adjusting valve timing)

Caution

When turning the camshaft, the crankshaft must not be at “TDC”. Otherwise, there is a risk of damage to valves and pis‐ ton crowns.

– Check that marking on camshaft sprocket is aligned with mark‐

ing on cylinder head cover -arrows-.

– Check that crankshaft is still positioned at TDC -arrow-.

• Vehicles with manual gearbox

1. Servicing work on pulley end 57

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

• Vehicles with automatic gearbox

– Fit toothed belt onto camshaft sprocket.

– Release piston of toothed belt tensioner and unscrew stud

-1-.

– Turn crankshaft at central bolt on toothed belt sprocket two

revolutions in direction of engine rotation and check whether camshaft and crankshaft markings align with their respective reference points.

1.8 Positioning crankshaft at “TDC” with en‐ gine installed

Procedure

– Remove engine cover panel -1- -arrows-.

Note

Disregard -item 2-.

58 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Unscrew bolt -1- and remove cover over coolant expansion

tank -arrow-.

– Unplug electrical connector -arrow- at Hall sender -G40- .

– Remove toothed belt cover (top).

Audi TT 1999 ➤

– Remove front left cover -arrows-.

– Detach air hose -1- leading to secondary air pump at air clean‐

er housing.

– Release hose clip -2- and detach air intake hose from air mass

meter -G70- .

– Unplug electrical connector at air mass meter -G70-

-item 3-.

– Unscrew bolts -4- and -5- and remove air cleaner housing.

1. Servicing work on pulley end 59

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Remove centre noise insulation -1 ... 3-.

– Disconnect air pipe at bottom of right-hand longitudinal mem‐

ber -arrows- (air pipe leads to charge air cooler).

– Remove right noise insulation -arrows-.

– Pull out sealing plug at gearbox.

– Turn crankshaft at central bolt on crankshaft sprocket in di‐

rection of engine rotation to TDC mark -arrow-.

• Vehicles with manual gearbox

60 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

• Vehicles with automatic gearbox

• At the same time the marking on the front of the camshaft sprocket must align with the marking on the cylinder head cover -arrows-.

– Rotate crankshaft one turn further if necessary.

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

Note

Audi TT 1999 ➤

♦

Hose connections and hoses for charge air system must be free of oil and grease before assembly.

♦

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

Tightening torque

Component Nm

Hose clips for air hoses 3.5

1.9 Positioning crankshaft at “TDC” with en‐

gine removed

Procedure

• Toothed belt cover (top section) removed

– Turn crankshaft at central bolt on crankshaft sprocket in di‐

rection of engine rotation to “TDC mark” -arrows-.

1. Servicing work on pulley end 61

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

• At the same time the marking on the front of the camshaft sprocket must align with the marking on the cylinder head cover -arrows-.

– Rotate crankshaft one turn further if necessary.

62 Rep. Gr.13 - Crankshaft group

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Audi TT 1999 ➤

4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

2 Removing and installing sealing

flanges and dual-mass flywheel/drive plate

2.1 Sealing flanges and dual-mass flywheel/drive plate - exploded view of com‐ ponents

Note

Servicing clutch ⇒ Rep. Gr. 30

1 - 90 Nm + 90° (1/4 turn) fur‐ ther

❑ Renew ❑ Do not lubricate with oil ❑ Use counterhold tool

-3415- when loosening and tightening

⇒ page 51

2 - Crankshaft sprocket

❑ Contact surface be‐

tween sprocket and crankshaft must be free of oil

❑ Can only be installed in

one position

❑ Removing and installing

⇒ page 65

3 - 15 Nm

4 - Oil seal

❑ Renewing ⇒ page 65 ❑ Do not lubricate with oil

5 - Sealing flange (front)

❑ Must be positioned on

dowel sleeves

❑ Removing and installing

⇒ page 67

6 - Cylinder block

❑ Removing and installing

crankshaft ⇒ page 73

❑ Dismantling and assem‐

bling pistons and con‐ rods ⇒ page 78

7 - 60 Nm + 90° (1/4 turn) further

❑ Renew

8 - Dual mass flywheel/drive plate

❑ Removing and installing dual-mass flywheel on vehicles with manual gearbox ⇒ page 69 ❑ Removing and installing drive plate on vehicles with automatic gearbox ⇒ page 70

2. Removing and installing sealing flanges and dual-mass flywheel/drive plate 63

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

9 - Intermediate plate

❑ Must be positioned on dowel sleeves ❑ Do not damage/bend when assembling ❑ Is fitted on sealing flange ⇒ page 64

10 - Sealing flange (rear) with oil seal

❑ With gasket for cylinder block ❑ Do not lubricate with oil ❑ Take care not to fold over or damage sealing lip of oil seal when fitting ❑ Remove sump prior to removing ⇒ page 132 ❑ To install, push guide sleeve from installation kit onto crankshaft.

