Engine BWA, BPY - 2.0 LTR, 4-Valve, Turbo - A005TT00520

Service
Workshop Manual
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve
turbo), mechanics
Engine ID BWA BPY
Edition 11.2006
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Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A005TT00520

Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 11.2006
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Removing and installing engine, detaching from gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.1 Assembly mountings - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Checking adjustment of assembly mountings (engine/gearbox mountings) . . . . . . . . . . . . 26
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2.3 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.1 Poly V-belt, bracket for ancillaries - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.5 Front sealing flange - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.6 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.7 Removing and installing sealing flange (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.1 Rear sealing flange and dual-mass flywheel - exploded view . . . . . . . . . . . . . . . . . . . . . . 48
2.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.3 Removing and installing sealing flange (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1 Crankshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.5 Extracting and driving in needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.6 Removing and installing chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4 Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.1 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.1 Toothed belt drive - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.1 Cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.2 Removing and installing inlet camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . 80
2.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Contents i
Audi TT 2007 ➤
3.1 Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

3.2 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.3 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.4 Checking axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.5 Renewing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.6 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.7 Renewing exhaust camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1 Oil pump and sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.1 Sump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.3 Balance shaft assembly with oil pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.4 Removing and installing balance shaft assembly with oil pump . . . . . . . . . . . . . . . . . . . . . . 127
2 Oil filter bracket and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.1 Oil filter bracket - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.2 Draining oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.3 Removing and installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2.4 Removing and installing oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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2.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.1 Cooling system components (on engine) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.2 Continued coolant circulation pump V51 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.3 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.4 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.5 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.6 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.7 Removing and installing coolant distributor housing with map-controlled engine cooling
thermostat F265 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.8 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.9 Radiator and radiator fans - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.10 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.11 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.12 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 163
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.1 Fitting hose connections with plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.2 Turbocharger - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.3 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.4 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.5 Removing and installing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.6 Adjusting vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.1 Charge air cooler - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.2 Turbocharging diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

1 Parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.1 Exhaust system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.2 Removing and installing front exhaust pipe with catalytic converters and front silencer . . 191
1.3 Aligning exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
ii Contents
Audi TT 2007 ➤
1.4 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
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Contents iii
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iv Contents
Audi TT 2007 ➤
00 – Technical data
1 Engine number
The engine number (including “Engine code” and “Serial num‐
ber”) can be found on the left of the joint between engine and
gearbox.
The engine code is also stamped on the right of the cylinder head
and on the cylinder block.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (up to 3 code letters) represents the “engine
code letters”, the second part (6 digits) the “serial number”. If more
than 999 999 engines were produced with the same code letters,
the first of the 6 digits is replaced by a letter.
Additionally there is a sticker on the toothed belt cover showing
the “engine code” and “serial number”.
The engine code is also to be found on the vehicle data sticker.
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1. Engine number 1
Audi TT 2007 ➤
2 Engine data
Code letters BWA BPY
Capacity ltr. 1.984 1.984
Power output kW at rpm 147/5100 147/5700
Torque Nm at rpm 280/1800 280/2000
Bore ∅ in mm 82.5 82.5
Stroke mm 92.8 92.8
Compression ratio 10.3 10.5
RON 98 1) 98 1)
Injection/ignition system FSI FSI
Firing order 1-3-4-2 1-3-4-2
Knock control yes yes
Turbocharging/super‐ yes yes
charging
Exhaust gas recirculation no no
Intake manifold change- no no
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over
Variable valve timing yes yes
Secondary air system no no
• 1) Unleaded petrol RON 95 can also be used, but results in
reduced power
2 Rep. Gr.00 - Technical data

Audi TT 2007 ➤
3 Safety precautions
When working on the fuel system please note the following warn‐
ings:
WARNING
The fuel system is pressurised. Before opening the system

place a clean cloth around the connection. Then release pres‐
sure by carefully loosening the connection.
Observe the following to avoid injuries to persons and/or damage

to the injection and ignition system:
♦ Always switch off the ignition before connecting or discon‐
necting electrical wiring for the injection or ignition system or
tester cables.
♦ Certain tests may lead to a fault being detected by the engine
control unit and stored in the memory. You must therefore in‐
terrogate the fault memory and erase it if necessary after
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completion of all tests and repair work. If you erase the fault
memory, you must then generate the readiness code in the
engine control unit in “Guided Fault Finding” mode ⇒ Vehicle
diagnosis, testing and information system VAS 5051.
♦ Always switch off the ignition before cleaning the engine.
Caution
♦ Observe notes on procedure for disconnecting the battery

⇒ Rep. Gr. 27 .
♦ Always switch off the ignition before connecting or dis‐
connecting the battery, otherwise the engine control unit
may be damaged.
When working on the cooling system note the following warnings:
WARNING
Hot steam or hot coolant can escape when expansion tank is

opened; cover filler cap with cloth and open carefully.
Note the following if testers and measuring instruments have to

be used during a road test:
WARNING
♦ Test equipment must always be secured on the rear seat

and operated from that position by a second person.
♦ If test and measuring instruments are operated from front
passenger's seat and the vehicle is involved in an acci‐
dent, the person sitting in this seat could be seriously
injured when the airbag is triggered.
3. Safety precautions 3
Audi TT 2007 ➤
4 Rules for cleanliness

Injection system/fuel system
Even small amounts of dirt can cause faults in the injection sys‐
tem. When working on the fuel supply/injection system, please
pay careful attention to the following basic rules:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Plug open lines and connections with suitable protective caps
immediately.
♦ Place parts that have been removed on a clean surface and
cover them over. Use only lint-free cloths.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).
♦ When the system is open: Do not work with compressed air.
Do not move the vehicle unless absolutely necessary.
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♦ Unplugged electrical connectors must be kept clean and dry.
Make sure connections are dry when attaching.
Turbocharger
When working on the turbocharger, pay careful attention to the
following “5 rules”:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place parts that have been removed on a clean surface and
cover them over. Use only lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have been stored loose (e.g. in tool boxes etc.).
♦ When the system is open: Do not work with compressed air if
this can be avoided. Do not move the vehicle unless absolutely
necessary.
4 Rep. Gr.00 - Technical data

Audi TT 2007 ➤
10 – Removing and installing engine

1 Removing and installing engine, de‐
taching from gearbox
1.1 Removing engine
Special tools and workshop

equipment required
♦ Drip tray for workshop hoist
-VAS 6208-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Hose clip pliers -V.A.G
1921-
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♦ Stepladder -VAS 5085-
♦ Engine bracket -T10012-
♦ Removal lever -80 - 200-
1. Removing and installing engine, detaching from gearbox 5

Audi TT 2007 ➤
Lambda probe open ring spanner set -3337-

Engine bung set -VAS 6122-
Note
♦ The engine is removed from underneath together with the

gearbox.
♦ Renew all cable ties which are released or cut open when re‐
moving the engine. Refit in the same position when installing
the engine.
♦ Heat insulation sleeves removed when taking out the engine
are to be reinstalled in the original position.
♦ Collect drained coolant in a clean container for re-use or dis‐
posal.
WARNING
Observe notes on procedure for disconnecting the battery. ⇒
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Electrical system; Rep. Gr. 27
– Remove luggage compartment floor covering.

– Release retaining clips -arrows- and detach cover for negative
terminal.
Note
Remove rear cross panel trim if cover for negative terminal of

battery is located under rear cross panel trim ⇒ Rep. Gr. 70 .
– With ignition switched off, disconnect earth wire -arrow- at

battery.
WARNING
Hot steam/hot coolant may escape when opening expansion

tank. Cover cap with cloth and open carefully.
– Open filler cap on coolant expansion tank

– Remove both front wheels.
6 Rep. Gr.10 - Removing and installing engine

Audi TT 2007 ➤
– Remove centre noise insulation -fasteners 1 ... 4-.
– Remove noise insulation panels (left and right) -arrows-.
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– Remove noise insulation frame -arrow-.
– Unplug electrical connector at air mass meter -G70- -3-.

– Open clamps -1 and 2- and disconnect air intake hose from
air mass meter.
– Detach air intake connection at lock carrier -4-.
– Pull off engine cover panel.

Audi TT 2007 ➤
– Remove air intake hose -arrow- using hose clip pliers -V.A.G
1921- .
– Remove electrical connector -arrow- for Lambda probe (be‐

fore catalytic converter) from bracket, unplug and move clear.
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– Unscrew Lambda probe -G39- -arrow- using tool from Lambda
probe open ring spanner set -3337- .
– Use screwdriver to pry off cover caps on wiper arms and un‐
screw hexagon nuts.
– Pull wiper arms off wiper shafts and remove.
– Pull off rubber seal -1- on plenum chamber cover.

– Detach plenum chamber cover -2-.
– Move engine wiring harness in plenum chamber clear.
– Remove engine control unit. ⇒ Rep. Gr. 24

Audi TT 2007 ➤
– Unplug engine wiring harness connector -1-.
– Release wiring protector for engine wiring harness -arrow- and

lift off.
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– Open wiring duct brackets -arrows-.
– Move electrical connector -1- clear and unplug connector.

– Open wiring duct bracket located below -2-.
– Open wiring duct bracket -3-.
– Remove engine control unit wiring harness from wiring duct.

Audi TT 2007 ➤
Note
Use removal lever -80 - 200- to lever out the wiring clips.
– Unplug electrical connector -1- for reversing light switch.

– Disconnect earth cable -2-.
– Unplug electrical connector -3-.
– Slide cover -4- to rear.
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– Detach wire -arrow- at starter and move clear.
– Press the two clips in direction of the -arrows- and remove

cover from electronics box in engine compartment.

Audi TT 2007 ➤
– Unscrew electrical wire -1- and move clear up to engine.

– Unscrew bolts -1- from above.
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– Place drip tray for workshop hoist -VAS 6208- beneath engine.
– To drain off coolant, detach bottom coolant hose -arrow-.
– Remove air pipe -1 and 2- for charge air cooler.

Audi TT 2007 ➤

– Unscrew the bolts -3- and remove radiator cowl from below.
– Detach top coolant hose from radiator -arrow-.
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– Detach coolant hoses going to heat exchanger -arrows-.
– Unscrew securing bolts -arrows- for front exhaust pipe/turbo‐

charger accessible from above.
Note
Shown in illustration from rear with engine removed.

Audi TT 2007 ➤
– Disconnect vacuum hose -arrow- leading to brake servo.
– Unclip securing clips -1- and -2- on both selector cables.

– Pull off selector cable end-pieces from gearbox selector lever
and relay lever.
– Detach cable support bracket from gearbox -arrows- and
place to one side.
WARNING
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Do not press clutch pedal after disconnecting hose leading to
slave cylinder.
– Pull out clip -2- as far a stop in -direction of arrow- and detach
hose -1-.
WARNING
Fuel supply line is pressurised. Wear safety goggles and pro‐

tective clothing to avoid possible injury and skin contact. Before
removing from hose connection wrap a cloth around the con‐
nection. Then release pressure by carefully pulling hose off
connection.
– Mark fuel line -2- and line going to ACF -1-.

– Disconnect fuel line -2- and move clear.
– Disconnect ACF line -1- and move clear.
– Disconnect vacuum line -3- going to activated charcoal filter
(press release tabs).
– Lift out ACF.

Audi TT 2007 ➤
– Detach coolant hoses -1 and 2-.

– Discharge the refrigerant system ⇒ Rep. Gr. 87 ; Air condi‐
tioner system with refrigerant R134a .
– Disconnect air conditioner pipes -arrows- at compressor.
– Plug the openings with sealing plugs from engine bung set -
VAS 6122- .
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– Loosen bolts -arrows- of assembly mounting for engine ap‐
prox. 2 turns.
– Loosen bolts -arrows- of assembly mounting for gearbox ap‐

prox. 2 turns.

Audi TT 2007 ➤
– Unplug electrical connector -arrow-.
– Remove air pipe -arrows-.
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– Unplug electrical connector -1- for high-pressure sender -
G65- .
– Detach air conditioner pipe from condenser -2-.
– Unplug electrical connector at oil level sender -1-.

– Unclip bracket -2-.

Audi TT 2007 ➤
– Unbolt heat shield for drive shaft (right-side) -arrows-.

– Remove drive shafts (left and right) ⇒ Rep. Gr. 40 .
– Remove nuts -1- and -2- on bracket for electrical connector for
Lambda probe on underside of vehicle and remove cover.
– Unscrew bolt -3- and move electrical wire for Lambda probe
clear.
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– Detach plug connector from bracket -arrow-.
– Unplug connector for Lambda probe after catalytic converter
-G130- .
– Unscrew remaining securing nuts -arrows- for front exhaust

pipe/turbocharger from below.

Audi TT 2007 ➤
– Unbolt bracket for exhaust system and tunnel brace -arrows-.
Note
To avoid any damage, the flexible joint in the front exhaust pipe
must not be bent more than 10°.
– Separate exhaust system at clamp -arrows-.
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– Remove front exhaust pipe with catalytic converter and front
silencer.
– Remove bolts -1 ... 3- and take out pendulum support.
– Unscrew the additional coolant pump -arrows-.

Audi TT 2007 ➤
– Bolt engine bracket -T10012- with securing bolt -1- and nut
-2- to cylinder block (tightening torque: approx. 20 Nm).
– Insert engine and gearbox jack -V.A.G 1383 A- in engine
bracket -T10012- and raise engine slightly.
Note
To unscrew bolts for assembly mounting use stepladder -VAS

5085- .
– Remove bolts -arrows- of assembly mounting on engine.
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– Remove bolts -arrows- of assembly mounting for gearbox.
Note
♦ Check that all hoses, pipes and wiring connections between

engine, gearbox and body have been detached.
♦ Carefully guide engine/gearbox assembly when lowering to
avoid damage.
– Pull engine/gearbox assembly as far forward as possible, and

lower gradually.
1.2 Separating engine and gearbox

• Engine/gearbox assembly removed and attached to engine
bracket -T10012- .

Audi TT 2007 ➤
– Unscrew bolt -1- with gearbox installed.

– Pull up cover plate -2- and remove.
Note
Shown in illustration with gearbox removed.
– Remove bolts -1 ... 8- on engine/gearbox flange.

– Detach starter.
Note
The manual gearbox can be detached from the engine without a

workshop hoist, a 2nd mechanic is required for this purpose.
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– Separate gearbox from engine.

Audi TT 2007 ➤
1.3 Securing engine to assembly stand

equipment required
♦ Lifting tackle -2024 A-
♦ Workshop hoist -VAS
6100-
♦ Engine and gearbox sup‐
port -VAS 6095-
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• Gearbox detached from engine.

Audi TT 2007 ➤
– Engage lifting tackle -2024 A- on engine and workshop hoist

-VAS 6100- .
Note
To adjust to the centre of gravity of the assembly, the perforated

rails of the support hooks must be positioned as shown.
WARNING
The support hooks and locating pins on the lifting tackle must
be secured with locking pins (arrows in illustration).
– Lift engine off engine bracket -T10012- using workshop hoist

-VAS 6100- .
Secure engine to engine and gearbox support -VAS 6095- when
dismantling/assembling engine.
1.4 Installing engine
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• Engine installed on engine bracket -T10012- .
Installation is carried out in the reverse order; note the following:
Note
♦ Reinstall all cable ties in the same locations when assembling.

♦ Secure all hose connections with the correct type of hose clips
(same as original equipment): ⇒ Parts catalogue
♦ 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.
♦ Clean input shaft splines and (in the case of used clutch plates)
the hub splines. Remove corrosion and apply only a very thin
coating of grease (⇒ Parts catalogue ) to the splines. Then
move clutch plate back and forth on input shaft until the hub
moves smoothly on the shaft. Remove any excess grease.
– Check whether dowel sleeves for centring the engine/gearbox

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

Audi TT 2007 ➤
– Ensure that the intermediate plate is engaged on the sealing

flange and pushed onto the dowel sleeves -arrows-.
– Check clutch release bearing for wear; renew if necessary.
– 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%.
Securing engine to gearbox

Item Bolt Nm
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1, 2 M12×65 80
3 1), 4 1) M12×135 80
5 ... 7 M10×60 40
8 M12×90 65
• 1) Bolt with M8 stud
A: Centring sleeves
– Push in splash plate -2- in such a way that the lower lug en‐
gages into the cylinder block and secure on top with bolt -1-.
Note
Shown in illustration with gearbox removed.
– Guide engine/gearbox assembly into the body.
– Tighten bolts -arrows- of assembly mounting for engine initially

hand-tight.

Audi TT 2007 ➤
– Tighten bolts of assembly mounting for gearbox -arrows- ini‐

tially hand-tight.
Note
♦ Use new securing bolts.

♦ The bolts are tightened to final torque only after adjusting the
engine mountings ⇒ page 25 .
– Remove engine bracket -T10012- from engine.
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Audi TT 2007 ➤
– Secure pendulum support to gearbox and subframe -1 ... 3-.

