CHZE-CHZB-DDHA - 3-Cylinder Direct Petrol Injection Engine (1 0 LTR 4-Valve TFSI EA211)

Service
Workshop Manual
Audi A1 2011 ➤
3-cylinder direct petrol injection engine (1.0 ltr. 4-valve
TFSI EA211)
Engine ID
CHZ CHZ DDH
E B A
Edition 11.2014
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service Department. Technical Information

Service
List 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
24 - Mixture preparation - injection
26 - Exhaust system with respect to the correctness of information in this document. Copyright by AUDI AG.
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Audi AG, Ingolstadt D4B804C90D8

Audi A1 2011 ➤
3-cylinder direct petrol injection engine (1.0 ltr. 4-valve TFSI EA211) - Edition 11.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine identification number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 4
2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 4
2.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Safety precautions when working on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.8 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.3 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.2 Supporting engine
permitted unless in installation
authorised position
by AUDI AG. AUDI AG does. . .not
. .guarantee
. . . . . or. .accept
. . . any
. . liability
..................... 31
2.3 Removingwith and installing
respect engine
to the correctness mountings
of information . . . . . Copyright
in this document. . . . . . .by. AUDI
. . . AG.
..................... 33
2.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.5 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.1 Exploded view - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.4 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.6 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.1 Exploded view - cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.3 Removing and installing sealing flange (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.2 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.1 Exploded view - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.3 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.4 Checking radial clearance of conrod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Contents i
Audi A1 2011 ➤
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.1 Exploded view - toothed belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.2 Exploded view - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.3 Detaching toothed belt from camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.4 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.1 Exploded view - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.2 ExplodedProtected
view by - camshaft housing
copyright. Copying for private.or. commercial
. . . . . . .purposes,
. . . . . in. part
. . .or. in. whole,
. . . . is. not
................... 101
2.3 Removing with
and installing cylinder head . . . . . . . . . . . . . . . .
respect to the correctness of information in this document. Copyright by AUDI AG.
. . . . . . .................. 103
2.4 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.2 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.3 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.4 Removing and installing camshaft control valve N205 / N318 . . . . . . . . . . . . . . . . . . . . . . 118
3.5 Removing and installing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.1 Exploded view - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 137
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.1 Exploded view - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3 Crankcase breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.1 Exploded view - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4 Oil filter/oil pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.1 Exploded view - oil filter/oil pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.2 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.3 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.4 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 146
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.3 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.1 Exploded view - coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.2 Exploded view - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.3 Exploded view - coolant temperature senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.6 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
ii Contents
Audi A1 2011 ➤
2.7 Removing and installing toothed belt sprocket for coolant pump . . . . . . . . . . . . . . . . . . . . 169
2.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 171
2.9 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 172
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.1 Exploded view - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4 Radiators/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.1 Exploded view - radiators/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.3 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4.4 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.1 Exploded view - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.3 Removing and installing charge pressure positioner V465 . . . . . . . . . . . . . . . . . . . . . . . . 187
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.1 Exploded view - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.2 Exploded view - hose connections for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.4 Removing and installing charge pressure sender G31 / intake air temperature sender 2 G299
...................................................................... 194
2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
24 - Mixture preparation - injection . . . . .Protected

. . . . by. .copyright.
. . . . Copying
. . . .for. private
. . . .or .commercial
. . . . .purposes,
. . . . in. part
. . or. .in .whole,
196is not
1 Injection system . . . . . . . . . . . . . . . . . with . . .respect
. . . .to. the
. . correctness
. . . . . . .of.information
. . . . . .in. this
. . document.
. . . . . . Copyright
. . . . . by
. .AUDI
. 196
AG.
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1.2 Reducing fuel pressure in high-pressure section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.1 Exploded view - air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.2 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.3 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3.4 Cleaning throttle valve module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4.1 Exploded view - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
4.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4.4 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
5.1 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
5.2 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
5.3 Removing and installing intake air temperature sender G42 / intake manifold pressure sender
G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
6 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
6.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
6.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
6.3 Removing and installing high-pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
7.1 Exploded view - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
7.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Contents iii
Audi A1 2011 ➤
8 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

8.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
1.1 Exploded view - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
1.2 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
1.3 Removing and installing silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.4 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2 Emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
2.1 Exploded view - emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
1.1 Exploded view - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
1.2 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
1.3 Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 244
1.4 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
1.5 Removing and installing Hall senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.6 by Removing
Protected and
copyright. Copying installing
for private engine
or commercial speed
purposes, sender
in part G28
or in whole, is not . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
iv Contents
Audi A1 2011 ➤
00 – Technical data
1 Identification
(ARL003952; Edition 11.2014)
⇒ “1.1 Engine identification number/engine data”, page 1
1.1 Engine identification number/engine da‐

ta
Engine number
♦ The engine number (“Engine code” and “Serial number”) can
be found on the left of the joint between engine and gearbox
-arrow-.
♦ Additionally there is a sticker on the toothed belt cover (top)
with engine code and serial number.
♦ Starting with the letter “C”, the engine codes consist of 4 let‐
ters.
♦ The first 3 characters of the engine code stand for the engine
capacity and the mechanical construction and design. They
are stamped on the cylinder block, together with the serial
number.
♦ The 4th character indicates the power output and torque of the
engine, and is determined by the engine control unit.
Notewith respect to the correctness of information in this document. Copyright by AUDI AG.
♦ The 4-character engine code can be found on the type plate

(in versions for some countries only) and on the vehicle data
sticker and the engine control unit.
♦ Fitting locations of the type plate (certain countries only) and
the vehicle data sticker ⇒ Maintenance ; Booklet 819 .
Engine data
Code letters CHZB CHZE DDHA
Capacity ltr. 0.999 0.999 0.999
Power output kW at rpm 70/5000 … 5500 60/5000 … 5500 70/5000 … 5500
Torque Nm at rpm 160/1500 … 3500 160/1500 … 3500 160/1500 … 3500
Bore ∅ in mm 74.5 74.5 74.5
Stroke mm 76.4 76.4 76.4
Compression 10.5 10.5 10.5
ratio
RON at least 95 1) 95 1) 95 1)
Injection system/ignition sys‐ FSI FSI FSI
tem
Exhaust gas recirculation no no no
Exhaust gas temperature con‐ no no no
trol
Turbocharging/supercharging Turbocharger Turbocharger Turbocharger
Knock control 1 sensor 1 sensor 1 sensor
Charge air cooling yes yes yes
1. Identification 1
Audi A1 2011 ➤
Code letters CHZB CHZE DDHA

Lambda control Probe before catalytic Probe before catalytic Probe before catalytic
converter converter converter
Probe after catalytic Probe after catalytic Probe after catalytic
converter converter converter
Variable valve timing Inlet Inlet Inlet
Exhaust Exhaust Exhaust
Intake manifold change-over yes yes yes
Secondary air system no no no
Valves per cylinder 4 4 4
Firing order 1-2-3 1-2-3 1-2-3
• 1) Unleaded regular grade petrol (RON 91) can also be used, but this will result in a loss of power
2 Rep. gr.00 - Technical data

Audi A1 2011 ➤
2 Safety precautions
⇒ “2.1 Safety precautions when working on the fuel supply sys‐
tem”, page 3
⇒ “2.2 Safety precautions when working on vehicles with start/
stop system”, page 4
⇒ “2.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 4
⇒ “2.4 Safety precautions when working on the cooling system”,
page 5
⇒ “2.5 Safety precautions when working on the ignition system”,
page 5
2.1 Safety precautions when working on the

fuel supply system
Please note the following warnings when working on the fuel sup‐
ply system:
WARNING
The fuel system operates at extremely high pressure. This can

cause injury.
♦ The injection system consists of a high-pressure section
(maximum approx. 120 bar) and a low-pressure section
(4 ... 7 bar).
♦ The fuel pressure in the high-pressure section must be
reduced to a residual pressure of approx. 6 bar prior to
opening the system. Procedure ⇒ page 200
Observe the following to prevent injuries to persons and 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.
♦ Always switch off ignition before washing engine.
♦ Erase any entries in event memory resulting from testing or
installation ⇒ Vehicle diagnostic tester, Guided Functions ,
then Generate readiness code .
Caution
To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
2. Safety precautions 3
Audi A1 2011 ➤
WARNING
Escaping fuel can cause a risk.