Installing intermediate plate

– Engage intermediate plate on sealing flange and slip onto

dowel sleeves -arrows-.

64 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

2.2 Renewing crankshaft oil seal (pulley end)

Special tools and workshop equipment required

♦ Oil seal extractor -3203-

♦ Counterhold tool -3415-

♦ Assembly tool -T10053-

Audi TT 1999 ➤

Procedure

• Engine in vehicle.

– Remove toothed belt ⇒ page 52 .

– Remove crankshaft sprocket; use counterhold tool -3415- to

lock sprocket in place.

2. Removing and installing sealing flanges and dual-mass flywheel/drive plate 65

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Before fitting oil seal extractor, fully screw in centre bolt for

sprocket into crankshaft.

– Unscrew inner section of oil seal extractor -3203- one turn out

of outer section and lock with knurled screw.

– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and screw it into oil seal as far as possible (applying firm pressure).

– Loosen knurled screw and turn inner section of oil seal ex‐

tractor against crankshaft until oil seal is pulled out.

– Clamp flats of oil seal extractor in vice and use pliers to remove

seal.

– Clean running surface and sealing surface.

– Place guide sleeve -T10053/1- onto crankshaft journal.

Note

Do not lubricate sealing lip and outer rim of oil seal before press‐ ing in.

– Slide oil seal over guide sleeve.

– Press in oil seal flush using the centre bolt of toothed belt

sprocket and press sleeve from assembly tool -T10053- .

66 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Renew centre bolt for crankshaft sprocket.

Note

♦

Contact surface between toothed belt sprocket and crankshaft must be free of oil.

♦

Do not lubricate bolt for crankshaft sprocket.

– Install crankshaft sprocket; use counterhold tool -3415- to lock

sprocket in place.

– Install toothed belt (adjust valve timing) ⇒ page 55 .

– Install poly V-belt ⇒ page 41 .

Tightening torque

Component Nm

Toothed belt sprocket to crankshaft

1)

•

Renew bolt.

2)

•

90° = one quarter turn.

90 + 90°

1)2)

Audi TT 1999 ➤

2.3 Removing and installing sealing flange (front)

Special tools and workshop equipment required

♦ Counterhold tool -3415-

♦ Assembly tool -T10053-

♦ Electric drill with plastic brush attachment

♦ Safety goggles

♦ Sealant ⇒ Parts catalogue

2. Removing and installing sealing flanges and dual-mass flywheel/drive plate 67

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Removing

• Engine in vehicle.

– Remove toothed belt ⇒ page 52 .

– Remove crankshaft sprocket; use counterhold tool -3415- to

lock sprocket in place.

– Remove sump ⇒ page 132 .

– Remove bolts -1 ... 6-.

– Lever off sealing flange and remove.

Installing

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

– Carefully remove sealant residue from cylinder block.

WARNING

Wear safety goggles.

– Remove sealant residue from sealing flange using a rotating

plastic brush or similar.

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

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

68 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

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

sealing flange as illustrated -arrow-.

• Thickness of sealant bead: 2 ... 3 mm

Note

♦

The bead of sealant must not be thicker than specified, other‐ wise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe.

♦

The sealing flange must be installed within 5 minutes after ap‐ plying sealant.

– Fit sealing flange and tighten bolts hand-tight.

Note

Use guide sleeve -T10053/1- to attach sealing flange with oil seal fitted.

– Tighten bolts for sealing flange in diagonal sequence.

– Install sump ⇒ page 134 .

Audi TT 1999 ➤

Note

After installing, allow sealant to dry for approx. 30 minutes Then (and only then) fill the engine with engine oil.

– Install crankshaft oil seal (pulley end) ⇒ page 65 .

– Install toothed belt (adjust valve timing) ⇒ page 55 .