– Install drive shafts ⇒ Running gear, front-wheel drive and four-
wheel drive; Repair group 40
– Install exhaust system and align it free of stress
⇒ page 194 .
– Install Lambda probe -G39- ⇒ Rep. Gr. 24 .
– Charge refrigerant circuit ⇒ Air conditioning system; Repair
group 87
– Attach and adjust selector mechanism at gearbox: ⇒ Rep. Gr.
34 .
– Adjust engine mountings ⇒ page 27 .
– Electrical connections and routing: ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
– Bleed fuel system ⇒ Motronic direct injection and ignition sys‐
tem (4-cylinder); Repair group 24; Servicing fuel injection sys‐
tem
– Check oil level ⇒ Maintenance ; Booklet 810 .
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– Connect battery ⇒ Electrical system; Rep. Gr. 27 .
– Fill up with coolant ⇒ page 147 .
– Installing air pipes with connectors ⇒ page 164
Note
♦ Drained-off coolant may only be used again if the original cyl‐

inder head and cylinder block are re-installed.
♦ Contaminated or dirty coolant must not be used again.
WARNING
Never use battery charging equipment for boost starting. There

is danger of damaging the vehicle's control units.
Tightening torque
Component Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Except for the following:
Pendulum support to gearbox 40 + 90° 1)2)
Pendulum support to subframe 100 + 90° 1)2)
Terminal B+ to starter 16
Earth wire to gearbox 23
• 1) Renew bolt
• 2) 90° = one quarter turn.

Audi TT 2007 ➤
2 Assembly mountings
2.1 Assembly mountings - exploded view
1 - Bolt
❑ Gearbox support to
gearbox
❑ Tightening torque ⇒
Rep. Gr. 34
2 - Bolts
❑ Pendulum support to
gearbox
❑ Renew
❑ 40 Nm + 90° (1/4 turn
further).
3 - Engine support
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❑ With support arm
4 - Bolt
❑ Engine support to en‐
gine
❑ 45 Nm
5 - Engine mounting
6 - Bolt
❑ Engine mounting to
body
❑ Renew
❑ 40 Nm + 90° (1/4 turn
further).
7 - Connecting bracket
8 - Bolt
❑ Connecting bracket to
engine mounting
❑ Renew
❑ 20 Nm + 90° (1/4 turn
further).
9 - Bolt
❑ Connecting bracket to body
❑ Renew
❑ 20 Nm + 90° (1/4 turn further).
10 - Bolt
❑ Engine mounting to body
❑ Renew
❑ 40 Nm + 90° (1/4 turn further).
11 - Bolts
❑ Engine mounting to engine support
❑ Renew
❑ 60 Nm + 90° (1/4 turn further).
2. Assembly mountings 25
Audi TT 2007 ➤
12 - Pendulum support
13 - Bolt
❑ Pendulum support to subframe
❑ Renew
❑ 100 Nm + 90° (1/4 turn further).
14 - Bolt
❑ Gearbox mounting to gearbox support
❑ Tightening torque ⇒ Rep. Gr. 34
15 - Bolt
❑ Gearbox mounting to body
16 - Gearbox mounting
❑ With support arm
17 - Bolt
❑ Gearbox support to gearbox
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18 - Bolt
❑ Gearbox support to gearbox
19 - Gearbox support
2.2 Checking adjustment of assembly

mountings (engine/gearbox mountings)
Procedure
– Lift out activated charcoal filter from retainer
-in direction of arrow- with pipes connected and lay aside.

Audi TT 2007 ➤
Proceed as follows:
– Check distances at mounting (right-side) for engine and gear‐
box:
• The two bolt heads -2- must be parallel with edge of support
arm -3- for engine mounting.
• There must be a distance of -x- = 16 mm between engine
mounting -1- and engine support -4-.
Note
Distance -x- = 16 mm can also be checked with a metal rod of

suitable size, or similar.
– If the distance measured is too large or small, the assembly

mountings must be adjusted ⇒ page 27 .
2.3 Adjusting assembly mountings
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equipment required
♦ Support bracket -10 - 222
A-
♦ 2x spindle -10 - 222 A /11-
♦ Adapter -10 - 222 A /20-
(2x)
♦ Hooks -10 - 222 A /2-
♦ Engine support bracket
(basic set) -T40091-
(supplementary set) -
T40093- with -T40093/3-2-
and -T40093/3-3-
Proceed as follows:
• Tightening torques ⇒ page 25 .
Audi TT 2007 ➤

air mass meter.
– Pull activated charcoal filter with hoses attached upwards out
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of the retainer -arrow- and place to side.
– Remove bracket for activated charcoal filter.
– Disconnect coolant pipe -arrows-.
– Detach gear selector cable -arrow-.

Audi TT 2007 ➤
– Position support bracket -10 - 222 A- on bolted flanges of wing

panels using the following tools:
♦ 2x Rack -10 - 222 A /1-
♦ Support bracket -10 - 222 A-
♦ Spindle -10 - 222 A /11- (spindle faces front)
♦ Hooks -10 - 222 A /2-
♦ Adapter -10 - 222 A /20-
♦ Connecting piece -T40091/3- (2x)
– Attach spindle -10 - 222 A /11- with hook -10 - 222 A /2- and
adapter -10 - 222 A /20- to gearbox lifting eye.
– Tighten spindle slightly to take up weight of engine/gearbox
assembly.
– Fit adapter -T40092/3-2- (left-side) and -T40093/3-3- (right-
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side) to supports -T40093/3- .
– Unbolt earth wire from longitudinal member (left-side).
– Remove connecting bolt for front section of longitudinal mem‐
ber on left and right.
– Secure adapter -T40092/3-2- (left-side) and -T40093/3-3-
(right-side) to longitudinal members using the removed bolts
-arrow-.
Note
The illustration shows the left side of the vehicle.
– Fit square-section pipes -T40091/1- with connecting pieces -

T40093/4- into connecting pieces -T40091/3- and supports -
T40093/3-- as shown in illustration.
Audi TT 2007 ➤
– Push support -T40091/2- with sliding support -T40093/5- into

the two connecting pieces -T40093/4- .
WARNING
Accident risk from loose components of support bracket.

♦ Secure support -T10091/2- with pins and split pins of con‐
necting pieces -T40093/4- .
♦ Secure connecting pieces and supports with clamping
bolts.
– Fit spindle -10 - 222 A /11- with adapter -10 - 222 A /20- onto
sliding support and onto engine lifting eye.
– Take up weight of engine/gearbox assembly by evenly tight‐
ening two spindles.
– Unscrew bolts -arrows- on engine assembly mounting one af‐
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ter the other, renew them (if not already renewed when engine
was installed) and screw in loosely.
– Unscrew bolts -arrows- on gearbox assembly mounting one

after the other, renew them (if not already renewed when en‐
gine was installed) and screw in loosely.
– Slacken bolts on left and right-hand support arms by about two
turns each.

Audi TT 2007 ➤
– Using a tyre iron, adjust engine/gearbox assembly between

engine mounting -1- and engine support -4- until the specifi‐
cations listed below are obtained:
• The two bolt heads -2- must be parallel with the edge of the
support arm -3-.
• There must be a distance of -x- = 16 mm between engine
mounting -1- and engine support -4-.
Note
Distance -x- = 16 mm can also be checked with a metal rod of

suitable size, or similar.
– Tighten bolts of assembly mounting at gearbox.
– Ensure that the edges of the support arm (on the gearbox as‐
sembly mounting) -1- and gearbox mounting -2- are parallel.
• Dimension -x- must be identical on both sides of mounting.
– Tighten bolts for assembly mounting.
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Remaining installation steps are carried out in reverse sequence;
note the following:
– Tighten bolts for front section of longitudinal member ⇒ Rep.
Gr. 50 .
Audi TT 2007 ➤
13 – Crankshaft group
1 Cylinder block (pulley end)
1.1 Poly V-belt, bracket for ancillaries - ex‐

ploded view
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. Ensure that the belt
is properly seated in the pulleys when installing.
1 - Vibration damper
❑ For poly V-belt
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❑ Removing and installing
⇒ page 38
2 - Bolt
❑ 10 Nm + 90°
Renew ⇒ Parts catalogue
3 - Bolt
❑ 23 Nm
4 - Tensioner for poly V-belt
❑ Pivot with open-end
spanner to slacken poly
V-belt
❑ Secure tensioner in po‐
sition using locking pin -
T10060A-
5 - Bracket for ancillaries
⇒ page 35
❑ Tightening sequence
⇒ page 33
6 - Bolt
❑ 23 Nm
7 - Nut
❑ 23 Nm
8 - Alternator
⇒ Electrical system; Re‐
pair group 27
❑ To facilitate attachment
of alternator, knock
back threaded bushes for alternator securing bolts slightly
9 - Bolt
❑ Apply locking fluid when fitting
❑ Locking fluid ⇒ Parts catalogue
32 Rep. Gr.13 - Crankshaft group

Audi TT 2007 ➤
❑ Tightening sequence ⇒ page 33

10 - Bush
❑ 2x
11 - Bolt
❑ 25 Nm
12 - Air conditioner compressor
❑ Removing and installing ⇒ Air conditioning; Repair group 87
13 - Poly V-belt
❑ Routing of poly V-belt ⇒ page 33
❑ Check for wear
❑ Do not kink
❑ Removing and installing ⇒ page 33
Routing of poly V-belt
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Tightening sequence on bracket for ancillaries
– Proceed as follows:
1. Screw in bolts -1 ... 6- hand-tight.
2. Tighten bolts -1 ... 6- to 45 Nm.
1.2 Removing and installing poly V-belt

Special tools and workshop equipment required
1. Cylinder block (pulley end) 33

Audi TT 2007 ➤
♦ Locking pin -T10060A-
Removing
air mass meter.
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– Lift out activated charcoal filter from retainer with pipes con‐
nected -arrow- and lay aside.
Note

when it is refitted, this can cause breakage.
– Mark direction of rotation of poly V-belt.
– To slacken poly V-belt, turn tensioner in -direction of arrow-.

Audi TT 2007 ➤
– Lock tensioner in position with locking pin -T10060A- .

– Remove poly V-belt.
Installing
Note
Before fitting poly V-belt, make sure all ancillary units (alternator
and air-conditioner compressor) are firmly secured.
– Fit the poly V-belt onto the crankshaft and air conditioner com‐
pressor pulleys.
– Then position poly V-belt on alternator pulley and release ten‐
sioner.
– Check that poly V-belt is properly seated.
– Start engine and check that belt runs properly.
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1.3 Removing and installing bracket for an‐
cillaries

Audi TT 2007 ➤
Removing
air mass meter.
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– Lift out activated charcoal filter from retainer with pipes con‐
nected -arrow- and lay aside.
Note


– Take off poly V-belt.

Audi TT 2007 ➤
– Remove tensioner for poly V-belt -arrows-.

– Discharge the refrigerant system ⇒ Rep. Gr. 87 ; Air condi‐
tioner system with refrigerant R134a .
– Remove alternator ⇒ Electrical system; Repair group 27 .
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– Remove right noise insulation -arrows-.

– Remove air conditioner compressor ⇒ Rep. Gr. 87 ; Heating,
air conditioning system .

Audi TT 2007 ➤
– Detach bracket for ancillaries: bolts -1 … 6-.

Installing
• Tightening torques ⇒ page 32
– Tighten bolts in the sequence -1 ... 6-.
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– Install alternator ⇒ Electrical system; Repair group 27 .
– Install air conditioner compressor ⇒ Rep. Gr. 87 ; Heating, air
conditioning system .
– Install poly V-belt ⇒ page 33 .
– Connect battery. Procedures required ⇒ Electrical system;
Repair group 27 .
1.4 Removing and installing vibration damp‐

er
Removing
• Poly V-belt must be removed ⇒ page 33 .

Audi TT 2007 ➤
cardiagn.com
– Unscrew vibration damper and remove.
Note
To loosen and tighten the vibration damper, counterhold with ring

spanner on centre bolt.
Installing
– 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 crankshaft vibration damper must be loca‐
ted over the projection on the toothed belt sprocket.

Audi TT 2007 ➤
1.5 Front sealing flange - exploded view
1 - Bolt
❑ 90 Nm + 90° (1/4 turn)
further
❑ Renew
❑ Do not lubricate with oil
❑ Attaching counterhold
tool 3415 ⇒ page 65
2 - Crankshaft sprocket
❑ Contact surface be‐
tween sprocket and
crankshaft must be free
of oil
❑ Can only be installed in
one position
3 - Bolt
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⇒ page 40
4 - Oil seal
❑ Renewing ⇒ page 41
5 - Sealing flange (front)
❑ Must be positioned on
dowel pins
⇒ page 44
6 - Dowel pins
7 - Diamond-coated washer for
toothed belt sprocket
❑ Renew washer if tooth‐
ed belt sprocket is re‐
moved
8 - Bolt
9 - Cylinder block
❑ Removing and installing crankshaft ⇒ page 53
❑ Dismantling and assembling pistons and conrods ⇒ page 60
Tightening sequence for front sealing flange

2. Tighten bolts -1 ... 6- in diagonal sequence and in stages to
15 Nm.

Audi TT 2007 ➤
1.6 Renewing crankshaft oil seal - pulley end

equipment required
♦ Oil seal extractor -3203-
♦ Counterhold tool -3415-
♦ Assembly tool -T10053-
♦ Torque wrench -V.A.G
1331-
1332-
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Removing
– Remove poly V-belt ⇒ page 33 .
– Remove toothed belt ⇒ page 63 .
– Remove crankshaft toothed belt sprocket. To do this, counter-
hold sprocket with special tool -3415- .

Audi TT 2007 ➤
– Unscrew central bolt -1- for crankshaft toothed belt sprocket

-2- and remove sprocket.
– Remove diamond-coated washer -3- from toothed belt sprock‐
et.
– To guide oil seal extractor, screw central bolt into crankshaft
onto stop by hand.
– Unscrew inner part of oil seal extractor -3203- nine turns (ap‐
prox. 20 mm) from the outer part and lock in position with the
knurled screw.
– Lubricate threaded head of oil seal extractor -3203- , place it

in position and, while exerting firm pressure, screw it into oil
seal as far as possible.
– Loosen knurled screw and turn inner part against crankshaft
until oil seal is pulled out.
– Clamp flats of oil seal extractor in vice. Remove oil seal with
pliers.
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Installing
– Clean contact surface and sealing surface.
– Remove oil residue from crankshaft journal with a clean cloth.
– Position guide sleeve T10053/1 from assembly tool -T10053-

on crankshaft journal.
– Push oil seal over guide sleeve onto crankshaft journal.
– Press in oil seal with central bolt of toothed belt sprocket and
thrust sleeve of assembly tool -T10053- until flush.

Audi TT 2007 ➤
– Install crankshaft toothed belt sprocket -2- with new diamond-

coated washer -3- and new central bolt -1-.
Note
♦ Contact surfaces between toothed belt sprocket, diamond-

coated washer and crankshaft must be free of oil.
♦ Do not lubricate bolt for crankshaft sprocket.
– Use counterhold tool -3415- to tighten crankshaft toothed belt

sprocket.
Fit toothed belt (adjust valve timing) ⇒ page 66
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Audi TT 2007 ➤
1.7 Removing and installing sealing flange (front)

equipment required
1331-
1332-
♦ Electric drill with plastic
brush attachment
♦ Safety goggles
♦ Sealant ⇒ Parts catalogue
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Removing
– Remove poly V-belt ⇒ page 33 .
– Remove crankshaft toothed belt sprocket. To do this, counter-
hold sprocket with special tool -3415- .

Audi TT 2007 ➤
– Unscrew central bolt -1- for crankshaft toothed belt sprocket

-2- and remove sprocket.
– Remove diamond-coated washer -3- from toothed belt sprock‐
et.
– Remove bolts -1 ... 10-.

– Lever off front sealing flange and remove.
– Drive out oil seal with flange removed.
Installing
• Tightening torque ⇒ page 40
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Note
Place a cloth over the exposed section of the sump.
– Carefully remove any sealant residue on the cylinder block

and sump.
WARNING
Wear safety goggles.
– Remove sealant residue from sealing flange with rotating plas‐

tic 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 ∅).

Audi TT 2007 ➤
– Apply a thin bead of sealant at the edge of the joint between

the cylinder block and the sump -arrows-.
– Apply the bead of sealant onto the clean sealing surface of the
sealing flange as illustrated -arrow-.
• Thickness of sealant bead: 2 ... 3 mm
Caution
Make sure oil strainer is not clogged by excess sealant.
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♦ The bead of sealant must not be thicker than specified.
Note
Sealant bead must not be wider than 3 mm, otherwise excess

sealant could ingress into sump and clog strainer in oil intake pipe.
– Coat the lower sealing surface on the sealing flange lightly with
sealant -hatched area-.
Note
The sealing flange must be installed within 5 minutes after apply‐

ing sealant.
– Push the sealing flange carefully onto the dowel sleeves on

the cylinder block.
Note
Use guide sleeve -T10053/1- to attach sealing flange with oil seal
fitted.
– Tighten sealing flange bolts in three stages as follows:

2. Tighten bolts -1 ... 6- in diagonal sequence and in stages.
3. Tighten bolts -7 ... 10-.
– Install crankshaft oil seal (pulley end) ⇒ page 42 .

