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
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.
All rights reserved. No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A0057005920
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
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
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

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
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
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
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
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
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
– 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
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
– 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
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
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
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
– 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
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
– 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
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
– 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
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
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
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
– 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
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
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
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
– 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
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
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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