Tightening torque

Component Nm

Sealing flange to cylinder block 15

2.4 Removing and installing dual-mass fly‐ wheel

Special tools and workshop equipment required

♦ Counterhold tool -3067-

2. Removing and installing sealing flanges and dual-mass flywheel/drive plate 69

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Removing

– Attach counterhold tool -3067- in position indicated for slack‐

ening bolts.

A - Installation position for counterhold tool when tightening bolts

B - Installation position for counterhold tool when slackening bolts

– Mark installation position of dual-mass flywheel on crankshaft.

Note

To prevent damage to the dual-mass flywheel when removing, the bolts -B- must not be removed with an impact wrench or sim‐ ilar. The bolts may only be removed by hand using conventional tools.

– Rotate the dual-mass flywheel -A- so that the bolts align with

the holes -arrows-.

– When unscrewing the bolts, make sure that the bolt heads do

not come into contact with the dual-mass flywheel; the fly‐ wheel will otherwise be damaged as the bolts are screwed out.

Installing

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

– Use new securing bolts.

Tightening torque

Component Nm

Dual-mass flywheel to crankshaft

1)

•

Renew bolt.

2)

•

90° = one quarter turn.

2.5 Removing and installing drive plate

Special tools and workshop equipment required

60 + 90°

1)2)

70 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

♦ Clutch counterhold tool -VW 558-

♦ Depth gauge

♦ Hexagon bolt M8x45 and hexagon nut M10 (2x)

Removing

– Insert clutch counterhold tool -VW 558- in hole on cylinder

block and use hexagon bolt M8x45 to secure to drive plate (fit two M10 nuts between counterhold tool and drive plate).

A - Installation position for counterhold tool when slackening bolts

B - Installation position for counterhold tool when tightening bolts

– Mark installation position of drive plate on crankshaft.

– Unbolt drive plate.

Audi TT 1999 ➤

Installing

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

– Fit drive plate using washer with notches -1-.

– Use new securing bolts.

– Tighten bolts to 30 Nm.

– Measure depth -a- at three points (measurement is taken

through the hole in the drive plate to the machined surface of the cylinder block).

– Calculate average value.

• Specification: 19.5 … 21.1 mm.

2. Removing and installing sealing flanges and dual-mass flywheel/drive plate 71

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

If the value is below specification:

– Remove drive plate again and re-fit with shim -2-.

– Tighten bolts to 30 Nm.

– Repeat measurement.

If the specification is obtained:

– Tighten bolts for drive plate.

Tightening torque

Component Nm

Drive plate to crankshaft

1)

•

Renew bolt.

2)

•

90° = one quarter turn.

60 + 90°

1)2)

72 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

3 Removing and installing crankshaft

Note

♦

When carrying out repairs, secure engine to assembly stand with engine and gearbox support -VW 540- ⇒ page 27 .

♦

From approx. 05.2000 onwards, bearing shells of the correct thickness are matched to the bearings in the cylinder block at the factory. Coloured dots are used to identify the thickness of the bearing shells ⇒ page 75 .

3.1 Crankshaft - exploded view of components

1 - Bearing shell

❑ For cylinder block (with

oil groove)

❑ Do not interchange

used bearing shells (mark positions)

❑ From approx. 05.2000

onwards: install new bearing shells for the cylinder block with the correct coloured mark‐ ings ⇒ page 75

2 - Drive chain sprocket

❑ For oil pump chain ❑ Renewing ⇒ page 75

3 - Bearing shell

❑ For bearing cap (without

oil groove)

❑ Do not interchange

used bearing shells (mark positions)

❑ From approx. 05.2000

onwards: the crankshaft bearing shells in the bearing caps are only supplied as spare parts with “yellow” colourcoding.