♦ The power supply for the fuel system pressurisation pump
- G6- must be disconnected before opening the fuel sys‐
tem, since -G6- will be activated briefly when the driver's
door is opened with the battery still connected.
♦ Remove fuse for fuel pump control unit - J538- in fuse
holder C - SC- under dash panel (driver's side); for iden‐
tification of fuses refer to ⇒ Current flow diagrams, Elec‐
trical fault finding and Fitting locations.
2.2 Safety precautions when working on ve‐

hicles with start/stop system
When performing repairs on vehicles with start/stop system, note
the following:
WARNING
Risk of injury due to automatic engine start on vehicles with

start/stop system.
♦ On vehicles with activated start/stop system (this is indi‐
cated by a message in the instrument cluster display), the
engine may start automatically on demand.
♦ Therefore it is important to ensure that the start/stop sys‐
tem is deactivated
Protected bywhen performing
copyright. repairs
Copying for private (switch
or commercial off in part or in whole, is not
purposes,
ignition, if required switch on ignition again).
2.3 Safety precautions when using testers

and measuring instruments during a
road test
Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
Accidents can be caused if the driver is distracted by test

equipment while road-testing, or if test equipment is not prop‐
erly secured.
Persons sitting in the front passenger's seat could be injured if
the airbag is triggered in an accident.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Test equipment must always be secured on the rear seat
with a strap and operated from the rear seat by a second
person.

Audi A1 2011 ➤

cooling system
When working on the cooling system note the following warnings:
WARNING
Hot steam/hot coolant can escape - risk of scalding.

♦ The cooling system is under pressure when the engine is
hot.
♦ To allow pressure to dissipate, cover filler cap on coolant
expansion tank with cloth and open carefully.
Risk of injury as the radiator fan may start up automatically.
♦ Unplug electrical connectors before starting to work in the
area of radiator cowl.
Caution
Overheating can occur if the filler cap is not fitted properly.

♦permitted
The unless
filler authorised
cap must engage positively and audibly when it
by AUDI AG. AUDI AG does not guarantee or accept any liability
is closed.

ignition system
To prevent injuries to persons and/or irreparable damage to the
fuel injection and ignition system, the following must be noted:
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as the
ignition system and xenon headlights.
necting electrical wiring for the injection or ignition system or
tester cables.
♦ Erase any entries in event memory resulting from testing or
installation ⇒ Vehicle diagnostic tester, Guided Functions ,
then Generate readiness code .
♦ Always switch off the ignition before cleaning the engine.
necting the battery, otherwise the engine control unit may be
damaged.
♦ If you want to turn over the engine at cranking speed without
actually starting it (e.g. compression test), first unplug the con‐
nectors from the ignition coils. In addition, remove fuse for fuel
pump control unit - J538- ; for identification of fuses refer to
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
2. Safety precautions 5
Audi A1 2011 ➤
Caution
To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .

Audi A1 2011 ➤
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 7
⇒ “3.2 General notes”, page 7
⇒ “3.3 General repair instructions”, page 8
⇒ “3.4 Foreign particles in engine”, page 8
⇒ “3.5 Contact corrosion”, page 8
⇒ “3.6 Routing and attachment of pipes, hoses and wiring”, page
8
⇒ “3.7 Installing radiators and condensers”, page 9
⇒ “3.8 Checking vacuum system”, page 9
3.1 Rules for cleanliness

Even small amounts of dirt can cause malfunctions. For this rea‐
son, please observe the following rules when working on the fuel
supply system, injection system and turbocharger:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Immediately seal open lines and connections with clean plugs,
for example from engine bung set - VAS 6122- .
♦ Place parts that have been removed on a clean surface and
cover them over. Do not use fluffy cloths.
♦ Carefully cover or seal open components if repairs cannot
permitted unless be by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
carried out immediately. with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ 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.
♦ Make sure that no fuel runs onto the fuel hoses. Should this
occur, the fuel hoses must be cleaned again immediately.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
3.2 General notes

♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and fault finding, the event memory must
be interrogated. The vacuum hoses and connections must al‐
so be checked (unmetered air).
♦ A voltage of at least 11.5 V is required for proper operation of
the electrical components.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and will
damage the Lambda probe.
♦ The vehicles are fitted with a crash/fuel shut-off system. This
system is designed to reduce the risk of a vehicle fire after a
crash by deactivating the fuel pump via the fuel pump relay.
♦ At the same time, this system also improves the engine's start‐
ing performance. When the driver's door is opened, the fuel
pump is activated for 2 seconds in order to build up pressure
in the fuel system ⇒ page 3 .
3. Repair instructions 7
Audi A1 2011 ➤
3.3 General repair instructions

♦ Clean tools and workbench etc. before working on the injection
system.
♦ If the high-pressure fuel lines are to be re-used, you must mark
them before removal. High-pressure pipes must always be re-
installed on the same cylinder.
♦ Position high-pressure pipes so they are free of stress. Tighten
all unions lightly to start with before tightening to final torque.
♦ Never attempt to bend high-pressure fuel lines to shape.
♦ When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
♦ All cable ties which are released or cut open when removing
must be refitted in the same position when installing.
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. O-type clips or screw-type clips must not be
used.
3.4 Foreign particles in engine

♦ When performing assembly work on the engine, all open pas‐
sages in the intake and exhaust systems must be sealed with
suitable plugs (e.g. from engine bung set - VAS 6122- ) to
prevent foreign particles from entering the engine.
Note
If the turbocharger has suffered mechanical damage

⇒ page 182
3.5 Contact corrosion

Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
used.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Note the following:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend the use of Audi accessories.
♦ Damage caused by contact corrosion is not covered under
warranty.
3.6 Routing and attachment of pipes, hoses

and wiring
♦ Mark fuel lines, hydraulic lines, vacuum lines, lines for activa‐
ted charcoal filter and electrical wiring etc. before removal so
they can be re-installed in the original positions and correctly
connected. Make sketches or take photographs if necessary.

