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.
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
Page 8
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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
Page 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.
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
Page 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.
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
Page 12
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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
Page 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.
– 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
Page 14
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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
Page 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.
– 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
Page 16
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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
Page 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.
– 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
Page 18
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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
Page 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.
– 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
Page 20
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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
Page 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.
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
Page 22
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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
Page 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.
– 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
Page 24
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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
Page 25
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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
Page 26
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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
Page 27
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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
Page 28
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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
Page 29
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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
Page 30
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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.
Second mechanic is required to separate engine/gearbox as‐
sembly.
24 Rep. Gr.10 - Removing and installing engine
Page 31
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•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
Page 32
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– 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
Page 33
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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
Page 34
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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
Page 35
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– 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
Page 36
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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:
– 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
Page 37
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– 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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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.
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
Page 41
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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.
Except for the following:
Front exhaust pipe to turbocharger40
Pendulum support to: Gearbox
Subframe
Heat shield for drive
shaft to:
Cylinder block35
Bevel box25
40 + 90°
20 + 90°
Gearbox strut25
Rear cross piece to subframe
30 + 90°
Cross piece to longitudinal member20
Hose clips for air hoses3.5
1)
•
Renew bolts.
2)
•
90° = one quarter turn.
3)
•
Install using locking fluid; locking fluid ⇒ Parts catalogue .
Audi TT 1999 ➤
1)2)
1)2)
1)2)3)
1. Removing and installing engine 35
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– 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:
2.2Adjusting assembly mountings
Special tools and workshop equipment required
36 Rep. Gr.10 - Removing and installing engine
Page 43
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with respect to the correctness of information in this document. Copyright by AUDI AG.
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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– 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
Page 45
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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.
– 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
ComponentNm
Support arm to:Gearbox support
Engine support
60 + 90°
60 + 90°
1)2)
1)2)
Hose clips for air hoses3.5
1)
•
Renew bolts.
2)
•
90° = one quarter turn.
Audi TT 1999 ➤
2. Adjusting assembly mountings 39
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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.
1.1Poly 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
Page 47
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❑ 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.
1.2Removing and installing poly V-belt
Special tools and workshop equipment required
1. Servicing work on pulley end 41
Page 48
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– 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
Page 49
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– 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.
1.3Removing 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
Page 50
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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 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
ComponentNm
Vibration damper
to crankshaft
1)
•
Renew bolts.
Bolt strength rating 8.8
Bolt strength rating 10.940
•90° = one quarter turn.
10 + 90°
1)2)
1.4Removing 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
Page 51
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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 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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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-.
– 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
Page 53
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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.
– 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
Page 54
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– 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
Page 55
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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 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
ComponentNm
Bracket for ancillaries to cylinder block45
Support for in‐
take manifold
to:
Intake manifold20
Bracket for ancillaries45
Radiator fan to radiator cowl10
Tensioner for poly V-belt to bracket for ancilla‐
ries
Pulley to power steering pump23
23
Front cross piece to longitudinal member20
Audi TT 1999 ➤
1. Servicing work on pulley end 49
Page 56
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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
Page 57
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❑ 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
Page 58
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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.
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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with respect to the correctness of information in this document. Copyright by AUDI AG.
– 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
Page 61
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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 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
Page 62
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– 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
ComponentNm
Toothed belt cover (bottom) to cylinder block
Toothed belt cover (centre) to cylinder block
1)
10
1)
10
Engine support to cylinder block45
Connecting bracket to body/engine mounting25
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
Page 63
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– 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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– 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.
1.8Positioning crankshaft at “TDC” with en‐
gine installed
Procedure
– Remove engine cover panel -1- -arrows-.
Note
Disregard -item 2-.
58 Rep. Gr.13 - Crankshaft group
Page 65
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– 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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– 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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•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
ComponentNm
Hose clips for air hoses3.5
1.9Positioning 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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•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
Page 69
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2.1Sealing 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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❑ 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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– 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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– 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
Page 73
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2. Removing and installing sealing flanges and dual-mass flywheel/drive plate 67
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– 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
Page 75
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– 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.
2. Removing and installing sealing flanges and dual-mass flywheel/drive plate 69
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– 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
ComponentNm
Dual-mass flywheel to crankshaft
1)
•
Renew bolt.
2)
•
90° = one quarter turn.
2.5Removing and installing drive plate
Special tools and workshop equipment required
60 + 90°
1)2)
70 Rep. Gr.13 - Crankshaft group
Page 77
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– 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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– 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
ComponentNm
Drive plate to crankshaft
1)
•
Renew bolt.
2)
•
90° = one quarter turn.
60 + 90°
1)2)
72 Rep. Gr.13 - Crankshaft group
Page 79
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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 .
3.1Crankshaft - 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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❑ 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
ComponentNm
Sender wheel to crankshaft
1)
•
Renew bolts.
2)
•
90° = one quarter turn.
10 + 90°
1)2)
74 Rep. Gr.13 - Crankshaft group
Page 81
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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 blockColour 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.
3.2Crankshaft dimensions
To approx. 05.2000
Honing dimension
(in mm)
Basic dimension54.00 –0.022
1st undersize53.75 –0.022
2nd undersize53.50 –0.022
3rd undersize53.25 –0.022
Crankshaft main
bearing journal ∅
–0.042
–0.042
–0.042
–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 dimension54.00 –0.017
1st undersize53.75 –0.017
2nd undersize53.50 –0.017
3rd undersize53.25 –0.017
3.3Removing and installing drive chain
Crankshaft main
bearing journal ∅
–0.037
–0.037
–0.037
–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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– 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
Page 83
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– 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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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. Dismantling and assembling pistons and conrods 79
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❑ 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
Page 87
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❑ 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.
– 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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– 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.
4.3Piston 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)
1)
81.01
81.51
4.4Measuring radial clearance of conrods
Special tools and workshop equipment required
♦ Plastigage
82 Rep. Gr.13 - Crankshaft group
Page 89
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– 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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❑ 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
Page 91
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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.
❑ 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
Page 92
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.
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 .
1.2Removing 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
Page 93
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.
– 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
Page 94
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.
– 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
Page 95
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.
– 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
ComponentNm
Cylinder head cover to cylinder head10
Retaining strip for heat insulation sleeve to cyl‐
10
1)
inder head cover
Vacuum reservoir to cylinder head10
Capacitor to cylinder head cover10
1)
•
Install using locking fluid; for locking fluid refer to ⇒ Parts
catalogue .
Audi TT 1999 ➤
1.3Removing 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
Page 96
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.
– 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
Page 97
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.
– 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
Page 98
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.
– 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
Page 99
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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.
– 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
Page 100
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.
– 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
ComponentNm
Turbocharger to exhaust manifold
Flange for combination valve for secondary air
35
1)2)
10
system to cylinder head
Flange for coolant to cylinder head10
Heat shield to cylinder head23
Hose clips for air hoses3.5
1)
•
Renew bolts.
2)
•
Coat threads and contact surface of bolt heads with hightemperature paste; for high-temperature paste refer to ⇒
Parts catalogue .
1.4Removing 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
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