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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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.
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.
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.
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.
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.
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.
♦ 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 ➤
1.2Engine data
Code lettersAJQAPPARY
Capacityltr.1.7811.7811.781
Power outputkW at rpm132/5500132/5500132/5500
TorqueNm at rpm235/1950 … 4700235/1950 … 4700235/1950 … 4700
Bore∅ in mm818181
Strokemm86.486.486.4
Compression
In exceptional circumstances, fuel with not less than 95 RON can also be used, but this will cause a
loss of power.
9.59.59.5
1)
98
98
1)
98
1)
Code lettersATCAUMAUQ
Capacityltr.1.7811.7811.781
Power outputkW at rpm132/5500110/5700132/5500
TorqueNm at rpm235/1950 … 4700210/1750 … 4600235/1950 … 4700
Bore∅ in mm818181
Strokemm86.486.486.4
1. Technical data 1
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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 lettersAWPBVPBVR
Capacityltr.1.7811.7811.781
Power outputkW at rpm132/5500120/5700140/5700
TorqueNm at rpm235/1950 … 4700225/1950 … 4700240/1980 … 5400
Bore∅ in mm818181
Strokemm86.486.486.4
Compression
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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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.
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.
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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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.
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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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.
– 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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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.
– 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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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.
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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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.
– 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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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.
– 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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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.
– 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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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.
– 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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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.
– 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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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.
– 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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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.
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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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.
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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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.
– 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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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.
– 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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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.
– 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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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.
– 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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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.
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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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.
– 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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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.
– 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.
1.2Separating 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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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.
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.