Audi TT 2007 ➤
– Install crankshaft toothed belt sprocket -2- with new diamond-

coated washer -3- and new central bolt -1-.
Note
♦ Contact surfaces between toothed belt sprocket, diamond-

coated washer and crankshaft must be free of oil.
♦ Do not lubricate bolt for crankshaft sprocket.
– Use counterhold tool -3415- to tighten crankshaft toothed belt

sprocket.
note the following:
Installing toothed belt and adjusting valve timing ⇒ page 66 .
– Install vibration damper ⇒ page 38 .
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Audi TT 2007 ➤
2 Cylinder block (gearbox end)
2.1 Rear sealing flange and dual-mass flywheel - exploded view
Note
Servicing clutch:⇒ Rep. Gr. 30
1 - Bolt
❑ For dual-mass flywheel/
drive plate
❑ 60 + 90° (60 Nm + 90°
(1/4 turn) further
❑ Renew
2 - Dual-mass flywheel
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dual-mass flywheel
⇒ page 49
one position. Holes are
off-set
3 - Intermediate plate
❑ Must be positioned on
dowel sleeves
❑ Do not damage/bend
when assembling
❑ Is fitted on sealing
flange ⇒ page 49
4 - Bolt
⇒ page 49
5 - Sealing flange with oil seal
(rear)
❑ Renew only as com‐
plete unit
❑ Use guide sleeve provi‐
ded when fitting
⇒ page 50
❑ Do not lubricate/grease
sealing lip of oil seal
❑ Before installing, remove oil residue from crankshaft journal with a clean cloth.
❑ Guide sleeve is not to be removed until sealing flange has been slipped onto crankshaft journal
6 - Dowel pin
7 - Cylinder block
❑ Removing and installing crankshaft ⇒ page 53
❑ Dismantling and assembling pistons and conrods ⇒ page 60
8 - Bolt

Audi TT 2007 ➤
Tightening sequence (gearbox end)

2. Tighten bolts -1 ... 6- in diagonal sequence and in stages to
15 Nm.
Installing intermediate plate

– Fit intermediate plate on sealing flange and push onto dowel
sleeves -arrows-.
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2.2 Removing and installing dual-mass fly‐
wheel
Removing
Caution
To prevent damage to the dual-mass flywheel when removing,

the bolts -B- must not be removed with an impact wrench or
similar. The bolts may only be removed by hand using con‐
ventional tools.
– Mark position of dual-mass flywheel in relation to engine.
2. Cylinder block (gearbox end) 49

Audi TT 2007 ➤
– Rotate the dual-mass flywheel -A- so that the bolts -B- align
centrally with the holes -arrows-.
– When unscrewing bolts -B-, ensure that none of the bolt heads
come into contact with the dual-mass flywheel -arrows-. The
flywheel will otherwise be damaged as the bolts are screwed
out further.
– Insert counterhold -3067- in hole on cylinder block -B-.

– Unbolt dual-mass flywheel.
Installing
– Use new securing bolts.
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– Insert counterhold -3067- in hole on cylinder block -A-.
2.3 Removing and installing sealing flange

(rear)
♦ Electric drill with plastic brush attachment
♦ Safety goggles

Audi TT 2007 ➤
♦ Sealant ⇒ Parts catalogue

Removing
• Gearbox removed.
– Remove dual-mass flywheel ⇒ page 49 .
– Detach intermediate plate at sealing flange and dowel sleeves
-arrows-.
– Remove bolts -1 ... 8-.

– Pull off sealing flange (rear).
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Installing
Note
Place a cloth over the exposed section of the sump.
– Carefully remove any sealant residue on the cylinder block

and sump.
– Cut off tube nozzle at front marking (nozzle approx. 2 mm ∅).
– Apply a thin bead of sealant at the edge of the joint between

the cylinder block and the sump -arrows-.
2. Cylinder block (gearbox end) 51

Audi TT 2007 ➤
– Coat the lower sealing surface on the sealing flange lightly with
sealant -hatched area-.
Caution
Make sure oil strainer is not clogged by excess sealant.

♦ The bead of sealant must not be thicker than specified.
Note
The sealing flange must be installed within 5 minutes after apply‐

ing sealant.
– Carefully push sealing flange -2- together with guide sleeve

-1- (fitted on replacement part) onto crankshaft when instal‐
ling.
– Push the sealing flange carefully onto the dowel sleeves on
the cylinder block.
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– Tighten bolts in the specified sequence:
2. Tighten bolts -1 ... 6- in diagonal sequence and in stages.
3. Tighten bolts -7 ... 8-.

note the following:
– Fit intermediate plate on sealing flange and push onto dowel
sleeves -arrows-.
– Install dual-mass flywheel ⇒ page 49 .

Audi TT 2007 ➤
3 Crankshaft
3.1 Crankshaft - exploded view
Note
Secure engine to repair stand using engine and gearbox support

-VAS 6095- when dismantling/assembling engine ⇒ page 20 .
1 - Bolt
❑ 65 Nm + 1/4 turn (90 °)
further
❑ Renew
2 - Bearing cap
❑ Bearing cap 1: Pulley
end
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❑ Bearing shell retaining
lugs (cylinder block/
bearing cap) must be on
the same side
3 - Bolt
❑ 10 Nm + 1/4 turn (90 °)
further
❑ Renew
❑ Sender wheel must be
renewed if bolts are
loosened ⇒ page 54
4 - Needle bearing
❑ For vehicles with man‐
ual gearbox
❑ Extracting and driving in
⇒ page 57
5 - Sender wheel
❑ For engine speed send‐
er -G28-
one position. Holes are
off-set
❑ Sender wheel must be
renewed if bolts are
loosened
⇒ page 54
6 - Crankshaft
❑ After removing, place it down so that the sender wheel -item 5- is not damaged and the crankshaft does
not rest on the sender wheel
❑ Axial clearance ⇒ page 55
❑ Radial clearance ⇒ page 56
❑ Do not rotate the crankshaft when checking the radial clearance
❑ Crankshaft dimensions ⇒ page 55
3. Crankshaft 53
Audi TT 2007 ➤
7 - Thrust washers
❑ For bearing No. 3
8 - Bearing shell for cylinder block
❑ With oil groove
❑ Do not interchange used bearing shells (mark positions)
❑ Classification for replacement parts ⇒ page 57
9 - Chain sprocket
❑ For oil pump chain
10 - Bearing shell
❑ Without oil groove
❑ The crankshaft bearing shells in the bearing caps are only supplied as spare parts with “yellow” colour-
coding.
Removing and installing sender wheel
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– 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 because holes
are offset.

Audi TT 2007 ➤
Identification of top crankshaft bearings
Note
Arrow points in direction of travel.
Top bearing shells of the correct thickness are allocated to the

cylinder block at the factory. Coloured dots are used to identify
the thickness of the bearing shells.
Letter codes on the lower sealing surface of the cylinder block
indicate the thickness of the bearing shell to be fitted at each lo‐
cation.
G = Yellow
B = Blue
W = White
Note
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♦ Use blue bearing shells if the identification is no longer visible.
♦ The bottom crankshaft bearing shells are only supplied as re‐
placement parts with “yellow” marking.
3.2 Crankshaft dimensions

(in mm)
Honing dimension Crankshaft main Conrod journal ∅
bearing journal ∅
-0.017 -0.022
Basic dimension 54.00 47.80
-0.037 -0.042
-0.017 -0.022
1st undersize 53.75 47.55
-0.037 -0.042
-0.017 -0.022
2nd undersize 53.50 47.30
-0.037 -0.042
-0.017 -0.022
3rd undersize 53.25 47.05
-0.037 -0.042
3.3 Measuring axial clearance of crankshaft

3. Crankshaft 55
Audi TT 2007 ➤
♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge -VAS 6079-
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Procedure
– Bolt dial gauge -VAS 6079- with dial gauge bracket -VW 387-
onto cylinder block and set it against crank web.
– Push crankshaft against dial gauge by hand and set gauge to
“0”.
– Push crankshaft away from dial gauge and read off value.
Axial clearance:
• New: 0.07 ... 0.23 mm.
• Wear limit: 0.30 mm.
3.4 Measuring radial clearance of crank‐

shaft
♦ Plastigage
Procedure
Note
♦ Do not interchange used bearings.

♦ Bearing shells worn down to nickel layer must be renewed.
– Remove main bearing caps and clean bearing caps and jour‐
nals.
– Place Plastigage onto bearing journal or into bearing shells
(length of Plastigage should correspond to width of bearing).
• The Plastigage must be positioned in the centre of the bearing
shell.

Audi TT 2007 ➤
– Fit main bearing caps and tighten to 65 Nm without rotating

crankshaft.
– Remove main bearing caps once more.
– Compare width of Plastigage with measurement scale:
Radial clearance:
• New: 0.017 ... 0.037 mm.
• Wear limit: 0.15 mm.
3.5 Extracting and driving in needle bearing

for crankshaft
♦ Puller -T10055-
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♦ With adapter -T10055/3-
♦ Centring mandrel -3176-
♦ Or drift -VW 207 C-

♦ Puller e.g. Kukko -21/2-
Removing
– Extract with commercially available puller e.g. Kukko -21/2-
-arrow-, adapter -T10055/3- and puller -T10055- .
Installing
Note
The lettering on the needle bearing must be visible when installed.
3. Crankshaft 57
Audi TT 2007 ➤
– Drive in with drift -VW 207 C- or centring mandrel -3176- .
Installation depth of -a- = 2 mm
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3.6 Removing and installing chain sprocket
♦ Drift sleeve -30 - 100-
♦ Thrust plate -40 - 105-
♦ Two-arm puller, commercially available

♦ Protective gloves

Audi TT 2007 ➤
Removing
– Remove sump with oil pump ⇒ page 120 .
– Remove front sealing flange ⇒ page 44 .
– Pull chain sprocket off crankshaft with puller -2- (Kukko 44-1
or similar). Use special tool 40-105 to protect end of crank‐
shaft.
Installing
WARNING
Wear protective gloves.
– Heat chain sprocket in oven for approx. 15 minutes to 220°C.
Note
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Installation position: wide collar on sprocket facing towards en‐
gine,
– Fit chain sprocket on end of crankshaft using pliers, and press

onto crankshaft as far as the stop using drift sleeve -30 - 100- .
– Install sump with oil pump ⇒ page 120 .
3. Crankshaft 59
Audi TT 2007 ➤
4 Pistons and conrods - exploded view
1 - Conrod bolt
❑ 30 Nm + 1/4 turn (90°)
further
❑ Renew
❑ Lubricate threads and
contact surface
❑ Use old bolts when
measuring radial clear‐
ance
❑ To measure radial clear‐
ance, tighten to 30 Nm
but do not turn further
2 - Pressure relief valve
27 Nm
❑ Opening pressure:
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1.6 ... 1.9 bar
3 - Oil spray jet
❑ For piston cooling
4 - Conrod bearing cap
❑ Note installation posi‐
tion
❑ Due to the cracking
method used to sepa‐
rate the bearing cap
from the conrod in man‐
ufacture, the caps only
fit in one position and
only on the appropriate
conrod.
❑ Mark cylinder number
-B-
❑ Installation position:
Markings -A- face to‐
wards pulley end
5 - Bearing shells
❑ Upper bearing shell with oil hole for piston pin lubrication
❑ Installation position ⇒ page 62
❑ Axial clearance when new: 0.10...0.35 mm; wear limit: 0.40 mm
❑ Check radial clearance with Plastigage - (new): 0.02 ... 0.06 mm; wear limit: 0.09 mm. Do not turn crank‐
shaft when measuring radial clearance
6 - Conrod
❑ Only renew as a complete set
❑ Mark cylinder number -B-
❑ Installation position: Markings -A- face towards pulley end
❑ With oil drilling for piston pin lubrication
7 - Circlip
8 - Piston pin
❑ If difficult to move, heat piston to approx. 60 °C
❑ Remove and install using drift -VW 222 A-

Audi TT 2007 ➤
9 - Piston
❑ Checking ⇒ page 61
❑ Mark installation position and cylinder number
❑ Arrow on piston crown points to pulley end
❑ Install using piston ring clamp
❑ Piston and cylinder dimensions ⇒ page 62
❑ Checking cylinder bore ⇒ page 62
10 - Piston rings
❑ Offset gaps by 120 °
❑ Use piston ring pliers to remove and install
❑ “TOP” must face towards piston crown
❑ Checking ring gap ⇒ page 61
❑ Checking ring-to-groove clearance ⇒ page 61
Checking piston ring gap

– Insert ring at right angle to cylinder wall from above and push
down into lower cylinder opening approx. 15 mm from bottom
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of cylinder. Use a piston without rings to push ring into bore.
Piston ring New Wear limit
Dimensions in mm
Compression ring 0.20...0.40 0.8
Oil scraper ring 0.25...0.50 0.8
Checking ring-to-groove clearance

– Clean groove in piston before checking clearance.
Piston ring New Wear limit
Dimensions in mm
Compression ring 0.06...0.09 0.20
Oil scraper ring 0.03...0.06 0.15
Checking piston
– Measure approx. 10 mm from the bottom edge, perpendicular
to the piston pin axis.
♦ Deviation from nominal dimension: max. 0.04 mm
4. Pistons and conrods - exploded view 61

Audi TT 2007 ➤
Checking cylinder bore
cardiagn.com
♦ Cylinder dial gauge 50...100 mm
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-.
♦ Deviation from nominal dimension: max. 0.08 mm
Installation position of bearing shell
Bearing shell -1- with oil drilling -arrow- for conrod.
Bearing shell -2- without oil drilling for conrod bearing cap.
– Position bearing shells in centre of conrod and conrod bearing
cap when fitting.
Dimension -a- must be identical on both sides.
4.1 Piston and cylinder dimensions

Honing dimension Piston ∅ Cylinder bore ∅
Basic dimension mm 82.465 1) 82.51
• 1)
Dimension not including graphite coating (thickness 0.02
mm). The graphite coating wears down in service.

Audi TT 2007 ➤
15 – Cylinder head, valve gear

1 Toothed belt drive
1.1 Toothed belt drive - exploded view

Mark the rotation direction of the toothed belt with chalk or felt-tip
pen before removing. If the belt runs in the opposite direction
1 - Bolt
❑ 10 Nm
❑ Apply locking fluid when
fitting
❑ Locking fluid ⇒ Parts
catalogue
2 - Toothed belt cover (top)
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3 - Bolt
❑ 50 Nm + turn 180° fur‐
ther
❑ Renew
❑ Use counterhold tool
-3036- when loosening
and tightening
⇒ page 64
4 - Camshaft sprocket
❑ Remove toothed belt
prior to removing and in‐
stalling ⇒ page 66
❑ Installation position
fixed by Woodruff key
⇒ Item 7 (page 63)
❑ Detaching camshaft
sprocket ⇒ page 65
5 - Bolt
❑ 10 Nm
❑ Apply locking fluid when
fitting
❑ Locking fluid ⇒ Parts
catalogue
6 - Toothed belt cover (rear)
7 - Woodruff key
❑ Check for firm attachment
8 - Nut
❑ 25 Nm
9 - Semi-automatic tensioning roller
10 - Coolant pump
11 - O-ring
❑ Renew
1. Toothed belt drive 63

Audi TT 2007 ➤
12 - Bolt
❑ 25 Nm
13 - Damper wheel
14 - Bolt
❑ 15 Nm
15 - Bolt
❑ 35 Nm
16 - Damper wheel
17 - Sealing flange
18 - Diamond-coated washer for toothed belt sprocket
❑ Renew washer if toothed belt sprocket is removed
19 - Crankshaft sprocket
❑ Contact surface between sprocket and crankshaft must be free of oil
❑ Can only be installed in one position
20 - Bolt
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❑ 90 Nm + 90° (1/4 turn) further
❑ Renew
❑ Attaching counterhold tool 3415 ⇒ page 65
21 - Toothed belt
❑ Before removing, mark direction of rotation with chalk or felt-tipped pen
❑ Check for wear
❑ Removing ⇒ page 66
❑ Installing (adjusting valve timing) ⇒ page 66
22 - Toothed belt cover (bottom)
23 - Engine support
❑ Removing ⇒ Removing and installing toothed belt ⇒ page 66
❑ Installing ⇒ page 65
24 - Bolt
❑ 45 Nm
❑ Observe correct tightening sequence ⇒ page 75
25 - Cap for toothed belt cover
Loosening camshaft sprocket

– Use counterhold -3036- when loosening and tightening central
bolt.
64 Rep. Gr.15 - Cylinder head, valve gear

Audi TT 2007 ➤
Detaching camshaft sprocket

– Use two-arm puller -T40001- with claws T40001/6 and
T40001/7 to detach camshaft sprocket.
Removing and installing crankshaft sprocket

– Use counterhold -3415- when loosening and tightening central
bolt.
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Installing engine support
– Fit bolts -1 ... 3- and tighten hand-tight initially.
– Then tighten bolts, tightening torque ⇒ page 63 .