4 - Thrust washers

❑ For bearing No. 3 ❑ Note location

Audi TT 1999 ➤

5 - 65 Nm + 90° (1/4 turn) fur‐ ther

❑ Renew ❑ For measuring radial clearance of crankshaft tighten to 65 Nm, but not further

6 - Bearing cap

❑ Bearing cap 1: Pulley end ❑ Bearing cap 3 with recesses for thrust washers ❑ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side

3. Removing and installing crankshaft 73

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

7 - 10 Nm + 90° (1/4 turn) further

❑ Renew ❑ Sender wheel must be renewed if bolts are loosened ⇒ page 74

8 - Sender wheel

❑ For engine speed sender -G28❑ Can only be installed in one position (holes are off-set) ❑ Sender wheel must be renewed if bolts are loosened ❑ Removing and installing

⇒ page 74

9 - Crankshaft

❑ Axial clearance (new): 0.07 ... 0.23 mm ❑ Axial clearance: wear limit: 0.30 mm ❑ Check radial clearance with Plastigage ❑ Radial clearance (new): 0.02 ... 0.04 mm ❑ Radial clearance: wear limit: 0.15 mm ❑ Do not rotate the crankshaft when checking the radial clearance ❑ Crankshaft dimensions ⇒ page 75

Removing and installing sender wheel

– Sender wheel -2- must always be renewed after slackening off

bolts -1-.

Note

♦

If the countersunk bolts are tightened a second time, the seats for the bolt heads in the sender wheel will be deformed to such an extent that the bolt heads make contact with the crankshaft

-3- -arrows- and the sender wheel beneath the bolts will be loose.

♦

Sender wheel can only be fitted in one position (holes are offset).

Tightening torque

Component Nm

Sender wheel to crankshaft

1)

•

Renew bolts.

2)

•

90° = one quarter turn.

10 + 90°

1)2)

74 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

From approx. 05.2000 onwards: allocation of crankshaft bearing shells for cylinder block

From approx. 05.2000 onwards, bearing shells of the correct thickness are matched to the bearings in the cylinder block at the factory. Coloured dots are used to identify the thickness of the bearing shells.

Note

The -arrow- points to pulley end.

Letter codes on lower sealing surface of cylinder block indicate which bearing shell is to be fitted at each location.

Letter on cylinder block Colour coding of bearing

S = Black

R = Red

G = Yellow

Audi TT 1999 ➤

Note

The crankshaft bearing shells in the bearing caps are only sup‐ plied as spare parts with “yellow” coloured markings.

3.2 Crankshaft dimensions

To approx. 05.2000

Honing dimension (in mm)

Basic dimension 54.00 –0.022

1st undersize 53.75 –0.022

2nd undersize 53.50 –0.022

3rd undersize 53.25 –0.022

Crankshaft main

bearing journal ∅

–0.042

Conrod

bearing journal ∅

50.90 –0.022 –0.042

50.65 –0.022 –0.042

50.40 –0.022 –0.042

50.15 –0.022 –0.042

From approx. 05.2000

Honing dimension (in mm)

Basic dimension 54.00 –0.017

1st undersize 53.75 –0.017

2nd undersize 53.50 –0.017

3rd undersize 53.25 –0.017

3.3 Removing and installing drive chain

Crankshaft main

bearing journal ∅

–0.037

Conrod

bearing journal ∅

50.90 –0.022 –0.042

50.65 –0.022 –0.042

50.40 –0.022 –0.042

50.15 –0.022 –0.042

sprocket

Special tools and workshop equipment required

3. Removing and installing crankshaft 75

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

♦ Drift sleeve -30 - 100-

♦ Thrust plate -40 - 105-

♦ Claw-type puller Kukko 44-1

♦ Protective gloves

Removing

– Remove sump ⇒ page 132 .

– Remove sealing flange (front) ⇒ page 67 .

– Remove oil pump chain sprocket, chain tensioner and chain

⇒ Item 2 (page 131) .

– Pull off crankshaft drive chain sprocket using claw-type puller

Kukko 44-1 -item 2- (protect end of crankshaft with thrust plate

-40 - 105- -item 1-).

Installing

WARNING

Wear protective gloves.

– Heat drive chain sprocket in an oven for approx. 15 minutes

to 220 °C.

76 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Using pliers, locate drive chain sprocket on end of crankshaft.

• Wider collar on drive chain sprocket faces engine.

– Push drive chain sprocket onto crankshaft as far as the stop

using drift sleeve -30 - 100- .

– Install oil pump chain sprocket, chain tensioner and chain

⇒ Item 2 (page 131) .

– Install sealing flange (front) ⇒ page 67 .

– Install sump ⇒ page 134 .