Audi A1 2011 ➤
♦ To prevent damaging pipes, hoses and wiring, ensure suffi‐

cient clearance from all moving or hot components in engine
compartment (little space in engine compartment).
3.7 Installing radiators and condensers

Even when the radiator and condenser are correctly installed,
slight impressions may be visible on the fins of these components.
This does not mean that the components are damaged. If the fins
are only very slightly distorted, this does not justify renewal of the
radiator or the condenser.
3.8 Checking vacuum system

Special tools and workshop equipment required
♦ Hand vacuum pump - VAS 6213-
Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites
♦ Kinked or crushed lines
♦ Lines porous or leaking
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
– If an entry is stored in the event memory, check all vacuum
lines leading to the corresponding component and also check
the remaining vacuum lines leading to other components.
– If it is not possible to build up pressure with the hand vacuum
pump - VAS 6213- or if the pressure drops again immediately,
check the hand vacuum pump and connecting hoses for leaks.
3. Repair instructions 9
Audi A1 2011 ➤
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 10
⇒ “1.2 Separating engine and gearbox”, page 21
⇒ “1.3 Securing engine to engine and gearbox support”,
page 24
⇒ “1.4 Installing engine”, page 26
1.1 Removing engine
Special tools and workshop

equipment required
♦ Removal lever - 80-200-
♦ Stepladder (commercially
available) or -VAS 5085-
♦ Engine bung set - VAS

6122-
♦ Coolant collecting system -
VAS 5014- or drip tray for
workshop hoist - VAS
6208-
♦ Hose clip pliers - VAS
6362-
♦ Engine and gearbox jack -
VAS 6931-
10 Rep. gr.10 - Removing and installing engine

Audi A1 2011 ➤
♦ Extension -2024A/1- for lifting tackle - 2024A-
♦ Locking pin - T10060A-
♦ Engine support - T10483-
♦ Safety goggles
♦ Protective gloves
Procedure
Note
♦ The engine is removed from underneath together with the

gearbox.
♦ Reinstall all cable ties in the same locations when installing.
1. Removing and installing engine 11

Audi A1 2011 ➤
WARNING

cause injury.
♦ The fuel pressure in the high-pressure section of the in‐
jection system must be reduced to a residual pressure
prior to opening the system ⇒ page 200 .
WARNING

♦ The cooling
permitted system
unless authorisedisbyunder
AUDI AG. pressure
AUDI AG does when the engine
not guarantee or acceptis
any liability
hot. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Open filler cap -1- on coolant expansion tank.

– Release hose clip -2- and detach coolant hose.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .
– Remove wheel housing liners (front left and front right) ⇒
General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front) .
– Remove front wheels ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Wheels, tyres .
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
– Place coolant collecting system -VAS 5014- or drip tray for

workshop hoist - VAS 6208- underneath.
– Release hose clip -arrow-, disconnect coolant hose (bottom
left) from radiator and drain off coolant.

Audi A1 2011 ➤
– Release hose clips -1 and 2-, disconnect coolant hoses (bot‐

tom right) from water radiator for charge air cooling circuit and
drain off remaining coolant.
– Release fasteners -arrows- and detach air duct from lock car‐
rier.
Note
Disregard -item 1-.
– Disconnect crankcase breather hose -2-.

– Move vacuum line -5- clear.
– Remove bolt -1-.
– Loosen hose clip -4-.
– Lift air cleaner housing -3- off ball studs and detach.
– Release catch -arrow- and disconnect vacuum hose -1-.

Audi A1 2011 ➤

– Lift retaining clips -1 and 2- and disconnect coolant hoses from
heat exchanger for heater.
– Guide coolant hoses downwards and drain off coolant.
– Press release tabs and disconnect vacuum hose -2- from ac‐
tivated charcoal filter system.
– Disconnect fuel supply line -1- ⇒ Fuel supply system; Rep.
gr. 20 ; Plug-in connectors; Disconnecting plug-in connectors .
– Seal off open pipes/lines and connections with clean plugs
from engine bung set - VAS 6122- .
– Open screw-type clip -1- and place it on intake funnel of cat‐

alytic converter.
– Unscrew nuts -arrows- and tie up catalytic converter to rear.
– Remove nut -1- and move earth wire -2- clear.

– Loosen bolts -arrows- for support arm of engine mounting ap‐authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless
prox. 2 turns. with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi A1 2011 ➤
Note
Disregard -item 1-.
– Unplug electrical connector -arrow- for radiator outlet coolant

temperature sender - G83- .
– Move coolant hose -1- clear at radiator cowl -arrows-.
– Unplug electrical connector -1- for radiator fan.

– Press locking tabs (left and right) for radiator cowl -arrow- si‐
multaneously.
– Lift radiator cowl off radiator and detach it downwards.

Audi A1 2011 ➤
– Release hose clips -1 and 2- and detach coolant hoses (top

left) from radiator.
Vehicles with manual gearbox:

– Remove bolts -arrows-, detach clutch slave cylinder -1- and
place to one side; do not open pipes.
Caution
Risk of serious damage to clutch slave cylinder.

♦ Do not operate clutch pedal with slave cylinder removed.
– Unplug electrical connectors on gearbox (front):

2 - For starter
3 - For gearbox neutral position sender - G701-
4 - For reversing light switch - F4-
– Detach electrical connector -1- from bracket and unplug.
– Detach gear selector cable and gate selector cable from gear‐
box, remove cable support bracket and place to one side with
selector cables attached ⇒ Rep. gr. 34 ; Selector mechanism;
Removing and installing selector mechanism .
Vehicleswithwith dual
respect clutch
to the gearbox:
correctness of information in this document. Copyright by AUDI AG.
– Detach selector lever cable from selector lever ⇒ Rep. gr. 34 ;

Selector mechanism; Removing and installing selector mech‐
anism .
– Detach electrical connector -2- from bracket and unplug.
Caution
Risk of serious damage to gearbox components.

♦ Do NOT touch connector contacts in gearbox connector
with your hands. Doing so could cause static discharge to
damage the control unit and the mechatronic unit irrepar‐
ably.
– Touch vehicle earth with bare hands to eliminate any static

charge.
– Unplug electrical connector -1- for mechatronic unit for dual
clutch gearbox - J743- .

Audi A1 2011 ➤
All vehicles (continued):

– Release fastener -arrow A-.
– Open and remove cover -1- for electronics box -arrow B-.
– Release and unplug electrical connector (bottom) -1- at engine

control unit - J623- ⇒ page 231 .
– Unplug electrical connector -4-.
– Remove bolts -2, 3-, detach electrical wiring and move clear.
– Move engine wiring harness clear using removal lever -

80-200- -arrows- and lay down on top of engine.
Note
Disregard -item 1-.
Vehicles with air conditioner compressor:
Caution
If a used belt runs in the opposite direction when it is refitted,

this can cause breakage.
♦ Before removing, mark direction of rotation of poly V-belt
with chalk or felt-tip pen for re-installation.
– To slacken poly V-belt, swivel tensioner in anti-clockwise di‐

rection -arrow- and detach poly V-belt from pulley for air con‐
ditioner compressor.
– Lock tensioner with locking pin - T10060A- .
– Take off by
Protected poly V-belt.
copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi A1 2011 ➤
– Unplug electrical connector -1- on air conditioner compressor

regulating valve - N280- .
WARNING
Risk of injury caused by refrigerant.

♦ The air conditioner refrigerant circuit must not be opened.
– Remove bolts -arrows- for air conditioner compressor.
Caution
Risk of damage to air conditioner compressor and refrigerant

pipes/hoses.
♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Detach air conditioner compressor with refrigerant lines still

connected and tie up to right side.
– Detach drive shaft (left and right) from gearbox ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
Note
Take care not to damage the surface coating of the drive shaft.
– Remove nut -1- for coupling rod -3- (right-side) on anti-roll bar
-2-.
Note
♦ Counterhold stud with a Torx socket to loosen and tighten

nuts.
♦ Apply counterhold tool so that it is straight (not tilted).
– Remove bolts -arrows- and detach pendulum support.
WARNING
Risk of accident.
♦ Do NOT loosen bolted connection -1-.