Audi TT 2007 ➤
1.2 Removing and installing toothed belt

equipment required
♦ Support bracket -10 - 222
A-
♦ 2x spindle -10 - 222 A /11-
♦ Adapter -10 - 222 A /20-
(2x)
♦ Hooks -10 - 222 A /2-
(basic set) -T40091-
(supplementary set) -
T40093- with -T40093/3-2-
and -T40093/3-3-
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Pin wrench -T10020-

Audi TT 2007 ➤
Locking pin -T10060A-

Removing

air mass meter.
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WARNING


Audi TT 2007 ➤
– Unscrew bolts -arrows- and remove charge air pipe together

with hoses.
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– Unscrew bolts -1 ... 3- and remove pendulum support.
– Drain off coolant ⇒ page 147
WARNING
Fuel supply line is pressurised. Wear safety goggles and pro‐

tective clothing to avoid possible injury and skin contact. Before
removing from hose connection wrap a cloth around the con‐
nection. Then release pressure by carefully pulling hose off
connection.
– Mark fuel line -1- and line going to ACF -2-.

– Disconnect fuel line -1-.
– Disconnect ACF line -2-.
– Disconnect ACF line going to tank -3-.
– Lift out ACF in -direction of arrow-.

Audi TT 2007 ➤
– Detach the coolant hose at the bracket -1-.

– Remove bracket for activated charcoal filter -arrows-.
– Unbolt filler neck for windscreen washer reservoir -1-.

– Remove retaining clip; to do so, unscrew bolts -2 and 3-.
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– Unplug electrical connector -1- from coolant level indicator.
– Detach coolant expansion tank -arrows-.
– Disconnect coolant pipe -arrow-.

– Remove poly-V belt and remove locking pin -T10060A-
⇒ page 33 .
– Remove bracket for activated charcoal filter.

Audi TT 2007 ➤
– Disconnect coolant pipe -arrows-.
– Detach gear selector cable -arrow-.
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– Position support bracket -10 - 222 A- on bolted flanges of wing
panels using the following tools:
♦ 2x Rack -10 - 222 A /1-
♦ Support bracket -10 - 222 A-
♦ Spindle -10 - 222 A /11- (spindle faces front)
♦ Hooks -10 - 222 A /2-
♦ Adapter -10 - 222 A /20-
♦ Connecting piece -T40091/3- (2x)
– Attach spindle -10 - 222 A /11- with hook -10 - 222 A /2- and
adapter -10 - 222 A /20- to gearbox lifting eye.
– Tighten spindle slightly to take up weight of engine/gearbox
assembly.

Audi TT 2007 ➤
– Fit adapter -T40093/3-2- (left-side) and -T40093/3-3- (right-

side) to supports -T40093/3- .
– Unbolt earth wire from longitudinal member (left-side).
– Remove connecting bolt for front section of longitudinal mem‐
ber on left and right.
– Secure adapters to longitudinal members using the removed
bolts -arrow-.
Note
The illustration shows the left side of the vehicle.
– Fit square-section pipes -T40091/1- with connecting pieces -
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T40093/4- into connecting pieces -T40091/3- and supports -
T40093/3-- as shown in illustration.
– Push support -T40091/2- with sliding support -T40093/5- into

the two connecting pieces -T40093/4- .
WARNING
Accident risk from loose components of support bracket.

♦ Secure support -T10091/2- with pins and split pins of con‐
necting pieces -T40093/4- .
♦ Secure connecting pieces and supports with clamping
bolts.
– Fit spindle -10 - 222 A /11- with adapter -10 - 222 A /20- onto
sliding support and onto engine lifting eye.
– Take up weight of engine/gearbox assembly by evenly tight‐
ening two spindles.

Audi TT 2007 ➤
– Remove securing bolts from assembly mounting/engine sup‐

port -arrows- and remove complete assembly mounting.
Caution
When raising engine with support bracket -10-222A- , ensure

that components/hoses are not damaged, strained or torn off.
– Raise engine with support bracket -10-222A- until it is possible

to loosen and remove the two top bolts -1 and 2- securing the
engine support.
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– Set camshaft sprocket to TDC marking by turning crankshaft.
Marking on camshaft sprocket must align with arrow on tooth‐
ed belt cover.
– Remove vibration damper / pulley.

Audi TT 2007 ➤
– Unscrew bolts from toothed belt cover (bottom) -arrows-.
– Unscrew the bottom bolt -3- and remove engine support from
below.
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– Unscrew remaining toothed belt cover bolts -arrows- and re‐
move toothed belt cover from engine.
– Mark direction of rotation of toothed belt.
– Loosen tensioning roller and remove toothed belt.
– Turn crankshaft back slightly.
Installing
Note
♦ When turning the camshaft, the crankshaft must not be at

TDC. Otherwise, there is a risk of damage to valves and piston
crowns.
♦ The engine must be no more than warm to touch.
– Fit toothed belt on crankshaft sprocket (note rotation direc‐

tion).
– Secure toothed belt cover (bottom section) with the two bolts
at the bottom.
– Install vibration damper with new bolts.

Audi TT 2007 ➤
– Turn crankshaft and camshaft to TDC No. 1 cylinder

-arrows-.
– Fit toothed belt in the sequence: tensioning roller, camshaft
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sprocket, coolant pump and last onto idler roller -arrow-.
Note
Check tensioning roller is seated correctly in cylinder head.
– Tension toothed belt. To do so, turn hexagon key at the ec‐

centric adjuster clockwise (direction of arrow) until the notch
is above the indicator.
– Then release tension on toothed belt.
– Now tension toothed belt until the notch and the indicator are
aligned.
– Tighten securing nut
– Turn crankshaft two turns in direction of engine rotation and
set again to TDC. Make sure that the engine is rotated without
stopping during the final 45° (1/8 turn).
– Check tension of toothed belt again. Specification: indicator
and notch must align.

Audi TT 2007 ➤
– Check valve timing again.

If the markings do not align:
– Repeat adjustment of valve timing.
If the markings align:
– Install toothed belt cover -arrows-.
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Note
Note different bolt lengths. Bolt -3- is approx. 25 mm shorter than

bolts -1 and 2-.
– Insert bottom securing bolt -3- in engine support.

– Install engine support on cylinder block from below and tighten
bolt finger-tight.
– Raise engine with support bracket -10-222A- until it is possible
to screw in the two top bolts -1 and 2-.
– Tighten all bolts.
– Lower the engine down to installation position.
– Install complete assembly mounting for engine.

Audi TT 2007 ➤
– Secure assembly mounting for engine to engine support

-arrows-; to do so, bring surfaces into contact using support
bracket -10-222A- .
– Adjust engine mountings ⇒ page 27 .
– Attach fuel hoses onto connections. Make sure plug-in con‐
nectors are properly secured.
– Install coolant expansion tank.
– Fit noise insulation.
– Fit engine cover panel.
– Install vibration damper ⇒ page 38 .
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Audi TT 2007 ➤
2 Cylinder head
2.1 Cylinder head - exploded view
Note
♦ Renew the cylinder head bolts.

♦ On assembly, renew oil seals and gaskets as well as self-
locking nuts and bolts that are tightened by turning through to
a specified angle.
♦ When installing an exchange cylinder head with fitted cam‐
shafts, oil the contact surfaces between the roller rocker fin‐
gers and cams.
♦ The plastic protectors fitted to protect the open valves must
only be removed immediately before fitting the cylinder head.
♦ When fitting a new cylinder head or cylinder head gasket, drain
off all the old coolant and refill with new coolant.
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1 - Bolt
⇒ page 78
2 - Cylinder head cover
⇒ page 82
⇒ page 78
3 - Gasket
❑ Renew if damaged or
leaking
4 - Valve housing
5 - Oil filler cap
6 - Seal
leaking
7 - Bolt
❑ 4 Nm
8 - Gasket for cylinder head
cover
leaking
9 - Exhauster pump
10 - Bolt
❑ 4 Nm
11 - Inlet camshaft control
valve 1 -N205-
❑ Removing ⇒ page 80
12 - Seal
❑ Renew
2. Cylinder head 77
Audi TT 2007 ➤
13 - Bolt
❑ 10 Nm
14 - Cable retainer
15 - Seal
❑ Renew if damaged or leaking
16 - Bolt
❑ 10 Nm
17 - Housing
18 - Gasket
❑ Renew
19 - Transport plate
20 - Bolt
❑ 25 Nm
21 - Stud for intake manifold
❑ 10 Nm
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22 - Separating plate
23 - Cylinder head gasket
❑ Renew
❑ Check installation position: Part No. towards cylinder head
❑ If renewed, refill system with fresh coolant
24 - Bolt
❑ 10 Nm
25 - Hall sender -G40-
26 - Seal
27 - Stud for tensioning roller
❑ 10 Nm
28 - Stud for exhaust manifold
❑ 20 Nm
29 - Cylinder head
❑ Checking for distortion ⇒ page 79
30 - Cylinder head bolt
❑ Renew
❑ Note correct sequence when loosening ⇒ page 79
❑ Observe correct tightening sequence ⇒ page 79
Tightening sequence for cylinder head cover

2. Tighten bolts -1 ... 14- in diagonal sequence to 10 Nm.

Audi TT 2007 ➤
Loosening cylinder head bolts

– Loosen cylinder head bolts in the sequence indicated and re‐
move.
Tightening sequence for cylinder head

– Then tighten cylinder head bolts in the sequence -1 ... 10- as
follows:
1. Tighten with torque wrench initially to 40 Nm.
2. Turn 90° (1/4 turn) further using a rigid wrench.
3. Turn 90° (1/4 turn) further using a rigid wrench.
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Checking cylinder head for distortion
– Use straight edge and feeler gauge to measure for distortion
at several points.
♦ Max. permissible distortion: 0.05 mm
2. Cylinder head 79
Audi TT 2007 ➤
2.2 Removing and installing inlet camshaft control valve 1 -N205-

equipment required
1783-
♦ Torx bit set -V.A.G 1766-
♦ Ratchet insert 1/4" -VAS
6234-
♦ Spring type clip pliers -
VAS 5024 A-
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Removing
Note
Always renew seals and gaskets.

Audi TT 2007 ➤

air mass meter.
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– Detach wiring harness -2- from bracket.
– Remove bolt -3-.
Note
Do not pull on electrical connector when removing inlet camshaft

control valve 1 -N205- .
2. Cylinder head 81
Audi TT 2007 ➤
– Remove bolts -arrows- and take inlet camshaft control valve 1

-N205- out of housing.
Installing
Note
♦ Make sure the inlet camshaft control valve 1 -N205- and the
housing are free from any kind of dirt.
♦ Do not remove inlet camshaft control valve 1 -N205- from
packaging until you are ready to install it.
Caution
♦ Do not expose the inlet camshaft control valve 1 -N205-

to shock impacts.
– Lubricate the seal with engine oil.
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– Carefully fit inlet camshaft control valve 1 -N205- into housing
and press in by hand as far as the stop (exert pressure in line
with axis of valve).
– Screw in and tighten bolts using torque wrench -V.A.G 1783-
and ratchet insert 1/4" -VAS 6234- and Torx bit T20 and bit
holder from Torx bit set -V.A.G 1766- .
Further assembly is basically carried out in reverse order of dis‐
mantling.
2.3 Removing and installing cylinder head

cover
Removing
♦ Puller -T40039-

Audi TT 2007 ➤
♦ Hose clip pliers -V.A.G 1921-

air mass meter.
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1921- .
– Unscrew bolts -arrows-.

– Remove ignition coils with output stages ⇒ Rep. Gr. 28 .
2. Cylinder head 83
Audi TT 2007 ➤
– Disconnect ACF pipe from cylinder head cover -1-.

– Detach valve housing from cylinder head cover -arrows-.
– Unscrew crankcase breather line with heat shield from turbo‐

charger -1-.
– Disconnect ACF line going to turbocharger from cylinder head
cover -2-.
– Loosen cylinder head cover working from outside to inside.
– Remove cylinder head cover.
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Installing
Note
♦ Renew cylinder head cover gaskets if damaged.

♦ Tightening sequence for cylinder head cover ⇒ page 78
– Make sure toothed belt cover (top) is correctly fitted.

– Install ignition coils with output stages ⇒ Rep. Gr. 28 .

Audi TT 2007 ➤
2.4 Removing and installing cylinder head

equipment required
-VAS 6208-
♦ Two-arm puller -T40001-
♦ Puller -T40039-
♦ Hose clip pliers -V.A.G
1921-
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Pin wrench -T10020-
2. Cylinder head 85
Audi TT 2007 ➤

Removing
• Engine in vehicle.
Note
♦ All cable ties which are released or cut open when removing
must be refitted in the same position when installing.
♦ If engine oil is contaminated, perform oil change ⇒ Mainte‐
nance ; Booklet 810 .
♦ Before applying sealant, check updated information: ⇒ Parts
catalogue
– Obtain code on vehicles with coded radio / radio and naviga‐

tion system (RNS).

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air mass meter.
1921- .
WARNING


Audi TT 2007 ➤
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– Remove electrical connector -arrow- for Lambda probe (be‐

fore catalytic converter) from bracket, unplug and move clear.
2. Cylinder head 87
Audi TT 2007 ➤
– Disconnect coolant pipe going to coolant expansion tank

-arrow-.
– Disconnect coolant hose -1-.

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– Disconnect earth cable -1-.
– Disconnect water hoses -arrows-.
– Remove intake manifold ⇒ Motronic direct injection and igni‐
tion system (4-cylinder); Repair group 24; Servicing injection
system

Audi TT 2007 ➤
clear.

-G130- .
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2. Cylinder head 89
Audi TT 2007 ➤
Note

silencer.
– Remove drive shaft (right-side) ⇒ Rep. Gr. 40
– Detach air pipe -arrow- from charge air cooler.
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– Unbolt air pipe from turbocharger -arrows-.
– Detach electrical connectors -1 and 2- and move wire clear.
– Unscrew bolts -arrows- and remove air pipe.
Note

Audi TT 2007 ➤
– Unscrew oil supply pipe for turbocharger at cylinder block -1-

– Remove oil supply pipe for turbocharger -2-.
– Unscrew coolant supply pipe for turbocharger at cylinder block

-1-
– Unscrew coolant supply pipe at turbocharger -2-.
– Detach coolant supply pipe for turbocharger -3- from cylinder
block.
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– Remove oil return pipe -arrows- at turbocharger.
– Remove bolts -1- and -2- and remove support for turbocharg‐
er.
2. Cylinder head 91
Audi TT 2007 ➤
– Loosen the camshaft sprocket bolt using counterhold -3036- .
– Detach camshaft sprocket using two-arm puller -T40001- with

claws -T40001/6- and -T40001/7- .
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– Unbolt toothed belt cover (rear) from cylinder head -arrows-.
– Remove cylinder head cover ⇒ page 82 .

Audi TT 2007 ➤
– Loosen cylinder head bolts, keeping to sequence shown.
Note
Check that all hoses, pipes and wiring connections between en‐
gine, gearbox and body have been detached.
– Remove cylinder head.

Installing cylinder head
• Tightening torques and tightening sequence ⇒ page 77
Note
♦ Renew the cylinder head bolts.

♦ On assembly, renew oil seals and gaskets as well as self-
locking nuts and bolts that are tightened by turning through to
a specified angle.
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(same as original equipment) ⇒ Parts catalogue.
♦ If repairing, carefully remove any remaining gasket material
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.
♦ 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.
♦ No oil or coolant must be allowed to remain in the blind holes
for the cylinder head bolts in the cylinder block.
♦ High-temperature paste ⇒ Parts catalogue
WARNING
The engine must only be turned at the crankshaft, in the direc‐

tion of normal engine rotation (clockwise).
Note
Apply spanner to central bolt of crankshaft for turning engine.
2. Cylinder head 93
Audi TT 2007 ➤
– Align mark on camshaft sprocket with mark on toothed belt

cover. The indentations on the camshafts -arrows- face each
other.
– If crankshaft has been rotated: set No. 1 cylinder piston to top
dead centre and then turn crankshaft back slightly.
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Audi TT 2007 ➤
– Place cylinder head gasket in position.

♦ Note position of centralising pins in cylinder block -arrows-.
♦ Note installation position of cylinder head gasket. The Part No.
should be legible from inlet side.
– Fit cylinder head.
– Insert and hand-tighten cylinder head bolts.
– Tightening sequence for cylinder head ⇒ page 79 :
Note
Cylinder head bolts do not have to be torqued down again later

after repair work.
– Install cylinder head cover ⇒ page 85 .