Audi TT 1999 ➤

3. Removing and installing crankshaft 77

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

4 Dismantling and assembling pistons

and conrods

4.1 Different versions of conrods

♦ Gradual introduction of cracked instead of sawn conrods (from

approx. 05.2000 onwards)

♦ Distinguishing feature:

A - Sawn conrods = smooth mating surface

B - Cracked conrods = rough mating surface (produced by indus‐ trial cracking process)

4.2 Pistons and conrods - exploded view of components

Note

Oil spray jet and pressure relief valve ⇒ page 82 .

Pistons and sawn conrods

78 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

1 - Piston rings

❑ Offset gaps by 120° ❑ Remove and install us‐

ing piston ring clamp

❑ “TOP” must face to‐

wards piston crown

❑ Checking ring gap

⇒ page 81

❑ Checking ring-to-groove

clearance ⇒ page 81

2 - Piston

❑ Checking ⇒ page 81 ❑ Mark installation posi‐

tion and cylinder alloca‐ tion

❑ Arrow on piston crown

points to pulley end

❑ Install using piston ring

clamp

❑ Piston and cylinder di‐

mensions ⇒ page 82

3 - Conrod

❑ Only renew as a com‐

plete set

❑ Mark cylinder allocation

-B-

❑ Installation position:

Markings -A- face to‐ wards pulley side

❑ With oil passage for pis‐

ton pin lubrication

4 - Conrod bearing cap

❑ Mark cylinder allocation

-B-

❑ Installation position: Markings -A- face towards pulley side

Audi TT 1999 ➤

5 - 30 Nm + 90° (1/4 turn) further

❑ Renew conrod bolt ⇒ Item 8 (page 79) ❑ Lubricate threads and contact surface ❑ To measure radial clearance, tighten to 30 Nm but do not turn further

6 - Bearing shell

❑ Upper bearing shell with oil hole for piston pin lubrication ❑ Note installation position ❑ Do not interchange used bearing shells (mark positions) ❑ Ensure tight fit in retaining lugs ❑ Axial clearance (new): 0.10 ... 0.35 mm ❑ Axial clearance: wear limit: 0.40 mm ❑ Measuring radial clearance ⇒ page 82

7 - Cylinder block

❑ Checking cylinder bore ⇒ page 82 ❑ Piston and cylinder dimensions ⇒ page 82

8 - Conrod bolt

❑ Renew

4. Dismantling and assembling pistons and conrods 79

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

9 - Circlip

10 - Piston pin

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

Pistons and cracked conrods

1 - Conrod bolt, 30 Nm + 90° (1/4 turn) further

❑ Renew ❑ Lubricate threads and

contact surface

❑ Use old bolt for measur‐

ing radial clearance

❑ To measure radial clear‐

ance, tighten to 30 Nm but not further

2 - Conrod bearing cap

❑ Mark cylinder allocation

-B-

❑ Installation position:

Markings -A- face to‐ wards pulley side

3 - Bearing shells

❑ Upper bearing shell with

oil hole for piston pin lu‐ brication

❑ Installation position

⇒ page 82

❑ Do not interchange

used bearing shells (mark positions)

❑ Axial clearance (new):

0.10 ... 0.35 mm

❑ Axial clearance: wear

limit: 0.40 mm

❑ Measuring radial clear‐

ance ⇒ page 82

4 - Conrod

❑ Only renew as a com‐

plete set ❑ Mark cylinder allocation -B❑ Installation position: Markings -A- face towards pulley side ❑ With oil passage for piston pin lubrication

5 - Circlip

6 - Piston pin

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

7 - Piston

❑ Checking ⇒ page 81 ❑ Mark installation position and cylinder allocation ❑ Arrow on piston crown points to pulley end

80 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

❑ Install using piston ring clamp ❑ Piston and cylinder dimensions ⇒ page 82

8 - Piston rings

❑ Offset gaps by 120° ❑ Remove and install using piston ring clamp ❑ “TOP” must face towards piston crown ❑ Checking ring gap ⇒ page 81 ❑ Checking ring-to-groove clearance ⇒ page 81

Checking piston ring gap

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

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

– Use a piston without piston rings to push in the ring.

Audi TT 1999 ➤

Piston ring

New Wear limit

Dimensions in mm

1st compression ring 0.20 … 0.40 0.80 2nd compression ring 0.20 … 0.40 0.80 Oil scraper ring 0.25 … 0.50 0.80

Checking ring-to-groove clearance

– Clean groove in piston before checking clearance.