Audi A1 2011 ➤
– Remove nuts -arrows- for swivel joint on both sides.

– If fitted, loosen nut on bracket for front left vehicle level sender
-G78- .
– Detach swivel joints from wishbones.
Note
When carrying out repairs, take care to avoid damaging rubber

boot of swivel joint (protect boot if necessary).
– Pivot drive shaft (right-side) forwards; to do so, push engine/

gearbox assembly slightly forwards.
– Tie up drive shaft to longitudinal member -arrow-.
Note
– Swivel suspension strut (left-side) outwards and support with

support bracket -2024A/1- , as shown in illustration.
WARNING permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Accident risk from loose components of support bracket.
♦ Secure retaining pin and swivel joint with locking pin
-arrow- and nut -1-.
• Engine support - T10483- and adapters -/1- , -/2- and -/3- are
needed to lower engine/gearbox assembly.

Audi A1 2011 ➤
– Press engine support - T10483- into holes -arrows- in cylinder

block as far as stop.
– Hand-tighten bolts -1- initially.
– Hand-tighten bolt -arrow- initially.
– Tighten bolts -arrows- toProtected

20 Nm. by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Tighten all remaining boltswith
torespect
20 Nm ascorrectness
to the well. of information in this document. Copyright by AUDI AG.
– Attach engine and gearbox jack to engine bracket - T10483-
and raise engine/gearbox assembly slightly.
Note
Use a stepladder when unscrewing bolts.
– Remove bolts -arrows- for support arm of engine mounting.
Note
Disregard -items 1, 2-.

Audi A1 2011 ➤
– Remove bolts -arrows- securing gearbox mounting.
Caution
Danger of damage to vacuum lines or electrical wiring and to

engine compartment.
♦ Check that all vacuum lines and electrical wiring between
engine, gearbox, subframe and body have been detach‐
ed.
♦ Carefully guide engine/gearbox assembly out of engine
compartment when lowering.
– Pull engine/gearbox assembly as far forward as possible, and

lower gradually.
1.2 Separating engine and gearbox
⇒ “1.2.1 Separating engine and gearbox - vehicles with manual

gearbox”, page 21
⇒ “1.2.2 Separating engine and gearbox - vehicles with dual
clutch gearbox”, page 22
1.2.1 Separating engine and gearbox - vehi‐

cles with manual gearbox
♦ Shackle - 10-222A/12-
♦ Workshop hoist - VAS 6100-

Audi A1 2011 ➤
Procedure
• Engine/gearbox assembly removed and attached to engine
support - T10483- .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
– Fit shackle - 10-222A/12- on gearbox, as shown in illustration.
– Engage workshop hoist - VAS 6100- in shackle.
– Remove bolts -1, 2, 3- and -6 … 9- securing gearbox to engine.
Note
Disregard -items 4, 5, A-.
– Detach gearbox from engine.
1.2.2 Separating engine and gearbox - vehi‐

cles with dual clutch gearbox
♦ Shackle - 10-222A/12-

Audi A1 2011 ➤
Procedure
• Engine/gearbox assembly removed and attached to engine
support - T10483- .
– Move clear electrical wiring harness -arrow-.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
– Secure gearbox to workshop hoist - 10 - 222 A /12- using

shackle - VAS 6100- .
– Remove bolts -1 ... 8- securing gearbox to engine.
Note
Disregard -item
permitted A-.authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
unless
– Detach gearbox from engine.

Audi A1 2011 ➤
1.3 Securing engine to engine and gearbox

support
♦ Engine and gearbox support - VW 540-
♦ Lifting tackle - 2024A-
♦ Engine and gearbox support - VAS 6095-

Audi A1 2011 ➤
♦ Release tool - T10527-
Procedure
• Gearbox detached from engine ⇒ page 21 .
– Unplug electrical connector -1- for charge pressure sender -
G31- / intake air temperature sender 2 - G299- and move
electrical wiring clear.
– Move hoses -arrows- clear at air pipe -2-.
– Release fasteners using release tool - T10527- and detach air
pipe.
– Attach lifting tackle - 2024A- to engine and workshop hoist -

VAS 6100- as shown in illustration.
Note
To adjust to the centre of gravity of the assembly, the perforated

rails must be positioned as shown.
WARNING Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Accident risk from loose components of lifting tackle.

♦ The support hooks and retaining pins on the lifting tackle

must be secured with locking pins -arrows-.
– Lift engine off engine support - VAS 6100- using workshop

hoist - T10483- .

Audi A1 2011 ➤
– Secure engine to engine and gearbox support - VAS 6095-

with engine and gearbox support - VW 540- , as shown in
illustration.
– Put spacers -arrow- between support and engine.
• Dimension -a- = 10 mm
1.4 Installing engine

Tightening torques
Note
♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricants such as engine or gear oil may be used,
but do not use lubricants containing graphite.
♦ Do not use degreased parts.
♦ Tolerance for tightening torques: ± 15 %.
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
♦ Assembly mountings
⇒ “2.1 Exploded view - assembly mountings”, page 30
♦ Securing gearbox to engine ⇒ Rep. gr. 34 ; Removing and
installing gearbox; Tightening torques for gearbox

Audi A1 2011 ➤
Procedure
Note
♦ After removing, renew bolts tightened with specified tightening

angle.
♦ Renew self-locking nuts and bolts as well as seals, gaskets
and O-rings after removal.
♦ Secure all hose connections with correct type of hose clips (as
original equipment) ⇒ Electronic parts catalogue .
♦ Fit all cable ties in the original positions when installing.
– Install intermediate plate ⇒ page 50 .

– If not already fitted, install dowel sleeves -A- for centring en‐
gine and gearbox in cylinder block.
– Remove needle bearing in crankshaft if fitted ⇒ page 60 .
Vehicles with dual clutch gearbox:

– If not already fitted, install dowel sleeves -A- for centring en‐
gine and gearbox in cylinder block.
– Install needle bearing if not fitted in crankshaft ⇒ page 60 .
– Secure gearbox to engine. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Install gearbox support. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Take up engine/gearbox assembly with engine support -

T10483- .
– Guide engine/gearbox assembly into body.
– Initially hand-tighten bolts -arrows- for support arm of engine

mounting as far as stop.
Note

Audi A1 2011 ➤
– Initially screw in bolts -arrows- for gearbox mounting by hand

until they make contact.
– Remove engine support - T10483- from engine.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Ex‐
ploded view - starter .
– Install clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mechanism;
Removing and installing clutch slave cylinder .
– Install cables with cable support bracket or selector lever cable
⇒ Rep. gr. 34 ; Selector mechanism;
Protected by Exploded view
copyright. Copying for -private
selector
or commercial purposes, in part or in whole, is not
cables . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Install catalytic converter ⇒ page 240 .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .
– Install pendulum support ⇒ page 36 .
– Install wishbone, swivel joint and coupling rod ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Lower wishbone, swivel
joint; Exploded view - lower wishbone, swivel joint .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Exploded view - air
conditioner compressor drive unit .
– Install poly V-belt ⇒ page 40 .
– Install radiator cowl ⇒ page 179 .
– Connect fuel hoses ⇒ Fuel supply system; Rep. gr. 20 ; Plug-
in connectors; Disconnecting plug-in connectors .
– Electrical connections and routing ⇒ Electrical system; Rep.
gr. 97 ; Relay carriers, fuse carriers, electronics boxes; Over‐
view of fitting locations - relay carriers, fuse carriers, electron‐
ics boxes and ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
– Fit front wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres .
– Install engine control unit - J623- ⇒ page 231 .
– Install wheel housing liners ⇒ General body repairs, exterior;
Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
housing liner (front) .
– Install air cleaner housing ⇒ page 203 .
– Check oil level ⇒ Maintenance ; Booklet 819 .
Caution
Risk of irreparable damage to control units because of exces‐

sive voltage.
♦ Never use battery charging equipment for boost starting.
– Connect coolant hoses with plug-in connector ⇒ page 176 .