– Install wiper arms ⇒ Electrical system; Repair group 92 .
– Install toothed belt ⇒ page 66 .
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– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
– Install intake manifold ⇒ Motronic direct injection and ignition
system (4-cylinder); Repair group 24; Servicing injection sys‐
tem
– Connect battery ⇒ Electrical system; Repair group 27
– Bleed fuel system ⇒ Motronic direct injection and ignition sys‐
tem (4-cylinder); Repair group 24; Servicing fuel injection sys‐
tem
Note
♦ Drained-off coolant may only be used again if the original cyl‐

inder head and cylinder block are re-installed.
WARNING
Never use battery charging equipment for boost starting. There

is danger of damaging the vehicle's control units.
2.5 Checking compression

2. Cylinder head 95
Audi TT 2007 ➤
♦ Spark plug socket and extension -3122 B-
♦ Puller -T40039-
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♦ Compression tester -V.A.G 1763-

♦
Test sequence
Note
♦ Engine oil temperature at least 30 °C

♦ Battery voltage at least 12.7 V

Audi TT 2007 ➤

air mass meter.
– Remove ignition coils with output stages ⇒ Rep. Gr. 28 .
– Remove spark plugs with spark plug socket -3122 B- .
– Unplug 8-pin connector for injectors ⇒ Rep. Gr. 24
– Check compression pressure with compression tester -V.A.G
1763- and adapter -V.A.G 1763/6- .
Note
Using the compression tester: ⇒ Operating Instructions
– Operate starter until pressure reading on tester no longer

rises.
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Compression pressure:
New pressure in bar Wear limit in bar Permissible differ‐
ence between cylin‐
ders in bar
11.0 ... 14.0 7.0 3.0 (maximum)
– Install spark plugs ⇒ Maintenance ; Booklet 810 .
– Install ignition coils with output stages ⇒ Rep. Gr. 28 .
Note
Faults will have been stored in the memory because connectors

have been unplugged. Interrogate and, if necessary, erase fault
memory after completing the check.
– Read out fault memory of engine control unit. ⇒ VAS 5051

vehicle diagnostic, testing and information system in the func‐
tion ”Guided fault-finding”
2. Cylinder head 97
Audi TT 2007 ➤
3 Valve gear
Note
♦ Cylinder head and retaining frame must be renewed together.

♦ After installing camshafts, wait for approx. 30 minutes before
starting engine. Hydraulic valve compensation elements have
to settle (otherwise valves will strike pistons).
♦ After working on the valve gear, turn the engine carefully at
least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.
♦ Always fit new seals and gaskets.
3.1 Valve gear - exploded view
1 - Bolt
❑ 50 Nm + turn 180° fur‐
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ther
❑ Renew
❑ Use counterhold tool
-3036- when loosening
and tightening
⇒ page 64
2 - Camshaft sprocket
3 - Oil seal
4 - Cylinder head
❑ Machining limit
⇒ page 100
5 - Valve guide
6 - Valve stem oil seal
7 - Valve spring
8 - Upper valve spring plate
9 - Cotters
10 - Hydraulic valve clearance
compensation element
❑ Do not interchange
❑ Lubricate contact sur‐
face
11 - Parallel key
❑ Check for firm attach‐
ment
12 - Exhaust camshaft
❑ Checking axial clear‐
ance ⇒ page 107
❑ Check radial clearance with Plastigage (roller rocker fingers removed)
❑ Radial clearance when bearing ∅ is 24 mm: 0.024 ... 0.066 mm

Audi TT 2007 ➤
❑ Runout: max. 0.04 mm

13 - Retaining frame
❑ With integrated camshaft bearings
❑ Clean sealing surface; machining not permitted
❑ Remove old sealant residues
14 - Bolt
❑ Renew
15 - Camshaft adjuster
16 - Bolt
❑ 20 Nm + turn 45° further
❑ Renew
17 - Inlet camshaft
❑ Checking axial clearance ⇒ page 107
❑ Check radial clearance with Plastigage (roller rocker fingers removed)
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❑ Runout: max. 0.04 mm
18 - Chain tensioner
❑ Remove ⇒ page 101 Removing and installing camshaft adjuster
❑ Before removing, lock in place using locking pin -T10115-
19 - Drive chain
20 - Bolt
❑ 10 Nm
21 - Bolt
❑ 10 Nm
22 - Phase sensor
23 - Exhaust valve
❑ Do not machine, only grinding-in is permitted
❑ Valve dimensions ⇒ page 100
❑ Checking valve guides ⇒ page 112
24 - Inlet valve
❑ Do not machine, only grinding-in is permitted
❑ Valve dimensions ⇒ page 100
❑ Checking valve guides ⇒ page 112
25 - Sealing cap
❑ Renew
❑ Removing sealing cap with retaining frame installed: pierce on one side with an awl and pry out
❑ Installing: press in 1 ... 2 mm deep without sealant using thrust piece -3334-
3. Valve gear 99
Audi TT 2007 ➤
Cylinder head machining limit

– Machining of the cylinder head (surface grinding) is only per‐
missible down to the minimum dimension a.
♦ Minimum dimension a = 139.20 mm
Tightening sequence for retaining frame

1. Fit bolts in the sequence -1 ... 6- and hand-tighten in several
stages.
2. Tighten bolts in the sequence -1 ... 6- to 8 Nm using torque
wrench.
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3. Turn 90° (1/4 turn) further in the sequence -1 ... 6- using a
rigid wrench.
Note
Take care to keep retaining frame straight.
Valve dimensions
Note
Inlet and exhaust valves must not be machined. Only grinding-in

is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 33.85 ± 0.10 28.0 ± 0.1
∅b mm 5.98 ± 0.01 5.96 ± 0.01
c mm 104.0 ± 0.2 101.9 ± 0.2
α ∠° 45 45

Audi TT 2007 ➤
3.2 Removing and installing camshaft adjuster

equipment required
♦ Special wrench, long reach
-T40080-
♦ Camshaft clamp -T10252-
♦ Pin wrench -T10020-
♦ Locking pin -T10115-
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Removing
– Remove high-pressure pump ⇒ Rep. Gr. 24 .
– Remove cylinder head cover ⇒ page 82 .
– Remove exhauster pump.
– Remove housing for camshaft adjuster -arrows-.
3. Valve gear 101

Audi TT 2007 ➤
– Align mark on camshaft sprocket with mark on toothed belt

cover. The indentations on the camshafts -arrows- face each
other.
– Fit camshaft clamp -T10252- as shown and secure -arrows-.

– Loosen securing bolt from camshaft adjuster using special
wrench -T40080- .
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– Compress chain tensioner -arrow A- and lock with locking pin
-T10115- -arrow B-.
– Remove securing bolt from camshaft adjuster and remove
camshaft adjuster together with chain.
Installing
• The camshafts are located with the camshaft clamp -T10252- .

– Fit chain onto camshaft adjuster.

Audi TT 2007 ➤
– Position camshaft adjuster in front of exhaust camshaft so that

notch -A- and pin -B- face each other.
– Lay chain over inlet camshaft sprocket starting at top -arrow-

without changing its position.
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– Turn inlet camshaft slowly in direction of arrow -A- using pin
wrench -T10020- until the camshaft adjuster fits onto the cam‐
shaft.
Note
If it is not possible to fit the pin into the notch: remove chain and
fit chain again.
– Renew securing bolt for camshaft adjuster.

– Tighten securing bolt for camshaft adjuster. Use special
wrench -T40080- for this purpose.
– Remove locking pin -T10115- -arrow B-.

mantling.
– Install cylinder head cover ⇒ page 82
– Install high-pressure pump ⇒ Rep. Gr. 24 .
– Install exhauster pump ⇒ Rep. Gr. 47 .
3.3 Removing and installing camshafts

3. Valve gear 103

Audi TT 2007 ➤
♦ Two-arm puller -T40001-
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Removing
Note
♦ Sealing surfaces at bottom of retaining frame and top of cyl‐

inder head may not be machined.
♦ The camshaft bearings are integrated into the cylinder head
and retaining frame. Toothed belt must be slackened before
removing retaining frame.
♦ Renew camshaft oil seal and sealing cap if retaining frame has
been unfastened.
– Remove cylinder head cover ⇒ page 82

– Remove camshaft adjuster ⇒ page 101
– Remove toothed belt ⇒ page 66
– Loosen camshaft sprocket using counterhold tool -3036- .

Audi TT 2007 ➤
– Use puller -T40001- , claw -T40001/6- and claw -T40001/7- to

pull off camshaft sprocket.
– Detach toothed belt cover (rear) from cylinder head.
– Unscrew retaining frame bolts in the sequence -6 ... 1- and

carefully remove retaining frame.
– Remove camshafts together with drive chain from cylinder
head.
Installing
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Note
♦ The sealing surfaces must be free of oil and grease.

♦ Pistons must not be at TDC.
♦ Ensure that all roller rocker fingers contact the valve ends cor‐
rectly.
– Remove old sealant from groove in retaining frame and from

sealing surfaces.
– Make sure dirt and remnants of sealant do not drop into cyl‐
inder head.
– Lubricate running surfaces of the camshafts with oil.
– Position drive chain on chain sprockets as follows (with cam‐

shafts removed):
– Lubricate running surfaces of camshafts.
• Cams -A- of cylinder 4 must face each other.
• Recesses -arrows- on both camshafts must face each other.
• The side surfaces of the recesses should be positioned exactly
vertical.
– Insert camshafts together with drive chain into cylinder head
and chain tensioner.
3. Valve gear 105

Audi TT 2007 ➤
– Check TDC position of camshafts again.

• Cams -A- of cylinder 4 must face each other.
• Recesses -arrows- on both camshafts must face each other.
• The side surfaces of the recesses should be positioned in ex‐
actly vertical line to the cylinder head.
– Lubricate running surfaces of camshafts.
– Apply an even, slightly projecting sealant bead into the clean

groove of the retaining frame.
Sealant ⇒ Parts catalogue
Note
♦ Do not apply the sealant thicker than prescribed.
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♦ No time should be allowed to elapse when fitting and securing
retaining frame, as sealant starts to harden as soon as sealing
surfaces make contact.
♦ Note the use-by date of the sealant.
– Fit retaining frame so that it goes past the exhaust gas recir‐
culation valve -N18- -arrow-.
– Renew bolts for retaining frame.
Note
Camshafts must be in correct position in axial bearings in retain‐

ing frame.
– Tighten bolts in several stages; tightening sequence

⇒ page 100 .
Note
Take care to keep retaining frame straight.

Audi TT 2007 ➤
– Then check that camshafts are in TDC position (insert cam‐

shaft clamp -T10252- as far as stop).
Note
♦ If necessary, turn camshafts slightly backwards or forwards

when inserting camshaft clamp -T10252- .
♦ Disregard -arrows-.
– If it is not possible to insert camshaft clamp -T10252- , retain‐

ing frame must be removed and camshafts installed for a
second time ⇒ page 105 .
– Detach camshaft clamp -T10252- .
– Drive in cap ⇒ Item 25 (page 99) approx. 1...2 mm deep using
thrust piece -3334- .
– Install camshaft oil seal ⇒ page 114
– Install toothed belt cover (rear).
– Insert parallel key into camshaft.
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– Install camshaft sprocket. To tighten bolt, hold camshaft
sprocket in position using counterhold tool -3036- .
Note
♦ When turning the camshaft, the pistons must not be at TDC.

This could otherwise result in damage to valves and pistons.
♦ Make sure parallel key is correctly seated.

– Install camshaft adjuster ⇒ page 101 .
– Install cylinder head cover ⇒ page 82
mantling.
3.4 Checking axial clearance of camshafts

3. Valve gear 107

Audi TT 2007 ➤
Test sequence
– Perform measurement with retaining frame removed.
– Fit camshaft to be tested in retaining frame.
– Attach dial gauge -VAS 6079- with dial gauge bracket -
VW 387- to cylinder head.
– Press camshaft against dial gauge by hand.
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– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
• Axial clearance: 0.05 ... 0.17 mm
3.5 Renewing valve stem oil seals

(with cylinder head installed)

Audi TT 2007 ➤

equipment required
♦ Spark plug socket and ex‐
tension -3122 B-
♦ Valve stem seal puller
-3364-
♦ Valve stem seal fitting tool
-3365-
♦ Adapter -T40012-
1331-
♦ Removal / installing device
for valve cotters -VAS
5161- with guide plate for
2.0 ltr. and 3.0 ltr. FSI en‐
gine -VAS 5161/19A-
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Removing valve stem oil seals
– Remove the camshafts. ⇒ page 103
Note
In order to renew the valve stem oil seals of exhaust valves of

cylinder 3 and cylinder 4, the exhaust gas recirculation valve -
N18- must also be removed.
– Remove roller rocker fingers and place onto a clean surface.

When doing so, make sure that roller rocker fingers are not
interchanged.
– Remove spark plugs with spark plug socket -3122 B- .
3. Valve gear 109

Audi TT 2007 ➤
– Secure guide plate for 2.0 ltr. and 3.0 ltr. FSI engine -VAS
5161/19A- with knurled screws -VAS 5161/12- to cylinder
head as shown.
– Set piston of the respective cylinder to “bottom dead centre”.
– Screw adapter -T40012- into spark plug hole and connect to
compressed air supply of at least 6 bar.
– Knock loose sticking valve cotters using punch -VAS 5161/3-

and a plastic-headed hammer.
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– Screw snap-in device -VAS 5161/6- with engaging fork -VAS
5161/5- into guide plate for 2.0 ltr. and 3.0 ltr. FSI engine -VAS
5161/19A- .
– Insert assembly cartridge -VAS 5161/8- into guide plate for 2.0
ltr. and 3.0 ltr. FSI engine -VAS 5161/19A- .
– Attach pressure fork -VAS 5161/2- to snap-in device -VAS
5161/6- .
Note
Attach pressure fork -VAS 5161/2- to exhaust side as shown.
– Press down assembly cartridge -VAS 5161/8- . At the same

time, turn knurled screw of assembly cartridge -VAS 5161/8-
clockwise until ends engage in valve cotters.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the assembly cartridge.
– Release the pressure fork -VAS 5161/2- .
– Remove assembly cartridge -VAS 5161/8- .

Audi TT 2007 ➤
– Pull off valve stem oil seal with valve stem seal puller -3364- .
– If valve stem seal puller -3364- cannot be used on account of
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restricted space, knock out pin -arrow- with a punch and re‐
move the impact extractor attachment.
– Position lower part of valve stem seal puller -3364- on valve

stem oil seal.
– Insert a punch -1- through hole in lower section of puller.
– Apply assembly lever to puller and pull out valve stem oil seal
-arrow-.
Installing valve stem oil seals
– To prevent damage to the new valve stem seals -B-, attach

plastic sleeve -A- to valve stem.
– Lubricate sealing lip of valve stem oil seal -B-, place it in the
valve stem oil seal fitting tool -3365- and push carefully onto
valve guide.
– Remove plastic sleeve -A-.
– Insert valve spring and valve spring plate.
– Set up disassembly and assembly tool -VAS 5161- as shown.
3. Valve gear 111

Audi TT 2007 ➤
Inlet side
Exhaust side
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Note
♦ If valve cotters have been removed from assembly cartridge,

they need to be put into insertion device -VAS 5161/18- first.
♦ Press assembly cartridge -VAS 5161/8- onto insertion device
from above and pick up valve cotters.
– Press down assembly cartridge -VAS 5161/8- with pressure

fork -VAS 5161/2- and pull knurled screw of assembly car‐
tridge up, at the same time turning it in both directions.
– Release the pressure fork -VAS 5161/2- with knurled screw
still in pulled-out position.
– Remove disassembly and assembly tool -VAS 5161- .
mantling.
– Installing camshafts ⇒ page 103 .
3.6 Checking valve guides


Audi TT 2007 ➤
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Test sequence
– Insert valve into guide. Valve stem end must be flush with
guide. Only insert inlet valve into inlet guide and exhaust valve
into exhaust guide, as the stem diameters are different.
– Measure the amount of sideways play.
Wear limit
Inlet valve guide Exhaust valve guide
0.80 mm 0.80 mm
Note
♦ If the wear limit is exceeded, repeat the measurement with

new valves. Renew cylinder head if wear limit is still exceeded.
♦ If the valve has to be renewed as part of a repair, use a new
valve for the measurement.
3. Valve gear 113

Audi TT 2007 ➤
3.7 Renewing exhaust camshaft oil seal

equipment required
♦ Oil seal extractor -2085-
♦ Assembly tool -3066-
♦ Puller -T40001-
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Pin wrench -T10020-

Audi TT 2007 ➤

Removing

air mass meter.
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WARNING

3. Valve gear 115

Audi TT 2007 ➤

– Loosen camshaft sprocket (apply counterhold tool -3036- ).
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– Detach the camshaft sprocket using puller -T40001- and claws
T40001/6 and T40001/7.
– To guide oil seal extractor, screw special tool 2085/2 from oil
seal extractor -2085- by hand into camshaft as far as it will go.
– Unscrew inner part of oil seal extractor -2085- two turns (ap‐
prox. 3 mm) from the outer part and lock in position with the
knurled screw.

Audi TT 2007 ➤
– Lubricate threaded head of oil seal extractor -2085- , place it

in position and, while exerting firm pressure, screw it into oil
seal as far as possible.
– Loosen knurled screw and turn inner part of extractor against
camshaft until oil seal has been extracted.
– Clamp flats of oil seal extractor in vice. Remove oil seal with
pliers.
Installing
– Do not lubricate sealing lip of oil seal.
– Fit guide sleeve -T10071/1- from assembly tool -T10071- onto

camshaft journal.
– Push oil seal over guide sleeve onto shaft.
– Detach guide sleeve.
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– Press in oil seal all the way using guide sleeve -T10071/3- and
bolt -T10071/4- from assembly tool -T10071- .
– Install camshaft sprocket.