Piston ring

New Wear limit

Dimensions in mm

1st compression ring 0.06 … 0.09 0.20 2nd compression ring 0.05 … 0.08 0.20 Oil scraper ring 0.03 … 0.06 0.15

Checking piston

– Measure approx. 10 mm from the bottom edge, perpendicular

to the piston pin axis.

• Maximum deviation from nominal dimension: 0.04 mm.

Nominal dimension

⇒ “4.3 Piston and cylinder dimensions”, page 82 .

4. Dismantling and assembling pistons and conrods 81

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Checking cylinder bore

– Use 50 ... 100 mm internal dial gauge to take measurements

at 3 points in transverse direction -A- and longitudinal direction

-B-.

• Maximum deviation from nominal dimension: 0.08 mm.

Nominal dimension

⇒ “4.3 Piston and cylinder dimensions”, page 82 .

Installation position of bearing shell with cracked conrods

– Insert bearing shells in centre of conrod/conrod bearing cap.

• Distance -a- = 3.0 mm.

Oil spray jet and pressure relief valve

1 - Oil spray jet (for cooling of pistons)

2 - Bolt with pressure relief valve, 27 Nm

• Engines with sawn conrods: opening pressure 2.5 ... 3.2 bar.

• Engines with cracked conrods: opening pressure 1.3 ... 1.6 bar.

4.3 Piston and cylinder dimensions

Honing dimension (in mm)

Basic dimension

Repair oversize

1)

•

Dimension not including graphite coating (thickness 0.02

mm). The graphite coating wears down in service.

Piston ∅ Cylinder bore ∅

80.95

81.45

1)

81.01

81.51

4.4 Measuring radial clearance of conrods

Special tools and workshop equipment required

♦ Plastigage

82 Rep. Gr.13 - Crankshaft group

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Procedure

– Remove conrod bearing caps.

– Clean bearing caps and bearing journals.

– Place Plastigage onto bearing journal or into bearing shells

corresponding to width of bearing.

– Fit conrod bearing cap and tighten to 30 Nm. Do not rotate

crankshaft.

– Remove conrod bearing caps once more.

– Compare width of Plastigage with measurement scale:

Radial clearance:

• New: 0.01 ... 0.05 mm.

• Wear limit: 0.12 mm.

– Renew bolts for conrod bearings.

Audi TT 1999 ➤

4. Dismantling and assembling pistons and conrods 83

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

15 – Cylinder head, valve gear

1 Removing and installing cylinder

head

1.1 Cylinder head - exploded view of components

1 - Cylinder head

❑ Removing and installing

⇒ page 89

❑ Checking for distortion

⇒ page 85 , ⇒ page 85

❑ Machining limit

⇒ page 85 , ⇒ page 85

❑ If renewed, refill system

with fresh coolant

2 - Oil deflector

❑ Note installation posi‐

tion

3 - Cylinder head bolt

❑ Renew ❑ Note correct sequence

when loosening

⇒ page 92

❑ Note correct sequence

when tightening

⇒ page 94

4 - Gaskets for cylinder head cover

❑ Renew if damaged or

leaking

❑ Before fitting, apply

sealant at sealing points

⇒ page 86 and ⇒ page 86

5 - Cylinder head cover

❑ Removing and installing

⇒ page 86

6 - Gasket

❑ For ignition coil bolted onto cylinder head cover ❑ Renew if damaged

7 - Ignition coil

8 - 10 Nm

9 - Filler cap

10 - Seal

❑ For ignition coil bolted onto cylinder head cover

❑ Renew if damaged or leaking

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

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

11 - 10 Nm

❑ First tighten inner nuts ❑ Tighten outer nuts in diagonal sequence

12 - 10 Nm

13 - 10 Nm

14 - Intake manifold

❑ Removing and installing ⇒ page 94

15 - 20 Nm

16 - Gasket

❑ Renew

17 - Support for intake manifold

18 - 45 Nm

19 - Cylinder head gasket

❑ Renewing ⇒ “1.3 Removing and installing cylinder head”, page 89 ❑ Installation position: Part No. towards cylinder head ❑ If renewed, change coolant in entire system

Audi TT 1999 ➤

Checking cylinder head for distortion

– Use straight edge and feeler gauge to measure for distortion

at several points.

• Max. permissible distortion: 0.1 mm

Cylinder head machining limit

Machining of the cylinder head (surface grinding) is only permis‐ sible down to the minimum dimension -a-.