Audi A1 2011 ➤
Note
Do not reuse coolant.
– Fill up with coolant ⇒ page 152 .

– After renewing engine:
♦ Erase any entries in event memory ⇒ Vehicle diagnostic test‐
er, Guided Functions , Interrogate event memory , then
Generate readiness code .
♦ Reset misfire adaption using ⇒ Vehicle diagnostic tester; se‐

lect 01 - Reset adaptions misfires in Guided Func-
tions .

Audi A1 2011 ➤
2 Assembly mountings
⇒ “2.1 Exploded view - assembly mountings”, page 30
⇒ “2.2 Supporting engine in installation position”, page 31
⇒ “2.3 Removing and installing engine mountings”, page 33
⇒ “2.4 Removing and installing gearbox mounting”, page 34
⇒ “2.5 Removing and installing pendulum support”, page 36
2.1 Exploded view - assembly mountings
1 - Engine support
❑ Tightening torque and
sequence ⇒ page 31
2 - Bolt
❑ Renew after removing
❑ Tightening sequence
⇒ page 31
3 - Engine mounting
❑ With support arm
❑ Do not separate engine
mounting and support
arm
❑ Removing and installing
⇒ page 33
4 - Bolt
❑ 20 Nm +90°
5 - Centre hex stud
❑ 30 Nm +90°
6 - Bolt
❑ 30 Nm +90°
7 - Pendulum support

Audi A1 2011 ➤
⇒ page 36
8 - Bolt
❑ 40 Nm +90°
9 - Bolt
❑ 30 Nm +90°
10 - Bolt
❑ Tightening torque ⇒ Rep. gr. 34 ; Assembly mountings; Exploded view - assembly mountings
11 - Gearbox mounting
❑ With support arm
❑ Removing and installing ⇒ page 34
12 - Gearbox support
❑ Removing and installing ⇒ “2.4 Removing and installing gearbox mounting”, page 34
13, 14 - Bolt
❑ Tightening torque ⇒ Rep. gr. 34 ; Assembly mountings; Exploded view - assembly mountings
Engine support - tightening torque and sequence
Note
After removing, renew bolts tightened with specified tightening

angle.
– Tighten bolts in stages in the sequence shown:

Stage Bolts Tightening torque/angle specification
1. -1 … 3- 7 Nm
2. -1 … 3- 40 Nm
3. -1 … 3- Turn 90° further
2.2 Supporting engine in installation posi‐

tion
♦ Support bracket - 10-222A-
2. Assembly mountings 31
Audi A1 2011 ➤
♦ Adapters - 10-222A/19-
♦ Engine support bracket (basic set) - T40091-
♦ -T40093/6- from engine support supplement set - T40093-

Audi A1 2011 ➤
Procedure
– Remove air cleaner housing ⇒ page 203 .
G31- / intake air temperature sender 2 - G299- and move clear
electrical wiring.
pipe.
– Set up support bracket - 10-222A- on top edges of body flang‐

es (left and right) and longitudinal member (right-side), as
shown in illustration.
– Engage hooks of spindles -10-222A/11- in engine lifting eyes
(left and right).
– Tighten spindles slightly to take up weight of engine/gearbox
assembly; do not lift.
Assembling
Installation is carried out in the reverse order; note the following:
Note
♦ Renew O-rings after removing.

♦ Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
Tightening torques
♦ ⇒ “2.1 Exploded view - air cleaner housing”, page 202
2.3 Removing and installing engine mount‐

ings
Removing
– Remove bolts -arrows-.
– Detach electrical connector -1- for coolant shortage indicator
switch - F66- and move coolant expansion tank to side.
– Support engine in installation position ⇒ page 31 .
Audi A1 2011 ➤
– Remove nut -1- and move earth wire -2- clear.

– Remove bolts -arrows- for support arm of engine mounting.
– Remove bolts -arrows- and detach engine mounting -1-.

Installing
Note

angle.
– Fit engine mounting -1- on longitudinal member.

– Initially screw in bolts -arrows- by hand until they make con‐
tact.
– Tighten bolts.
– Initially hand-tighten bolts -arrows- for support arm of engine

mounting as far as stop.
• The support arm must not turn when you tighten the bolts.
– Tighten bolts.
Remaining installation steps are carried out in reverse sequence;
note the following:
– Detach support bracket - 10-222A- ⇒ page 31 .
Tightening torques
♦ ⇒ “2.1 Exploded view - assembly mountings”, page 30
♦ Nut -1- for earth wire -2- ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations
2.4 Removing and installing gearbox

mounting
Removing
– Support engine in installation position ⇒ page 31 .

Audi A1 2011 ➤
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;

– Remove bolts -arrows- securing gearbox mounting.
– Remove bolts -arrows A, B, C- and detach gearbox mounting.

Installing
Note

angle.
– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;

– Detach support bracket - 10-222A- ⇒ page 31 .
Tightening torques
♦ ⇒ Rep. gr. 34 ; Assembly mountings; Exploded view - as‐
sembly mountings
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
Audi A1 2011 ➤
2.5 Removing and installing pendulum sup‐

port
Removing
insulation .
WARNING
Risk of accident.
♦ Do NOT loosen bolted connection -1-.
– Remove bolts -arrows- and detach pendulum support.

Installing
Note

angle.
– Secure pendulum
permitted support
unless authorised by AUDIfirst to gearbox
AG. AUDI AG does not and thenorto
guarantee sub‐
accept any liability
frame.
Tightening torques
♦ ⇒ “2.1 Exploded view - assembly mountings”, page 30

Audi A1 2011 ➤
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Exploded view - poly V-belt drive”, page 37
⇒ “1.2 Removing and installing poly V-belt”, page 40
⇒ “1.3 Removing and installing tensioner for poly V-belt”,
page 43
⇒ “1.4 Removing and installing engine support”, page 43
⇒ “1.5 Removing and installing vibration damper”, page 45
⇒ “1.6 Renewing crankshaft oil seal (pulley end)”, page 47
1.1 Exploded view - poly V-belt drive

⇒ “1.1.1 Exploded view - poly V-belt drive,
Protected vehicles
by copyright. without
Copying air
for private or commercial purposes, in part or in whole, is not
conditioner compressor”, page 37permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ “1.1.2 Exploded view - poly V-belt drive, vehicles with air con‐
ditioner compressor”, page 39
1.1.1 Exploded view - poly V-belt drive, vehicles without air conditioner compres‐
sor
1. Cylinder block (pulley end) 37