♦ Check installation position: The thinner web of the camshaft
sprocket faces outwards -arrows- and the marking for No. 1
cylinder TDC is visible.
3. Valve gear 117

Audi TT 2007 ➤
– Fit securing bolt of camshaft sprocket (use counterhold

-3036- ).
Note
If a piston is at TDC the valves could strike the piston when turning
the camshaft. Pistons must therefore not be at TDC This could
otherwise result in damage to valves and pistons.
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Audi TT 2007 ➤
17 – Lubrication
1 Oil pump and sump
Note
If large quantities of metal shavings or other particles are found

in the engine oil when repairing the engine (possibly caused by
partial seizure of crankshaft and conrod bearings), clean the oil
passages thoroughly and renew the oil cooler to prevent further
damage occurring later.
Checking oil pressure ⇒ page 141

Viscosity grades and oil specifications: ⇒ Maintenance ; Booklet
810
Oil capacities: ⇒ Exhaust emissions test
1.1 Sump - exploded view
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Balance shaft assembly with oil pump ⇒ page 125
Oil filter bracket ⇒ page 132
1 - Bolt
⇒ page 40
2 - Oil dipstick
❑ The oil level must not be
above max. mark.
3 - Guide tube for oil dipstick
4 - Guide tube
5 - Spacer plate
6 - Balance shaft assembly
with oil pump
❑ With pressure relief
valve (12 bar)
❑ Note the centring
sleeves ⇒ page 125
❑ Balance shaft assembly
with oil pump - exploded
view ⇒ page 125
⇒ page 127
7 - Bolt
❑ Renew
❑ Note different bolt
lengths ⇒ page 127
⇒ page 127
8 - Bolt
⇒ page 120
1. Oil pump and sump 119

Audi TT 2007 ➤
9 - Sump
❑ Clean sealing surface
before installing
10 - Bolt
11 - Seal
❑ Attached to ⇒ Item 12 (page 120) .
12 - Oil drain plug
❑ 30 Nm
❑ With captive seal
❑ Renew
13 - Chain sprocket
14 - Bolt
❑ 10 Nm
15 - Protective cap
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16 - With oil level/oil temperature sender -G266-
17 - Seal
❑ Renew
❑ Lubricate before installing
18 - Bolt
❑ Renew
19 - Chain guard
20 - Chain
21 - Sealing flange (front)
❑ Must be positioned on dowel pins
Removing and installing ⇒ page 44
Tightening sequence for sump

1. Tighten bolts -1...20- securing sump to cylinder block in di‐
agonal sequence initially to 5 Nm.
2. Tighten sump/gearbox bolts -arrows- to 40 Nm.
3. Tighten bolts securing sump to cylinder block in diagonal
sequence to 15 Nm.
1.2 Removing and installing sump

120 Rep. Gr.17 - Lubrication

Audi TT 2007 ➤
♦ Allen key (long reach) -T10058-
♦ Electric drill with plastic brush attachment

♦ Safety goggles
♦ Silicone sealant ⇒ Parts catalogue
Removing
cardiagn.com
air mass meter.

Audi TT 2007 ➤
cardiagn.com

Audi TT 2007 ➤
– Detach air pipe -1- from charge air cooler.

– Unplug connector from charge air pressure sender -G31- ⇒
Rep. Gr. 24 ; Overview of fitting locations .
– Remove air pipe.
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– Unplug electrical connector -1- at oil level and oil temperature
sender -G266- .
– Unbolt oil return pipe from turbocharger -arrows-.
– Drain off engine oil.

Audi TT 2007 ➤
– Unscrew sump/gearbox bolts -arrows-.

– Unscrew bolts -1 ... 20- in diagonal sequence.
– Take off sump: if necessary loosen it by striking lightly with a
rubber hammer.
Installing
♦ Silicone sealant: ⇒ Parts catalogue
Note
♦ Note expiry date of silicone sealant.

♦ The sump must be installed within 5 minutes after applying the
silicone sealant.
– Remove sealant residue from cylinder block using a flat scra‐

per.
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WARNING
Wear safety goggles.
– Remove remaining sealant from sump (with rotating plastic

brush or similar).
– Cut off nozzle of tube at front marking (∅ of nozzle approx. 3

mm).

Audi TT 2007 ➤
– Apply the bead of silicone sealant onto the clean sealing sur‐
face of the sump, as illustrated.
♦ Thickness of sealant bead: 2 ... 3 mm
Note
♦ The sump must be installed within 5 minutes after applying the

silicone sealant.
♦ 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.
♦ Be particularly careful when applying the bead of sealant
around the rear sealing flange (arrows in illustration).
– Fit sump immediately and tighten bolts as follows; tightening

sequence ⇒ page 120
Note
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♦ When installing sump with engine removed from vehicle, en‐
sure that sump is positioned flush with cylinder block at fly‐
wheel end.
♦ After fitting sump assembly, the sealant must dry for approx.
30 minutes. Then (and only then) fill the engine with engine
oil.
– Fill up with engine oil and check oil level.

The remaining installation steps are carried out in the reverse se‐
quence. Note the following points:
1.3 Balance shaft assembly with oil pump -

exploded view
Balance shaft assembly ⇒ page 119
Oil filter bracket ⇒ page 132

Audi TT 2007 ➤
1 - Chain guard
2 - Chain
❑ Before removing, mark
running direction (fitting
position) with paint
3 - Dowel sleeves
4 - Spacer plate
5 - Balance shaft assembly
with oil pump
❑ Before installing, check
that the two dowel
sleeves for centring oil
pump/cylinder block are
fitted
⇒ page 127
6 - Bolt
❑ 9 Nm
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7 - Cover
❑ Prevents foam build-up
in engine oil
8 - Bolt
❑ 40 Nm
9 - Bolt
❑ 8 Nm
10 - Oil intake pipe
❑ Clean strainer if dirty
11 - O-ring
❑ Renew
12 - Bolt
❑ Renew
❑ Note different bolt lengths ⇒ page 127
13 - Bolt
❑ Renew
❑ Note different bolt lengths ⇒ page 127
14 - Outer rotor
❑ Check contact surfaces for scores
❑ Marking must be visible
15 - Inner rotor
❑ Check contact surfaces for scores
16 - Oil pump cover
17 - Chain sprocket
18 - Bolt
❑ Renew

Audi TT 2007 ➤
19 - Chain tensioner with tensioning rail

❑ Pre-tensioning before installing ⇒ page 131
20 - Bolt
❑ 15 Nm
Positions of bolts for balance shaft housing

A - Hexagon collared bolt M7x40
B - Hexagon collared bolt M7x70
C - Hexagon collared bolt M7x90
D - Hexagon collared bolt M7x55
E - Screw plug with O-ring
Tightening sequence for balance shaft housing
cardiagn.com
1. Screw in bolts -arrows- hand-tight.
2. Tighten bolts -arrows- to 15 Nm in diagonal sequence start‐
ing from inside and working outwards.
3. Turn bolts -arrows- 90° further (1/4 turn) in diagonal se‐
quence starting from inside and working outwards using a
rigid wrench.
1.4 Removing and installing balance shaft

assembly with oil pump
♦ Locking pin -T10027-
Removing
– Remove sump ⇒ page 120 .
WARNING
The engine must only be turned at the crankshaft, in the direc‐

tion of normal engine rotation (clockwise).

Audi TT 2007 ➤
Note
– Set camshaft sprocket to TDC marking by turning crankshaft.

Marking on camshaft sprocket must align with arrow on tooth‐
ed belt cover.
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– Pull off chain guard. Retaining tabs can be released with a
small screwdriver (insert in openings -arrows-).
– Loosen bolt on oil pump chain sprocket. Counterhold on cen‐

tral bolt of vibration damper.

Audi TT 2007 ➤
– Use screwdriver to slacken chain rail -arrow- and lock it in po‐

sition using a 3 mm Allen key -1-.
– Detach oil pump chain sprocket and disengage chain at bal‐

ance shaft drive.
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– Remove baffle plate by unscrewing bolts -1 and 2-.
– Loosen bolts -arrows- on balance shaft assembly, working

from outside inwards, and then remove balance shaft assem‐
bly.
Installing
• Chain tensioner must be pre-tensioned ⇒ page 131 .
– Renew all bolts on balance shaft assembly.
– Renew seal on bolt for balance shaft assembly
⇒ Item 13 (page 126) .

Audi TT 2007 ➤
– Fit spacer plate onto dowel sleeves on balance shaft assembly

as shown -arrows-.
– Install balance shaft assembly with oil pump and spacer plate.
Tighten securing bolts -arrows-, working from inside outwards.
Note
♦ Note different bolt lengths. ⇒ page 127

♦ Note tightening sequence ⇒ page 127
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♦ Note the dowel sleeves.
– Install baffle plate. To do so, insert pins in balance shaft as‐

sembly -arrows-.
Note
– Rotate engine to TDC of No. 1 cylinder by turning central bolt

of crankshaft sprocket in normal direction of rotation. Marking
on camshaft sprocket and marking on crankshaft must be
aligned to TDC of cylinder No. 1 -arrows-.

Audi TT 2007 ➤
– Marking on chain sprocket of balance shaft -arrow- must be

positioned opposite the locating hole. Use locking pin -
T10027- to lock chain sprocket in this position. Place chain on
chain sprocket of balance shaft.
– Install oil pump chain sprocket with new bolt and hand-tighten
the bolt.
Note
The oil pump chain sprocket can only be installed correctly in one
position. When installing, you may ONLY turn the oil pump.
– Remove locking pin -T10027- and Allen key -1-. Secure oil
pump chain sprocket. Counterhold on central bolt of vibration
damper.
mantling.
– Install sump ⇒ page 120 .
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1.4.1 Pre-tensioning chain tensioner
– Pre-tension the piston by hand -arrow-.
– Press chain rail in direction of arrow and lock in position using

a 3 mm Allen key -1-.

Audi TT 2007 ➤
2 Oil filter bracket and oil cooler
2.1 Oil filter bracket - exploded view

Sump with balance shaft assembly ⇒ page 119
Balance shaft assembly with oil pump ⇒ page 125
1 - Pipe
❑ For crankcase breather
2 - Oil pressure switch -F1-
❑ 1.4 bar - black
❑ 21 Nm
3 - Bolt
❑ 15 Nm
❑ With earth wire for oil
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pressure switch
4 - Bracket
5 - Bolt
❑ 15 Nm
6 - Oil cooler
❑ See note ⇒ page 119
❑ Ensure clearance from
surrounding compo‐
nents
❑ Diagram of coolant hose
connections
⇒ page 146
⇒ page 134
7 - Gasket
❑ Renew
8 - Oil filter housing
❑ Remove and install us‐
ing oil filter tool -3417- or
36 mm socket, e.g.
socket, 36 mm -T10125-
❑ Draining ⇒ page 133
9 - Screw plug
10 - Seal
❑ Renew
❑ Lubricate lightly with oil
11 - Oil filter element
❑ Observe change intervals ⇒ Maintenance ; Booklet 810
12 - Bolt
❑ 15 Nm
13 - Baffle plate

Audi TT 2007 ➤
14 - Gasket
❑ Renew
15 - Oil filter bracket
Installation position of baffle plate
Installation position of seal
cardiagn.com
– Note position of service tab on seal -arrow-.
– Flat side of seal must face outwards.
2.2 Draining oil filter housing
Note
A valve in the oil filter housing will be opened when the oil drain
adapter -T40057- is screwed in. The valve will be closed again as
soon as the oil drain adapter -T40057- is unscrewed.
2. Oil filter bracket and oil cooler 133

Audi TT 2007 ➤
♦ Oil drain adapter -T40057-
– Unscrew dust cap from oil filter housing -arrow-.
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– Direct hose of oil drain adapter -T40057- into a drip tray and
screw oil drain adapter -T40057- into oil filter housing.
– Drain engine oil
2.3 Removing and installing oil cooler

♦ Drip tray for workshop hoist -VAS 6208-

Audi TT 2007 ➤
Removing
WARNING

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air mass meter.

Audi TT 2007 ➤

– Remove intake manifold and fuel rail ⇒ Motronic direct injec‐
tion and ignition system (4-cylinder); Repair group 24; Servic‐
ing injection system
– Unbolt bracket for connectors -arrows- from coolant pipe.
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– Detach coolant hoses -arrows- from coolant pipe.

– Unscrew bolt -1- and detach coolant pipe.

Audi TT 2007 ➤
– Remove oil cooler -arrows-.

Installing
Note
♦ Renew gaskets and seals.

2.4 Removing and installing oil filter bracket

cardiagn.com

Audi TT 2007 ➤
Removing
WARNING


Removing
air mass meter.
cardiagn.com


Audi TT 2007 ➤

– Take off poly V-belt.
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– Remove tensioner for poly V-belt -arrows-.
– Remove alternator ⇒ Electrical system; Repair group 27 .
– Remove intake manifold and fuel rail ⇒ Motronic direct injec‐
tion and ignition system (4-cylinder); Repair group 24; Servic‐
ing injection system
– Unbolt bracket for connectors -arrows- from coolant pipe.

Audi TT 2007 ➤

– Detach coolant hoses -arrows- from coolant pipe.

– Unscrew bolt -1- and detach coolant pipe.
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– Remove oil cooler -arrows-.
– Detach pipe -1- for crankcase breather system.

– Unscrew earth cable -2- for oil pressure switch.
– Unscrew bolts -arrows- and remove oil filter bracket.
Installing
Note

– Install baffle plate ⇒ Item 13 (page 132)


Audi TT 2007 ➤
2.5 Checking oil pressure and oil pressure switch
cardiagn.com
♦ Oil pressure tester -V.A.G 1342-
♦ Voltage tester -V.A.G 1527 B-
♦ Auxiliary measuring set -V.A.G 1594 C-
Test requirements
• Engine oil level OK, checking ⇒ Maintenance ; Booklet 810
• Oil pressure warning lamp must light up for approx. 3 seconds
when ignition is switched on.
• In vehicles with auto-check system, the “OK” display must light
up (select symbol).
• Engine oil temperature at least 80°C (radiator fan must have
run once)

Audi TT 2007 ➤
Note
Functional check and servicing the visual and acoustic oil pres‐
sure warning: Current flow diagrams, ⇒ Vehicle diagnosis, testing
and information system VAS 5051; “Function and component se‐
lection” .
Test sequence
– Remove the oil pressure switch -F1- -A- and screw it onto
tester.
– Screw tester into oil filter bracket in place of the oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester -V.A.G 1527 B- with adapter leads from
auxiliary measuring set -V.A.G 1594 C- to battery positive (+)
and oil pressure switch -F1- -B-. LED must not light up.
– If the LED lights up, renew 1.4 bar oil pressure switch.
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If the LED does not light up:
– Start engine and run at increased speed: at 1.2 ... 1.6 bar
pressure the LED should light up, otherwise renew oil pressure
switch -F1- .
– Increase engine speed further. At 2,000 rpm and an oil tem‐
perature of 80 °C the oil pressure should be between 2.7 ... 4.5
bar.

Audi TT 2007 ➤
19 – Cooling
1 Removing and installing parts of cool‐
ing system
WARNING

Note
♦ The cooling system is under pressure when the engine is hot.