• Minimum dimension: -a- = 139.20 mm

1. Removing and installing cylinder head 85

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Sealing points on double bearing cap/cylinder head

– Apply small quantity of sealant to sealing points -arrows- on

top sealing surface of cylinder head; for sealant refer to ⇒ Parts catalogue .

Sealing points: hydraulic chain tensioner/cylinder head and cam‐ shaft adjuster/cylinder head

– Apply small quantity of sealant to sealing points -arrows- on

top sealing surface of cylinder head; for sealant refer to ⇒ Parts catalogue .

1.2 Removing and installing cylinder head

cover

Special tools and workshop equipment required

♦ Puller -T40039- for vehicles with push-fitted ignition coils

♦ Sealant ⇒ Parts catalogue

Removing

– Remove engine cover panel -1- -arrows-.

Note

Disregard -item 2-.

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

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Unscrew bolt -1- and remove cover over coolant expansion

tank -arrow-.

– Unplug electrical connector -arrow- at Hall sender -G40- .

– Remove toothed belt cover (top).

Audi TT 1999 ➤

– Disconnect crankcase breather hose -3- at cylinder head cov‐

er.

– Unscrew vacuum reservoir -1-, disengage and move clear to

one side.

– Unbolt wiring bracket -2- from cylinder head cover.

– Detach capacitor -4-.

– Disconnect earth cable -2-.

– Unplug electrical connectors -1-.

– Move wiring clear.

Vehicles with bolted on ignition coils:

– Unbolt ignition coils -3-.

1. Removing and installing cylinder head 87

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Vehicles with push-fitted ignition coils:

– Pull ignition coils out with puller -T40039- .

All models:

– Remove toothed belt cover (top).

– Unscrew nuts -arrows- and remove cylinder head cover.

Installing

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

Note

♦

Renew cylinder head cover gaskets if damaged.

♦

Hose connections and hoses for charge air system must be free of oil and grease before assembly.

♦

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

– Apply small quantity of sealant to sealing points -arrows- on

top sealing surface of cylinder head; for sealant refer to ⇒ Parts catalogue .

– Apply small quantity of sealant to sealing points -arrows- on

top sealing surface of cylinder head; for sealant refer to ⇒ Parts catalogue .

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

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– First tighten inner cylinder head cover nuts, then tighten outer

nuts in diagonal sequence.

– Make sure toothed belt cover (top) is correctly fitted.

– Install ignition coils ⇒ Rep. Gr. 28 .

Note

Renew gaskets for bolted on ignition coils if damaged.

Tightening torques

Component Nm

Cylinder head cover to cylinder head 10 Retaining strip for heat insulation sleeve to cyl‐

10

1)

inder head cover Vacuum reservoir to cylinder head 10 Capacitor to cylinder head cover 10

1)

•

Install using locking fluid; for locking fluid refer to ⇒ Parts

catalogue .

Audi TT 1999 ➤

1.3 Removing and installing cylinder head

Removing

• Engine in vehicle.

Note

All cable ties which are released or cut open when removing must be fitted in the same position when installing.

– Drain off coolant ⇒ page 144 .

– Remove air intake hose -2- between top air intake pipe and

bottom air intake pipe.

– Detach retaining clip -1- for top air intake pipe.

– Remove intake manifold ⇒ page 94 .

1. Removing and installing cylinder head 89

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Detach air hose -1- leading to secondary air pump at air clean‐

er housing.

– Release hose clip -2- and detach air duct from air mass meter

-G70- .

– Unplug electrical connector at air mass meter -G70-

-item 3-.

– Unscrew bolts -4- and -5- and remove air cleaner housing.

– Detach mechanical air recirculation valve -3-, pressure control

valve for crankcase breather -6- and charge pressure control solenoid valve -N75- -item 4- from air duct.

– Pull locking clip out at turbocharger connection and detach air

duct -5-.

Note

Seal off opening in turbocharger intake system with a clean cloth.

– Detach hoses -1- and -2- from top air pipe.

– Disconnect air intake hose -3- leading to turbocharger from top

air pipe.

– Unscrew bolts -2- and -5- on retaining clip for top air pipe.

– Unscrew bolts -1- and -4- for heat shield at back of cylinder

head.