Audi A1 2011 ➤
1 - Bolt
❑ Use counterhold tool -
T10475- with adapters -
T10475/1- and -
T10475/2- to loosen and
tighten
Caution
Risk of irreparable dam‐
age to engine.
To
♦ avoid disturbing valve
timing, do not turn crank‐
shaft when bolt is re‐
moved.
❑ 150 Nm +180°
2 - Vibration damper
❑ Version fitted in vehicle
may differ from illustra‐
tion
⇒ page 45
Caution
age to engine.
To
shaft out of “TDC” posi‐
tion when vibration
damper is removed.
3 - Poly V-belt
❑ Check for wear
❑ Before removing, mark direction of rotation with chalk or felt-tip pen
❑ Do not kink
❑ Routing of poly V-belt ⇒ page 41
❑ Assigning to decoupler pulley ⇒ page 39
❑ When installing, make sure it is properly seated on pulleys.
4 - Bolt
❑ 23 NmProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Tensionerpermitted
for poly V-belt
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Pivot with socket to slacken poly V-belt
❑ Lock in position with locking pin - T10060A- .
6 - Bolt
❑ Tightening torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
7 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
38 Rep. gr.13 - Crankshaft group

Audi A1 2011 ➤
Different versions of decoupler pulley
Note
Poly V-belts of different lengths are assigned to decoupler pulleys

-A, B-.
– Assign poly V-belt ⇒ Electronic parts catalogue .
1.1.2 Exploded view - poly V-belt drive, vehicles with air conditioner compressor
1 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen
❑ Do not kink
❑ Routing of poly V-belt
⇒ page 42
⇒ page 40
❑ Assigning to decoupler
pulley ⇒ page 39
❑ When installing, make
sure it is properly seated
on pulleys.
2 - Bolt
Caution
age to engine.
To
shaft when bolt is re‐
moved.
❑ Tightening torque
⇒ Item 1 (page 38)
3 - Vibration damper
❑ Version fitted in vehicle
may differ from illustra‐
tion
⇒ page 45

Audi A1 2011 ➤
Caution
age to engine.
To
shaft out of “TDC” posi‐
tion when vibration
damper is removed.
4 - Tensioner for poly V-belt

❑ Pivot with socket to slacken poly V-belt
❑ Lock in position with locking pin - T10060A- .
5 - Bolt
❑ 23 Nm
6 - Bolt
❑ Tightening torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
7 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
8 - Dowel sleeve
❑ For air conditioner compressor
9 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant hoses or pipes
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Detaching
and attaching air conditioner compressor at bracket
10 - Bolt
❑ Tightening torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Exploded view
- air conditioner compressor drive unit
1.2 RemovingProtected
andbyunless
permitted installing
authorised bypoly
AUDI AG. V-belt
AUDI AG does not guarantee or accept any liability
⇒ “1.2.1 Removing and installing poly V-belt - vehicles without air
conditioner compressor”, page 40
⇒ “1.2.2 Removing and installing poly V-belt, vehicles with air
1.2.1 Removing and installing poly V-belt - ve‐

hicles without air conditioner compres‐
sor

Audi A1 2011 ➤
Removing
Caution
If a used belt runs in the opposite direction
permitted whenbyitAUDI
unless authorised is refitted,
AG. AUDI AG does not guarantee or accept any liability
this can cause breakage. with respect to the correctness of information in this document. Copyright by AUDI AG.

– To slacken poly V-belt, turn tensioner in anti-clockwise direc‐

tion -arrow-.
– Take off poly V-belt.
Installing
– Fit poly V-belt as shown in illustration.
1- Vibration damper
2- Tensioner for poly V-belt
3- Alternator
– Turn tensioner in direction of -arrow- and remove locking pin

- T10060A- .
– Release tensioner.
– Check that poly V-belt is properly seated.
– Start engine and check that poly V-belt runs properly.
1.2.2 Removing and installing poly V-belt, ve‐

hicles with air conditioner compressor

Audi A1 2011 ➤
Removing
Caution

– To slacken poly V-belt, turn tensioner in anti-clockwise direc‐

tion -arrow-.
– Take off poly V-belt.
Installing
– Fit poly V-belt as shown in illustration.
1- Vibration damper
2- Tensioner for poly V-belt
3- Alternator
4- Air conditioner compressor
– Turn tensioner anti-clockwise -arrow- and remove locking pin
- T10060A- .
– Release tensioner.
– Check that poly V-belt is properly seated.
– Start engine and check that poly V-belt runs properly.

Audi A1 2011 ➤
1.3 Removing and installing tensioner for

poly V-belt
⇒ “1.3.1 Removing and installing tensioner for poly V-belt, vehi‐
cles without air conditioner compressor”, page 43
⇒ “1.3.2 Removing and installing tensioner for poly V-belt, vehi‐
cles with air conditioner compressor”, page 43
1.3.1 Removing and installing tensioner for

poly V-belt, vehicles without air condi‐
tioner compressor
Removing
– Detach poly V-belt from tensioner
⇒ “1.2.1 Removing and installing poly V-belt - vehicles without
air conditioner compressor”, page 40 .
– Remove bolts -arrows- and detach poly V-belt tensioner -1-.
Installing
Tightening torques
♦ ⇒ “1.1.1 Exploded view - poly V-belt drive, vehicles without air
1.3.2 Removing and installing tensioner for

poly V-belt, vehicles with air conditioner
compressor
Removing
– Detach poly V-belt from tensioner
⇒ “1.2.2 Removing and installing poly V-belt, vehicles with air
conditioner compressor”, page 41 .
– Remove bolts -arrows- and detach poly V-belt tensioner -1-.
Installing
Tightening torques
♦ ⇒ “1.1.2 Exploded view - poly V-belt drive, vehicles with air
1.4 Removing and installing engine support


Audi A1 2011 ➤
♦ Engine bung set - VAS 6122-
Removing
– Remove engine mounting ⇒ page 33 .
– Remove tensioner for poly V-belt ⇒ page 43 .
– Remove bolts -arrows- for toothed belt cover (bottom) -1-.
– Unscrew bolts -2- and remove bracket -1-.
– Press release tabs and disconnect vacuum hose -2- from ac‐
tivated charcoal filter system.
WARNING
Risk of injury - fuel system operates under high pressure.

♦ To reduce the pressure in the fuel system, wrap a clean
cloth around the connection and carefully loosen the con‐
nection.
– Disconnect fuel supply line -1- ⇒ Fuel supply system; Rep.

gr. 20 ; Plug-in connectors; Disconnecting plug-in connectors .
– Seal off open lines and connections with clean plugs from en‐
gine bung set - VAS 6122- .

Audi A1 2011 ➤
– Move hoses and bracket -3- clear.