If necessary, relieve pressure before commencing repair work.
cardiagn.com
♦ Hose clip pliers -V.A.G 1921- or spring-type clip pliers -VAS
5024 A- are recommended for use in installing spring-type
clips.
♦ The arrow markings on coolant pipes and on ends of hoses
must align.
1. Removing and installing parts of cooling system 143

Audi TT 2007 ➤
1.1 Cooling system components (on engine) - exploded view
1 - Bolt
❑ 40 Nm
2 - Bolt
❑ 30 Nm
3 - Coolant pipe
4 - Connecting hose
5 - O-ring
❑ Renew
6 - Connection
7 - Bolt
❑ 10 Nm
8 - Retaining clip
9 - O-ring
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❑ Renew
10 - Coolant temperature
sender -G62-
❑
11 - Connecting hose
12 - Connecting piece
16 - Coolant pipe
17 - Bolt
❑ 5 Nm
19 - Coolant pipe
20 - Bolt
❑ 5 Nm
21 - Coolant distributor housing
❑ With thermostat
❑ Starts to open at 87°C
22 - Bolt
❑ 15 Nm
23 - Coolant pump
24 - Bolt
❑ 15 Nm
144 Rep. Gr.19 - Cooling

Audi TT 2007 ➤
1.2 Continued coolant circulation pump -V51- - exploded view
1 - Nut
❑ 3 Nm
2 - Coolant pipe
3 - Spring-type hose clip
4 - Coolant pipe
❑ To turbocharger
5 - Bolt
❑ 5 Nm
7 - Coolant hose
8 - Bracket
9 - Coolant hose
❑ Going to radiator
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11 - Continued coolant circula‐
tion pump -V51-
12 - Bolt
❑ 5 Nm
14 - Nut
❑ 5 Nm

Audi TT 2007 ➤
1.3 Diagram of coolant hose connections
1 - Radiator
⇒ page 158
❑ If renewed, refill system
with fresh coolant
2 - Continued coolant circula‐
tion pump -V51-
3 - Map-controlled engine cool‐
ing thermostat -F265-
⇒ page 155
4 - Coolant pump
⇒ page 155
5 - Cylinder head/cylinder
block
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with fresh coolant
6 - Turbocharger
⇒ page 164
7 - Expansion tank
❑ With filler cap
❑ Testing pressure relief
valve in filler cap
⇒ page 151
8 - Heat exchanger (for heating
system)
with fresh coolant
9 - Coolant connecting pipe
10 - Engine oil cooler
11 - Intake manifold
❑ Removing and installing ⇒ Rep. Gr. 24

Audi TT 2007 ➤
1.4 Draining and filling cooling system

equipment required
♦ Adapter for cooling system
tester -V.A.G 1274/8-
-VAS 6208-
♦ Hose clip pliers -
V.A.G 1921-
♦ Cooling system charge unit
-VAS 6096-
♦ Refractometer -T10007-
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Draining
Note
Collect drained coolant in a clean container for re-use or disposal.
WARNING


Audi TT 2007 ➤

cardiagn.com

Audi TT 2007 ➤

Filling
Note
♦ The cooling system is filled all year round with a mixture of

water and radiator antifreeze/anti-corrosion agent.
♦ Only use coolant additive G 12+ in accordance with TL -
VW 774 F- . Other coolant additives could seriously impair in
particular the anticorrosion properties. The resulting damage
could lead to loss of coolant and consequently to serious en‐
gine damage.
♦ Coolant additive G12+ can be mixed with additives G11 and
G12.
♦ G 12+ and coolant additives marked "meeting specification TL
-VW 774- F" prevent frost and corrosion damage as well as
scaling. Such additives also raise the boiling point of the cool‐
ant. For these reasons the cooling system must be filled all
year round with the correct antifreeze and anticorrosion addi‐
tive.
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♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Frost protection is required down to about –25 °C (in countries
with arctic climate: down to about –35 °C).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
antifreeze concentration must be at least 40 %.
♦ If greater frost protection is required in very cold climates, the
amount of G 12+ can be increased, but only up to 60 % (this
gives frost protection to about -40 °C), as otherwise frost pro‐
tection is reduced again, as is cooling effectiveness.
♦ Use only clean tap water for mixing coolant.
♦ If radiator, heat exchanger, cylinder head, cylinder head gas‐
ket or cylinder block are renewed, do not reuse old coolant.
♦ For checking anti-freeze protection in cooling system, use re‐
fractometer -T10007- for coolant additive G12+.
– Connect bottom coolant hose to radiator -arrow-.

Audi TT 2007 ➤
– Fill reservoir of cooling system charge unit -VAS 6096- with at

least 8 litres of premixed coolant (based on recommended ra‐
tio):
♦ G12+ (40%) and water (60%) for frost protection to -25 °C
– Screw adapter for cooling system tester -V.A.G 1274/8- onto
coolant expansion tank.
– Fit cooling system charge unit -VAS 6096- onto adapter for
cooling system tester -V.A.G 1274/8- .
– Run vent hose -1- into a small container -2-. (The vented air
draws along a small amount of coolant, which should be col‐
lected.)
– Close the two valves -A- and -B- (levers at right angles to di‐
rection of flow).
– Connect hose -3- to compressed air.
• Pressure: 6 ... 10 bar
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– Open valve -B- (lever in direction of flow).
The suction jet pump generates a partial vacuum in the cooling
system.
• The needle on the gauge should move into the green zone.
– Additionally open valve -A- briefly (lever in direction of flow) so
that the hose of cooling system charge unit -VAS 6096- is filled
with coolant.
– Close valve -A- again.
– Leave valve -B- open for another 2 minutes.
The suction jet pump will continue generating a vacuum in the
cooling system.
• The needle on the gauge should remain in the green zone.
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
If the needle does not reach the green area, repeat the process.
If the vacuum level drops, there is a leak in the cooling system.
– Detach compressed air hose.
– Open valve -A-.
The vacuum in the cooling system causes the coolant to be drawn
out of the cooling system charge unit -VAS 6096- ; the cooling
system is then filled.

Audi TT 2007 ➤
– Check the coolant level and top up coolant as far as the max
mark.
– Start engine, run for 2 minutes (maximum) at approx. 1500
rpm and top up coolant to overflow hole on expansion tank
with engine running.
– Fit expansion tank cap.
– Run engine until radiator fan cuts in.
WARNING

– Check coolant level and top up if necessary. When the engine

is at normal operating temperature, the coolant level must be
on the MAX mark; when the engine is cold, between the MIN
and MAX marks.
– Switch off engine.
cardiagn.com
1.5 Checking cooling system for leaks

equipment required
♦ Cooling system tester -
V.A.G 1274-

Audi TT 2007 ➤
Test condition
• Engine must be warm.
Test sequence
WARNING


– Fit cooling system tester -V.A.G 1274- with adapter for cooling
system tester -V.A.G 1274/8- on coolant expansion tank.
– Using hand pump on tester, build up a pressure of approx. 1.0
bar.
– If this pressure is not maintained, locate and rectify leaks.
Checking pressure relief valve in cap.
cardiagn.com
– Fit cooling system tester -V.A.G 1274- with adapter for cooling
system tester -V.A.G 1274/9- on filler cap.
– Operate hand pump.
♦ The pressure relief valve should open at a pressure of
1.4 ... 1.6 bar.
1.6 Removing and installing coolant pipes


Audi TT 2007 ➤
Removing
air mass meter.
cardiagn.com
– Remove pipe -A- and hose -B- -arrows-.
– Slacken clip -2-.

– Remove nut -3- and bolt -1-.
– Take out intake connecting pipe downwards.
– Drain off coolant ⇒ page 147 .

Audi TT 2007 ➤
– Unplug electrical connectors -arrows-.
– Detach coolant hoses from coolant pipes -arrows-.
cardiagn.com
– Detach hose -A- and unscrew bolt -B-. Remove front coolant
pipe.
– Release connectors -A- from bracket, detach hose -B- and

unscrew bolts -C-. Remove rear coolant pipe.
Installing
Note


Audi TT 2007 ➤
1.7 Removing and installing coolant distrib‐

utor housing with map-controlled engine
cooling thermostat -F265-
Removing
– Remove alternator ⇒ Electrical system; Rep. Gr. 27 ; Alter‐
nator .
– Remove coolant pipes ⇒ page 152 .
– Detach coolant hose -2- from coolant distributor housing; to
do so, pull out retaining clip -1-.
cardiagn.com
– Unscrew bolts -arrows- and remove coolant distributor hous‐
ing with map-controlled engine cooling thermostat -F265- from
engine.
Installing
Note

– Clean sealing surface for O-ring.

– Renew O-ring and lubricate with coolant.
– Install alternator ⇒ Electrical system; Rep. Gr. 27 ; Alternator .
1.8 Removing and installing coolant pump


Audi TT 2007 ➤
Removing
WARNING

cardiagn.com
air mass meter.

Audi TT 2007 ➤

cardiagn.com
– Unscrew coolant pump securing bolts -1- and remove coolant
pump -2-.
– Remove O-ring -3-.
Installing
– Clean and smoothen sealing surface for O-ring.
– Coat new O-ring -3- with coolant G12+.

– Fit coolant pump -2-.
• Installation position: Sealing plug in housing faces down‐
wards.
– Tighten coolant pump bolts -1-.
– Fit toothed belt ⇒ page 66 .

Audi TT 2007 ➤
1.9 Radiator and radiator fans - exploded view
1 - Radiator fan -V7-

⇒ page 163
2 - Nut
❑ 10 Nm
3 - Radiator cowl
4 - Coolant hose (top)
❑ To connection at cylin‐
der head
5 - O-ring
❑ Renew if damaged
6 - Radiator
⇒ page 158
❑ If renewed, change
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coolant in entire system
7 - O-ring
8 - Coolant hose (bottom)
❑ To connection for ther‐
mostat
9 - Bolt
❑ 5 Nm
❑ To charge air cooler
10 - Nut
❑ 10 Nm
11 - Bolt
❑ 5 Nm
❑ To radiator
12 - Radiator fan 2 -V177-
1.10 Removing and installing radiator


Audi TT 2007 ➤
Removing
WARNING

cardiagn.com
– Disconnect intake connecting pipe -arrow- with hose clip pliers
-V.A.G 1921- .
– Unbolt air intake connection at front of lock carrier -1- and re‐
move air intake connection.

Audi TT 2007 ➤
cardiagn.com
– Remove air pipe -arrows-.


Audi TT 2007 ➤
– Detach top coolant hose from radiator -arrow-.
cardiagn.com
– Unscrew bolts -arrows- on backside of radiator.
– Lift up radiator slightly and remove from below.
Installing
1.11 Removing and installing radiator cowl


Audi TT 2007 ➤
Removing
cardiagn.com

Installing

Audi TT 2007 ➤
1.12 Removing and installing radiator fan -

V7- and radiator fan 2 -V177-
Removing
– Remove radiator cowl ⇒ page 161 .
– Move wiring clear.
– Unscrew nuts -arrows- and remove fans.
Installing
– Install radiator cowl ⇒ page 161 .
cardiagn.com

Audi TT 2007 ➤
21 – Turbocharging/supercharging
1 Turbocharger
Note
♦ Observe the rules for cleanliness ⇒ page 4

(same as original equipment).
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. However (applies only
to plug-in connectors); the seal and the sealing surface of plug-
in connectors should be lubricated lightly with oil
⇒ page 164 .
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
cardiagn.com
♦ Hose clip pliers -V.A.G 1921- or spring-type clip pliers -VAS
5024A- are recommended for installing spring-type hose clips.
♦ Fill turbocharger with engine oil at connection for oil supply
pipe.
♦ After installing turbocharger, allow engine to idle for approx. 1
minute and do not rev up immediately to ensure turbocharger
is supplied with oil.
Fitting hose connections with plug-in connectors ⇒ page 164
1.1 Fitting hose connections with plug-in

connectors
Caution
The seal in the plug-in connector can be damaged if the se‐

curing clip is in the locked position when fitting the connector.
This can cause leakage. Note assembly instructions.
Removing:
– Release plug-in connector by pulling out retaining clip
-arrow-. Disconnect pipe/hose (do not use tools of any kind).
Installing
– When renewing seal, fit seal in groove on charge air hose.
Make sure that the seal is correctly seated in the groove all
round the complete circumference and that it is not twisted.
– Lubricate sealing surface and seal with oil.
164 Rep. Gr.21 - Turbocharging/supercharging

Audi TT 2007 ➤
– Move securing clip to released position -1-.

– Push charge air hose into connector as far as stop.
– Move securing clip to locked position -2- and press charge air
hose in once again.
– Then pull hose to check that it is fitted correctly and that plug-
in connector is locked.
1.2 Turbocharger - exploded view
cardiagn.com
Part I
Part II ⇒ page 167
Part III ⇒ page 168
Part IV ⇒ page 169
1. Turbocharger 165
Audi TT 2007 ➤
1 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold and vacuum
unit as one unit
⇒ page 170
2 - Gasket
❑ Renew
3 - Bolt
❑ 9 Nm
4 - Crankcase breather hose
5 - Heat shield
6 - ACF line
7 - Vacuum unit/pressure ac‐
tuator for turbocharger
cardiagn.com
⇒ page 179
❑ Adjusting ⇒ page 179
8 - Nipple
9 - Seal
❑ Renew
10 - Hose
11 - Hose
12 - Bolt
❑ 3 Nm
13 - Charge pressure control
solenoid valve -N75-
14 - Bolt
❑ 8 Nm
15 - Seal
❑ Renew
16 - Connection
17 - Securing clip
18 - Bolt
❑ 9 Nm
19 - Hose
20 - Bolt
❑ 7 Nm
21 - Mounting bracket
22 - Bolt
❑ 7 Nm
23 - Turbocharger air recirculation valve -N249-
❑ Note installation position ⇒ page 167

Audi TT 2007 ➤
24 - Seal
❑ Renew
Fitting location of turbocharger air recirculation valve -N249-

– Heed installation position -arrows-.
Part II
Part I ⇒ page 165
1 - Seal
❑ Renew
cardiagn.com
2 - Bolt
❑ 30 Nm
3 - Oil supply pipe
4 - Turbocharger
gether with exhaust
manifold and vacuum
unit as one unit
⇒ page 170
5 - Bolt
❑ 9 Nm
6 - Bolt
❑ 30 Nm
7 - Seal
❑ Renew
8 - Bolt
❑ 35 Nm
9 - Seal
❑ Renew
10 - Coolant supply pipe
11 - Bolt
❑ 23 Nm
12 - Bolt
❑ 23 Nm
13 - Bolt
❑ 9 Nm
14 - Seal
❑ Renew
15 - Gasket
❑ Renew
1. Turbocharger 167
Audi TT 2007 ➤
16 - Oil return pipe

17 - Bolt
❑ 9 Nm
18 - Gasket
❑ Renew
Part III
Part I ⇒ page 165
1 - Gasket
❑ Renew
2 - Nut
❑ 21 Nm
cardiagn.com
❑ Renew
❑ Coat studs of exhaust
manifold with high-tem‐
perature paste
❑ High-temperature paste
⇒ Parts catalogue
3 - Bolt
❑ 35 Nm
4 - Seal
❑ Renew
5 - Bolt
❑ 9 Nm
6 - Coolant return hose/pipe
7 - Turbocharger
gether with exhaust
manifold and vacuum
unit as one unit
⇒ page 170
8 - Bracket
9 - Bolt
❑ 30 Nm
❑ Lubricate bolts with
high-temperature paste
❑ High-temperature paste
⇒ Parts catalogue
10 - Bolt
❑ 30 Nm
❑ Lubricate bolts with high-temperature paste
❑ High-temperature paste ⇒ Parts catalogue

Audi TT 2007 ➤
11 - Bracket
12 - Bolt
❑ 23 Nm
13 - Nut
❑ 30 Nm
❑ Do not open when removing turbocharger
❑ Renew
❑ Coat studs of exhaust manifold with high-temperature paste
14 - Fastening strip
Part IV
Part I ⇒ page 165
cardiagn.com
1 - Turbocharger
gether with exhaust
manifold and vacuum
unit as one unit
⇒ page 170
2 - Vacuum unit for turbocharg‐
er
⇒ page 179
❑ Adjusting ⇒ page 179
3 - Bolt
❑ 10 Nm
4 - Locking plate
5 - Nut
❑ 9 Nm
❑ Secure with sealing
paint
❑ Sealing paint ⇒ Parts
catalogue
6 - Knurled nut
1. Turbocharger 169
Audi TT 2007 ➤
Further tightening torques

Component Nm
Charge air pipe (right-side) to sump 10
Charge air pipe (rear) to bracket 10
Oil supply pipe to oil filter bracket 25
1.3 Removing and installing turbocharger

cardiagn.com
♦ Tensioning strap -T10038-
♦ Lambda probe open ring spanner set -3337-

Audi TT 2007 ➤
Removing
air mass meter.
cardiagn.com
1921- .
– Unplug connectors -1- on ignition coils.
WARNING


– Disconnect coolant pipe going to coolant expansion tank

-arrow-.
1. Turbocharger 171
Audi TT 2007 ➤

– Unscrew coolant line -3-.
Note
– Remove heat shield -arrows-.
cardiagn.com
– Unscrew crankcase breather line with heat shield from turbo‐
charger -1-.
– Disconnect crankcase breather line from cylinder head cover
-2- and remove.
– Disconnect ACF line going to turbocharger from cylinder head
cover -3-.
– Unscrew oil supply pipe from turbocharger -4-.
– Remove electrical connector -arrow- for Lambda probe -G39-

and Lambda probe heater -Z19- (before catalytic converter)
from bracket, unplug and move clear.

Audi TT 2007 ➤

– Remove catalytic converter with front exhaust pipe
⇒ page 191
cardiagn.com

– Remove drive shaft (right-side) ⇒ Rep. Gr. 40
1. Turbocharger 173
Audi TT 2007 ➤
cardiagn.com
– Detach electrical connectors -1 and 2- and move wire clear.
Note

Audi TT 2007 ➤
– Unscrew oil supply pipe from turbocharger -2-.
– Unscrew coolant supply pipe at turbocharger -2-.
cardiagn.com
– Remove oil return pipe -arrows- at turbocharger.
– Remove bolts -1- and -2- and remove support for turbocharg‐
er.
1. Turbocharger 175
Audi TT 2007 ➤
– Remove bolts -1 ... 3- and take out pendulum support.
– Fit bolt -1-.

– Use tensioning strap -T10038- to move engine towards the
front.
Note
Make sure there is sufficient clearance around engine and turbo‐
cardiagn.com
charger.
– Disconnect coolant pipe -arrow-.
Note
♦ Shown in illustration from rear with engine removed.

♦ Do not unscrew nuts on fastening strip (bottom).
– Unscrew top nuts -arrows-.

– Lift out turbocharger/exhaust manifold.
Installing
Note
♦ Renew seals, gaskets and self-locking nuts.

♦ Fill turbocharger with engine oil at connection for oil supply
pipe.
free of oil and grease before assembly.

Audi TT 2007 ➤
– Position turbocharger as shown in illustration when fitting.