– Remove top air pipe and heat shield.

– Unbolt turbocharger from exhaust manifold -arrows-.

Note

Seal off opening in turbocharger intake system with a clean cloth.

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

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

Vehicles with variable valve timing:

– Unplug electrical connector -arrow- at inlet camshaft control

valve 1 -N205- .

All models:

– First unscrew coolant flange and then flange for combination

valve for secondary air system at cylinder head -arrows-.

Note

The electrical connectors and hoses remain attached.

Audi TT 1999 ➤

– Remove toothed belt from camshaft sprocket ⇒ page 57 .

– Remove cylinder head cover ⇒ page 86 .

1. Removing and installing cylinder head 91

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Slacken cylinder head bolts in the sequence: -1 ... 10-.

– Remove cylinder head bolts and detach cylinder head.

Installing

Note

♦

Renew the cylinder head bolts.

♦

Renew self-locking nuts and bolts when performing assembly work.

♦

Renew bolts which are tightened to a specified angle as well as oil seals and gaskets.

♦

Carefully remove any sealant residue from the cylinder head and cylinder block. Ensure that no long scores or scratches are made on the surfaces.

♦

Carefully remove any remaining emery and abrasive material.

♦

No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block.

♦

Do not remove new cylinder head gasket from packaging until it is ready to be fitted.

♦

Handle gasket very carefully. Damage to the silicone coating or the indented area will lead to leaks.

♦

Cylinder heads which have cracks between the valve seats or between a valve seat insert and the spark plug thread can be re-installed without reducing service life, provided the cracks are only slight and do not exceed a maximum of 0.3 mm in width, and no more than the first 4 turns of the spark plug threads are cracked.

♦

When installing an exchange cylinder head with fitted cam‐ shafts, the contact surfaces between the bucket tappets and cams must be oiled after installing the cylinder head.

♦

The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the cylinder head.

♦

Hose connections and hoses for charge air system must be free of oil and grease before assembly.

♦

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

♦

Fit all cable ties in the original positions when installing.

♦

When fitting a new cylinder head or cylinder head gasket, drain off all the old coolant and refill with new coolant.

– Set camshaft to “TDC for No. 1 cylinder” before fitting cylinder

head -arrows-.

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

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4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Check again that crankshaft is positioned at TDC -arrow-.

• Vehicles with manual gearbox

• Vehicles with automatic gearbox

Audi TT 1999 ➤

– Fit cylinder head gasket.

• Note position of centering pins -arrows- in cylinder block.

• The Part No. should be legible from inlet side.

– Fit the cylinder head.

– Fit cylinder head bolts and tighten hand-tight.

1. Removing and installing cylinder head 93

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Audi TT 1999 ➤ 4-cylinder 1.8 ltr. 5-valve turbocharged engine (110-140 kW), mechanics - Edition 12.2005

– Tighten cylinder head bolts as follows in the sequence shown:

1. Tighten with torque wrench to 40 Nm.

2.

Turn 90° (1/4 turn) further using a rigid wrench.

3.

Turn 90° (1/4 turn) further using a rigid wrench.

Note

Cylinder head bolts do not have to be torqued down again later after repair work.

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

– Install cylinder head cover ⇒ page 86 .

– Install toothed belt (adjust valve timing) ⇒ page 55 .

– Install intake manifold ⇒ page 94 .

– Observe notes on procedures required after connecting bat‐

tery ⇒ Rep. Gr. 27 .

– Check oil level ⇒ page 141 .

Note

If engine oil is contaminated, perform oil change ⇒ Maintenance ; Booklet 807 .

– Fill cooling system with fresh coolant ⇒ page 146 .

Tightening torques

Component Nm

Turbocharger to exhaust manifold

Flange for combination valve for secondary air

35

1)2)

10

system to cylinder head Flange for coolant to cylinder head 10 Heat shield to cylinder head 23 Hose clips for air hoses 3.5

1)

•

Renew bolts.

2)

•

Coat threads and contact surface of bolt heads with hightemperature paste; for high-temperature paste refer to ⇒ Parts catalogue .

1.4 Removing and installing intake manifold

Removing

Note

♦

The following description is for removal and installation on ve‐ hicles with secondary air system. Certain work steps may not apply to vehicles without secondary air system.

♦

All cable ties which are released or cut open when removing must be fitted in the same position when installing.

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