– Release clips -arrows- and detach toothed belt cover (top)
-1-.
Note
For illustration purposes, the installation position is shown without

the air pipe.
Note
Disregard -item 2-.
– Remove alternator from bracket and tie up to front ⇒ Electrical

system; Rep. gr. 27 ; Alternator; Removing and installing al‐
ternator .
– Unscrew bolts -1, 2 and 3- and detach engine support up‐

wards.
Installing
– Connect fuel hoses ⇒ Fuel supply system; Rep. gr. 20 ; Plug-
in connectors; Disconnecting plug-in connectors .
– Install poly V-belt tensioner ⇒ page 43 .
– Install engine mountings ⇒ page 33 .
Tightening torques
♦ ⇒ Fig. ““Engine support - tightening torque and sequence”“ ,
page 31
♦ ⇒ “1.1 Exploded view - poly V-belt drive”, page 37
♦ ⇒ “1.1 Exploded view - toothed belt cover”, page 68
♦ ⇒ “3.1 Exploded view - coolant pipes”, page 173
♦ ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view
- alternator
1.5 Removing and installing vibration damp‐

er

Audi A1 2011 ➤
♦ Counterhold tool - T10475- with adapters -T10475/1- and -

T10475/2-
Preparing adapter - T10475- :

– Fit adapters -T10475/1- and -T10475/2- onto counterhold tool
- T10475- , as shown in illustration.
Removing
insulation .
– Remove poly V-belt ⇒ page 40 .
– Slacken bolt -arrow- for vibration damper using counterhold

tool - T10475- with adapters -T10475/1- and -T10475/2- .
– Remove bolt and take off vibration damper.
Caution
Risk of irreparable damage to engine.

♦ To avoid disturbing valve timing, do not turn crankshaft
when vibration damper is removed.
Installing
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

angle.
♦ All contact surfaces between bolt, vibration damper and crank‐
shaft sprocket must be free of oil and grease.

Audi A1 2011 ➤
– Fit vibration damper -1- (pay attention to tooth-shaped profile

-arrow-).
– Screw in bolt -arrow- for vibration damper by hand until it

makes contact (lubricate thread of bolt).
– Tighten bolt using counterhold tool - T10475- with adapters -
T10475/1- and -T10475/2- .
note the following:
Tightening torques
1.6 Renewing crankshaft oil seal (pulley

end)
♦ Assembly tool - T10485-
♦ Extractor tool - T20143-

Audi A1 2011 ➤
Procedure
– Remove toothed belt ⇒ page 84 .
– Pry out oil seal using extractor tool -T20143/2- -arrow-.
– Clean contact surface and sealing surface.
Note
Do not lubricate new oil seal.
– Slide oil seal -1- over fitting sleeve -T10485/3- onto guide
sleeve -T10485/2- .
• Fitting position: closed side of oil seal faces guide sleeve.
– Detach fitting sleeve from guide sleeve.
– Fit guide sleeve -T10485/2- with oil seal -1- onto crankshaft.
– Use thrust piece -T10485/1- and bolt -1- for vibration damper
to pull in oil seal -2- onto stop.
– Install toothed belt (adjust valve timing) ⇒ page 97 .

Audi A1 2011 ➤
2 Cylinder block (gearbox end)

⇒ “2.1 Exploded view - cylinder block (gearbox end)”, page 49
⇒ “2.2 Removing and installing flywheel”, page 50
⇒ “2.3 Removing and installing sealing flange (gearbox end)”,
page 51
2.1 Exploded view - cylinder block (gearbox end)
Note
When performing assembly work, secure engine to engine and gearbox support ⇒ page 24 .
1 - Bolt
❑ 60 Nm +90°
2 - Flywheel
⇒ page 50
❑ Can only be installed in
one position
3 - Sender wheel
❑ For engine speed send‐
er - G28-
❑ Only renew together
with sealing flange
❑ Do not rotate out of po‐
sition or remove from
sealing flange
⇒ “2.3 Removing and in‐
stalling sealing flange
(gearbox end)”,
page 51 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4 - Engine speed sender
with respect- to the correctness of information in this document. Copyright by AUDI AG.
G28-
⇒ page 248
❑ Note installation posi‐
tion ⇒ page 250
5 - Bolt
6 - Dowel pin
❑ 2x
7 - Intermediate plate
❑ Do not damage or bend when assembling
❑ Installing ⇒ page 50
8 - Bolt
❑ Tightening torque and sequence ⇒ page 50
9 - Sealing flange (gearbox end)
❑ With oil seal and sender wheel
2. Cylinder block (gearbox end) 49

Audi A1 2011 ➤
❑ Do not take sender wheel out of sealing flange or rotate it out of position
❑ Renewing ⇒ page 51
Sealing flange (gearbox end) - tightening torque and sequence

– Tighten bolts in stages as follows:
Stage Bolts Tightening torque
1. -1 … 6- Screw in by hand until contact is made
2. -1 … 6- Tighten in stages and in diagonal se‐
quence; final torque 10 Nm.
Installing intermediate plate

– Engage intermediate plate -1- on sealing flange -2- -arrow B-
and push onto dowel sleeves -arrows A-.
2.2 Removing and installing flywheel

♦ Counterhold tool - 3067-

Audi A1 2011 ➤
Removing
• Gearbox removed
Caution
Risk of serious damage to flywheel.

♦ Remove bolts -B- using normal hand tools (do not use
pneumatic wrench or impact driver, etc.).
♦ When removing the bolts, make sure that the bolt heads
do not come into contact with the flywheel.
♦ Rotate the flywheel -A- so that the bolts -B- align centrally
with the holes -arrows-.
– Insert counterhold - 3067- in hole on cylinder block -item B-.

– Loosen and remove flywheel bolts.
Installing
Note

angle.
♦ Flywheel with sender wheel can only be fitted in one position.
– Insert counterhold - 3067- in hole on cylinder block -item A-.

Tightening torques
♦ ⇒ “2.1 Exploded view - cylinder block (gearbox end)”,
page 49
2.3 Removing and installing sealing flange

(gearbox end)
♦ Open ring spanner - V.A.G 1332/11-

Audi A1 2011 ➤
♦ Depth gauge - VAS 6082-
♦ Locking pin - T10340-
♦ Bolt M6x35 (3x)

Procedure
• Gearbox removed.
Note
For illustration purposes, the procedure is shown with the engine

removed.
– Remove flywheel ⇒ page 50 .

Audi A1 2011 ➤
Rotate crankshaft to “TDC” as follows:

– Unscrew plug for “TDC” hole on cylinder block.
– Screw locking pin - T10340- into cylinder block as far as stop
and tighten to 30 Nm.
– Rotate crankshaft in normal direction of rotation as far as stop.
• The locking pin is now in contact with the crank web.
Note
The crankshaft must be turned in the direction of normal engine

rotation for the crank web to make contact with the locking pin -
T10340- with the correct “TDC” position.
Caution
Risk of damage to engine.

♦ If the locking pin - T10340- cannot be screwed in as far as
the stop, the crankshaft is not in the correct position.
♦ In this case proceed as follows:
♦ Remove locking pin.
♦ Turn crankshaft by 90° in direction of engine rotation.
♦ Screw locking pin - T10340- into cylinder block as far as
stop and tighten to 30 Nm.
♦ Turn crankshaft further in normal direction of rotation as
far as stop.
– Remove sump ⇒ page 133 .

– Remove engine speed sender - G28- ⇒ page 248 .
– Detach intermediate plate -1- from dowel sleeves -arrows A-.

– Move intermediate plate upwards.
– At the same time, pull retaining tab -arrow B- for intermediate
plate out of opening behind sealing flange -2-.