– Install exhaust system and align it free of stress
⇒ page 194 .
– Install Lambda probe -G39- ⇒ Rep. Gr. 24 .
– Install drive shaft ⇒ Rep. Gr. 40 .
Note
After installing turbocharger, allow engine to idle for approx. 1 mi‐

nute and do not rev up immediately to ensure turbocharger is
supplied with oil.
1.4 Checking vacuum unit for turbocharger
cardiagn.com
♦ Hand-operated vacuum pump -VAS 6213-
Test condition:
♦ Hose from turbocharger via charge pressure solenoid valve -
N75- to vacuum unit must not be blocked.
♦ Charge pressure control solenoid valve -N75- OK.
1. Turbocharger 177
Audi TT 2007 ➤
Procedure:
air mass meter.
cardiagn.com
– Connect hand-operated vacuum pump -VAS 6213- to vacuum
unit -arrow-.
– Move adjuster ring -1- on hand-operated vacuum pump -VAS

6213- to position -B- to select “pressure”.
Caution
The pressure must not exceed 750 mbar. The vacuum unit
could be damaged if the pressure is exceeded.
– Operate hand-operated vacuum pump -VAS 6213- several

times and at the same time observe linkage.
The linkage -A- should start to move at a pressure of approx.
300 mbar and be at its limit stop at a pressure of approx.
700 mbar.

Audi TT 2007 ➤
The linkage should travel approx. 10 mm.
Note
If it is not possible to build up pressure with hand-operated vac‐

uum pump -VAS 6213- or if the pressure drops again immediate‐
ly, check hand-operated vacuum pump -VAS 6213- and connect‐
ing hoses for leaks. If no fault is found: renew vacuum unit
⇒ page 179 .
1.5 Removing and installing vacuum unit for

turbocharger
Removing
– Remove turbocharger ⇒ page 170
– Detach locking plate -1- on turbocharger linkage.
cardiagn.com
– Loosen lock nut -2-.
– Detach linkage from turbocharger -3-.
– Remove bolts -4- and take out vacuum unit -1-.
Installing
– Adjust vacuum unit for turbocharger ⇒ page 179 .
– Install turbocharger ⇒ page 170
1.6 Adjusting vacuum unit for turbocharger

Turbocharger removed
1. Turbocharger 179
Audi TT 2007 ➤

equipment required
♦ Universal dial gauge brack‐
et -VW 387-
♦ Hand-operated vacuum
pump -VAS 6213-
♦ Pressure control valve -
VAS 6342-
♦ Turbocharger tester -V.A.G
1397A-
♦ Dial gauge set, 4 pieces -
VAS 6341-
1783-
cardiagn.com
♦ Open-end spanner insert AF 10 -V.A.G 1783/1-
Adjusting

Audi TT 2007 ➤
– Disconnect hose -arrow- at vacuum unit on turbocharger.
– Detach locking plate -1- on turbocharger linkage.
cardiagn.com
– Loosen lock nut -2-.
– Pre-adjust bypass flap -1- at knurled nut -arrow- so that bypass

flap can still just be turned by hand.
– Hand-tighten lock nut.
1. Turbocharger 181
Audi TT 2007 ➤
– Connect up hand-operated vacuum pump -VAS 6213- , tur‐

bocharger tester -V.A.G 1397A- (connection II) and pressure
control valve -VAS 6342- as shown in illustration.
– Close pressure control valve -VAS 6342- at lever -1-.
– Move adjuster ring -1- on hand-operated vacuum pump -VAS
cardiagn.com
6213- to position -B- to select “pressure”.
– Switch on turbocharger tester -V.A.G 1397A- and set sliding
switch to position II.

Audi TT 2007 ➤
– Secure universal dial gauge bracket -VW 387- to turbocharger

-arrow-.
Note
The dial gauge values (mm) listed here include the 1 mm preload
that is initially set on the gauge.
– Attach dial gauge -VAS 6341/1- with extension, 30 mm -VAS

6341/3- and flat probe -VAS 6341/4- to universal dial gauge
bracket -VW 387- .
– With pressure at 0 bar, set dial gauge -VAS 6341/1- to 1 mm
preload.
– Set scale of dial gauge -VAS 6341/1- to 0.
– Make sure that dial gauge can move freely.
– Operate hand-operated vacuum pump -VAS 6213- until tur‐
bocharger tester -V.A.G 1397A- indicates 350 +/- 5 mbar.
– The dial gauge should now indicate a value between 4.1 mm
and 4.3 mm. If not, turn knurled nut until this value is indicated.
cardiagn.com
– Hand-tighten lock nut.
– Repeat measurement.
– Vent system via pressure control valve -VAS 6342- so that
pressure reading drops to 0 mbar.
– Set dial gauge -VAS 6341/1- to 0.
Note
The following measurements must be performed in continuous

sequence. Do not allow the pressure to drop to 0 between meas‐
urements.

bocharger tester -V.A.G 1397A- indicates 350 +/- 5 mbar.
– Read off and note value indicated on dial gauge -VAS 6341/1- .
bocharger tester -V.A.G 1397A- indicates 650 to 700 mbar.
– Vent system via pressure control valve -VAS 6342- so that
pressure reading drops to 350 +/- 5 mbar.
– Read off and note value indicated on dial gauge -VAS 6341/1- .
– Add values 1 and 2 together and divide by 2.
– The result (mean value) should be 5 +/- 0.25 mm.
– If the result (mean value) is not 5 +/- 0.25 mm, correct the
setting accordingly, tighten the lock nut hand-tight and repeat
the measurement.
– If the result (mean value) is 5 +/- 0.25 mm, tighten the lock nut
and secure with sealing paint. For sealing paint refer to ⇒
Parts catalogue .
1. Turbocharger 183
Audi TT 2007 ➤
– Secure locking plate -1- on linkage of vacuum unit.
cardiagn.com

Audi TT 2007 ➤
2 Charge air system

Charge air cooler - exploded view of components ⇒ page 185
Turbocharging diagram ⇒ page 186
Checking charge air system for leaks ⇒ page 187
2.1 Charge air cooler - exploded view of components
1 - Bolt
❑ 5 Nm
2 - Mounting
❑ For charge air cooler
3 - Charge air cooler
4 - Charge air pipe
❑ Fitting hose connec‐
tions with plug-in con‐
nectors ⇒ page 164
cardiagn.com
5 - Bolt
❑ 10 Nm
6 - Charge air hose
7 - Hose clip
8 - Charge air hose
❑ To throttle valve module
-J338-
9 - Hose clip
10 - Bolt
❑ 10 Nm
11 - Charge air pipe
12 - Hose clip
13 - Charge air hose
14 - Seal
❑ Renew
15 - Charge pressure sender -G31-
16 - Bolt
❑ 5 Nm
17 - Bolts
❑ 10 Nm
2. Charge air system 185

Audi TT 2007 ➤
2.2 Turbocharging diagram
1 - Vacuum unit
2 - Solenoid valve for charge
pressure control -N75-
3 - Turbocharger air recircula‐
tion valve -N249-
4 - Turbocharger
5 - Brake servo
6 - Non-return valve
7 - Coolant hose/pipe connec‐
tion
8 - Vacuum pump
9 - Non-return valve
10 - Oil filter bracket
11 - Activated charcoal filter
cardiagn.com
solenoid valve 1 -N80-
12 - Dual non-return valve
13 - Charge air cooler
14 - Throttle valve module -
J338-
15 - Pressure control valve
16 - To activated charcoal filter
17 - Air mass meter -G70-
2.3 Removing and installing charge air cool‐

er
Removing
– Remove radiator ⇒ page 158 .
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. Gr. 63
Note
To prevent damage to the condenser, refrigerant pipes and re‐

frigerant hoses, ensure that the pipes and hoses are not stretch‐
ed, kinked or bent.

Audi TT 2007 ➤
WARNING
The air conditioner refrigerant circuit must not be opened.
– Unscrew bolts -arrows-, to do so, release air ducts (left and

right) and swivel towards headlights.
– Tilt top edge of charge air cooler slightly to rear.
– Disengage charge air cooler from bottom mounting points by
lifting charge air cooler.
– Push charge air cooler towards engine.
– Support charge air cooler from below to prevent it from drop‐
ping.
– Remove bolts -arrows-.

– Detach charge air cooler upwards and remove from below.
cardiagn.com
Installing
– Install front bumper cover ⇒ General body repairs, exterior;
Rep. Gr. 63
2.4 Checking charge air system for leaks

♦ Charge air system tester -V.A.G 1687-
♦ Adapter -V.A.G 1687/5-

– Remove noise insulation tray ⇒ General body repairs, exteri‐
or; Rep. Gr. 50 ; Body - front, noise insulation .

Audi TT 2007 ➤
– Release clip -A- and detach hose -B- from charge air pipe.
– Fit adapter -V.A.G 1687/5- onto charge air hose -A- and turn
adapter through approx. 90° -B-.
Prepare charge air system tester -V.A.G 1687- as follows:
cardiagn.com
– Unscrew pressure control valve -2- all the way and close
valves -3- and -4-.
Note
Make sure knob is pulled out before turning pressure control valve
-2-.
– Connect charge air system tester -V.A.G 1687- as illustrated.

Audi TT 2007 ➤
– Connect pressure hose -1- (compressed air supply line) to

charge air system tester -V.A.G 1687- .
Note
If sight glass contains water, loosen drain plug and drain water
-6-.
– Open valve -3-.

– Adjust pressure to 0.5 bar via pressure control valve -2-.
Caution
The pressure must not exceed 0.5 bar. If the pressure is set
too high this can damage the engine.
– Open valve -4- and wait until test system is pressurised. Re-
adjust pressure to 0.5 bar if necessary.
– Check charge air system for visible or audible leaks and apply
cardiagn.com
commercially available leak detecting spray or use ultrasonic
tester -V.A.G 1842- .
Note
♦ A small amount of air escapes through the valves and enters

the engine. Therefore it is not possible to perform a pressure
retention test.
♦ Operation of ultrasonic tester -V.A.G 1842- ⇒ Operating in‐
structions .
♦ Release pressure by detaching coupling from adapter -V.A.G
1687/5- before removing adapter.
free of oil and grease before assembly.

Audi TT 2007 ➤
26 – Exhaust system
1 Parts of exhaust system
Note
♦ To avoid any damage, the flexible joint in the front exhaust

pipe must not be bent more than 10°.
♦ Renew gaskets and self-locking nuts.
♦ After working on the exhaust system, ensure that the system
is not under stress and that it has sufficient clearance from the
body. If necessary, loosen clamp and align silencers and ex‐
haust pipe so that sufficient clearance is maintained to the
body at all points and the mountings are evenly loaded.
♦ The exhaust manifold and the turbocharger are one compo‐
nent; removing and installing ⇒ page 164
cardiagn.com
1.1 Exhaust system - exploded view
1 - Bolt
❑ 23 Nm
2 - Bracket for exhaust system
3 - Clamp
❑ Align exhaust system so
it is free of stress before
tightening clamp
⇒ page 194
❑ Installation position
⇒ page 191
❑ Tighten bolt connec‐
tions evenly.
4 - Nut
❑ 23 Nm
5 - Bracket for exhaust system
6 - Rubber mounting
7 - Rubber mounting
8 - Mounting
9 - Bolt
❑ 23 Nm
10 - Tunnel brace
11 - Gasket
❑ Renew
12 - Nut
❑ 40 Nm
❑ Renew
190 Rep. Gr.26 - Exhaust system

Audi TT 2007 ➤
❑ Coat studs of turbocharger with high-temperature paste

13 - Lambda probe -G39- and Lambda probe heater -Z19-
❑ 55 Nm
❑ Grease only the threads with high-temperature paste. The paste must not penetrate into the slots on the
probe body.
14 - Front exhaust pipe with catalytic converters and front silencer
❑ Do not bend flexible joint more than 10° - otherwise it can be damaged
❑ Install flexible joint so that it is not under tension.
❑ Take care not to damage wire mesh on flexible joint.
❑ Protect catalytic converter from damage by knocks and impact
❑ Align exhaust system so it is free of stress ⇒ page 194
15 - Lambda probe after catalytic converter -G130- and Lambda probe heater 1 after catalytic converter -Z29-
❑ 55 Nm
cardiagn.com
❑ Grease only the threads with high-temperature paste. The paste must not penetrate into the slots on the
probe body.
16 - Rear silencer
❑ Align exhaust system so it is free of stress ⇒ page 194
17 - Rubber mounting
18 - Nut
❑ 23 Nm
Installation position of clamp

– Position clamp at angle shown when installing.
• Bolt connections face to right.
• Nuts face upwards.
• α = approx. 20°
1.2 Removing and installing front exhaust

pipe with catalytic converters and front
silencer
1. Parts of exhaust system 191

Audi TT 2007 ➤
♦ Lambda probe open ring spanner set -3337-
Removing
air mass meter.
cardiagn.com
– Unplug electrical connector -arrow- for Lambda probe -G39-
and Lambda probe heater -Z19- and move wiring clear.


Audi TT 2007 ➤
– Unscrew securing nuts -arrows- of front exhaust pipe/turbo‐

charger accessible from above.
clear.
cardiagn.com
-G130- .


Audi TT 2007 ➤
Note
cardiagn.com
silencer.
Installing
Note
Renew gaskets and self-locking nuts.
– Align the exhaust system so it is free of stress ⇒ page 194 .
1.3 Aligning exhaust system

• The exhaust system must be aligned when it is cool.
– Loosen bolt connections of front clamp ⇒ Item 3 (page 190) .
– Push rear silencer towards front of vehicle -arrow-, so that
rubber mounting (left-side) is preloaded by dimension -a- =
11 ... 13 mm.

Audi TT 2007 ➤
– Position clamp at angle shown when installing.

• Bolt connections face to right.
• Nuts face upwards.
• α = approx. 20°
•
– Tighten bolt connections on clamp evenly.
Aligning tailpipe:
– Align tailpipes so that distance -a- is the same on both sides.

– At the same time, distance -b- must be obtained between
bumper cut-out and top of tailpipes.
♦ Dimension b = min. 21 mm
– If necessary, unfasten rear silencer mounting to align tailpipes.
cardiagn.com
1.4 Checking exhaust system for leaks
– Start engine and run at idling speed.
– Plug the tailpipe (e. g. with rags or stopper) and leave plugged
until the check is complete.
– Listen for noise at connection points (cylinder head/exhaust
manifold, exhaust manifold/front exhaust pipe, etc.) to locate
any leaks.
– Rectify any leaks that are found.

Engine BWA, BPY - 2.0 LTR, 4-Valve, Turbo - A005TT00520

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What are the main components of the exhaust system discussed in the manual?

What are the main components of the exhaust system discussed in the manual?

What safety precautions should be observed when working on the exhaust system?

What safety precautions should be observed when working on the exhaust system?

Service

Service Department. Technical Information

All rights reserved.

Copyright © 2010 Audi AG, Ingolstadt A005TT00520

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.1 Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

1.4 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

2 Rep. Gr.00 - Technical data

The fuel system is pressurised. Before opening the system

Observe the following to avoid injuries to persons and/or damage

♦ Observe notes on procedure for disconnecting the battery

When working on the cooling system note the following warnings:

Hot steam or hot coolant can escape when expansion tank is

Note the following if testers and measuring instruments have to

♦ Test equipment must always be secured on the rear seat

4 Rules for cleanliness

4 Rep. Gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

Special tools and workshop

1. Removing and installing engine, detaching from gearbox 5

Lambda probe open ring spanner set -3337-

♦ The engine is removed from underneath together with the

Observe notes on procedure for disconnecting the battery. ⇒

– Remove luggage compartment floor covering.

Remove rear cross panel trim if cover for negative terminal of

– With ignition switched off, disconnect earth wire -arrow- at

Hot steam/hot coolant may escape when opening expansion

– Open filler cap on coolant expansion tank

6 Rep. Gr.10 - Removing and installing engine

– Remove centre noise insulation -fasteners 1 ... 4-.

– Remove noise insulation panels (left and right) -arrows-.

– Unplug electrical connector at air mass meter -G70- -3-.

1. Removing and installing engine, detaching from gearbox 7

– Remove electrical connector -arrow- for Lambda probe (be‐

– Pull off rubber seal -1- on plenum chamber cover.

8 Rep. Gr.10 - Removing and installing engine

– Unplug engine wiring harness connector -1-.

– Release wiring protector for engine wiring harness -arrow- and

– Move electrical connector -1- clear and unplug connector.

1. Removing and installing engine, detaching from gearbox 9

– Unplug electrical connector -1- for reversing light switch.

– Press the two clips in direction of the -arrows- and remove

10 Rep. Gr.10 - Removing and installing engine

– Unscrew electrical wire -1- and move clear up to engine.

– Unscrew bolts -1- from above.

– Remove air pipe -1 and 2- for charge air cooler.

1. Removing and installing engine, detaching from gearbox 11

– Unplug electrical connector -2-.

– Detach top coolant hose from radiator -arrow-.

– Unscrew securing bolts -arrows- for front exhaust pipe/turbo‐

Shown in illustration from rear with engine removed.

12 Rep. Gr.10 - Removing and installing engine