Audi A1 2011 ➤
Note with respect to the correctness of information in this document. Copyright by AUDI AG.
The sealing flange -1- is pressed off the crankshaft -3- together
with the sender wheel -2-.
– To press off, screw 3 bolts M6x35 -arrows- alternately into

sealing flange not more than 1/2 turn at a time.
– Detach sealing flange -1- together with sender wheel -2-.
Pressing in sealing flange with sender wheel
Note
♦ The sealing flange with PTFE oil seal is fitted with a sealing lip
support ring -2-. This support ring acts as an assembly sleeve
and must not be removed before installation.
♦ Sealing flange and sender wheel -1- must not be separated or
rotated out of position after removal from packaging.
♦ The sender wheel is held in its installation position by a locat‐
ing pin on the assembly tool - T10134- .
♦ The sealing flange and oil seal are one unit and can only be
replaced together with the sender wheel.
♦ The assembly tool - T10134- is held in the correct position rel‐
ative to the crankshaft by a guide pin which is inserted into a
hole in the crankshaft.
Construction of assembly tool - T10134- :

A - Tightening flats
B - Nut
C - Assembly housing
D - Locating pin
E - Hexagon socket head bolts (2x)
F - Guide pin for diesel engines (black handle)
G - Guide pin for petrol engines (red handle)
H - Knurled screws (3x)
I - Inner section

Audi A1 2011 ➤
Fitting sealing flange with sender wheel onto assembly tool -

T10134- :
– Unscrew nut -B- until it is just in front of tightening flats -A- on
threaded spindle.
– Clamp assembly tool - T10134- in a vice on tightening flats

-A- of threaded spindle.
– Press assembly housing -C- downwards so that it lies on nut
-B- -arrow-.
• Inner part of assembly device and assembly housing must
align (be level) with each other.
– If fitted, remove securing clip -arrow- from new sealing flange

-1-.
Note
Do not take the sender wheel out of the sealing flange or rotate it
out of position.
– Place sealing flange (with front side downwards) on a clean

flat surface.
– Press sealing lip support ring -1- downwards in direction of
-arrow- until it touches flat surface.

Audi A1 2011 ➤
• Upper edge of sealing lip support ring -1- must be flush

-arrows- with front edge of sealing flange -2-.
– Place front side of sealing flange -1- on assembly tool -

T10134- so that locating pin -D- is seated in hole -3- in sender
wheel -2-.
• Ensure that sealing flange lies flat on assembly tool.
– Screw knurled screws -H- onto sealing flange -1-.

– When securing, press sealing flange -1- and sealing lip sup‐
port ring -2- against surface of assembly tool - T10134- .
– This prevents locating pin from sliding out of hole in sender
wheel.
– Ensure that sender wheel remains fixed on assembly tool
when installing sealing flange.
Securing assembly tool - T10134- with sealing flange -1- on

crankshaft flange:
• Crankshaft flange must be free of oil or grease.
• Engine is at “TDC” position.
– Screw nut -B- to end of threaded spindle.
– Press threaded spindle of assembly tool - T10134- in direction
of -arrow- until nut -B- makes contact with assembly housing
-C-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Position flat edge of assembly housing

withtowards sealing sur‐
face for sump on cylinder block.

Audi A1 2011 ➤
– Secure assembly tool - T10134- with sealing flange -1- to

crankshaft flange -2-.
– To do so, screw hexagon socket head bolts -E- approx. 5 turns
into crankshaft flange with hexagon key.
– Insert guide pin for petrol engines (red handle) -F- into crank‐
shaft flange.
– Screw 2 bolts M6x35 -item 2- into cylinder block to guide seal‐

ing flange -1-.
Securing assembly tool - T10134- on crankshaft flange:

– Press assembly housing -C- by hand in direction of -arrow-
until sealing lip support ring -1- touches surface of crankshaft
flange -2-.
– Check that guide pin for petrol engines (red handle) -F- is fitted
correctly in hole in crankshaft. This ensures that sender wheel
reaches its final installation position.
The guide pin for diesel engines (black handle) must not be in‐
serted into threaded hole in crankshaft.
– Tighten the two hexagon socket head bolts on assembly tool

hand-tight.
– Screw nut -B- onto threaded spindle by hand until it touches
assembly housing -C-.
D - Pressing sender wheel onto crankshaft flange with assembly

tool - T10134- :
– Tighten nut -B- on assembly tool - T10134- to 35 Nm.
• There must be a small gap between cylinder block and sealing
flange -1- after nut has been tightened to 35 Nm.

Audi A1 2011 ➤
Checking installation position of sender wheel on crankshaft:

– Screw nut -B- to end of threaded spindle.
– Remove both bolts -2- from cylinder block.
– Unscrew knurled screws -H- from sealing flange -1-.
– Unbolt assembly tool - T10134- from crankshaft flange (re‐
move hexagon socket head bolts -E- from crankshaft flange).
– Detach sealing lip support ring.
– Apply depth gauge - VAS 6082- to crankshaft flange -2-.

– Measure distance -a- between crankshaft flange -2- and send‐

er wheel -1-.
• Specification: Distance -a- = 0.5 mm.
– Press sender wheel in further if measurement is too small
⇒ page 58 .
– If reading matches specification, continue with assembly
⇒ page 59 .
Pressing sender wheel in further:

– Secure assembly tool - T10134- to crankshaft flange.
– Ensure that locating pin of assembly tool - T10134- is fitted in
hole in sender wheel.
– Hand-tighten hexagon socket head bolts -E-.
– Slide assembly tool - T10134- onto sealing flange -1- by hand.
– Screw nut -B- onto threaded spindle by hand until it touches
assembly tool - T10134- .
– Insert guide pin for petrol engines (red handle) -F- into crank‐
shaft flange.
– Screw 2 bolts M6x35 -item 2- into cylinder block to guide seal‐
ing flange -1-.

Audi A1 2011 ➤
– Tighten nut -B- on assembly tool - T10134- to 40 Nm.

– Check installation position of sender wheel on crankshaft
again ⇒ page 58 .
– Tighten nut on assembly tool - T10134- to 45 Nm if measure‐
ment is too small.
– Check installation position of sender wheel on crankshaft
again ⇒ page 58 .
Assembling:
– Tighten bolts for sealing flange in diagonal sequence.
– Install sump ⇒ page 133 .
– Install intermediate plate ⇒ page 50 .
– Install flywheel ⇒ page 50 .
– After renewing sealing flange with sender wheel, misfire adap‐
tions must be reset. To do so, select 01 - Reset adaptions
misfires in Guided Functions mode of ⇒ Vehicle diagnos‐
tic tester.
Tightening torques
♦ ⇒ Fig. ““Sealing flange (gearbox end) - tightening torque and
sequence”“ , page 50
♦ ⇒ “2.1 Exploded view - cylinder block (gearbox end)”,
page 49
♦ Engine speed sender - G28-
⇒ “1.1 Exploded view - ignition system”, page 243
♦ ⇒ Fig. ““Plug for TDC drilling in cylinder block - tightening tor‐
que”“ , page 70

Audi A1 2011 ➤
3 Crankshaft
⇒ “3.1 Crankshaft dimensions”, page 60
⇒ “3.2 Renewing needle bearing in crankshaft”, page 60
3.1 Crankshaft dimensions
Caution
Risk of deformation of the cylinder block bearing pedestals.

♦ The crankshaft must not be removed. Even loosening the
main bearing cap bolts will cause deformation of the cyl‐
inder block bearing pedestals. This will result in reduced
bearing clearance. Even if bearing shells are not renewed,
a change in bearing clearance can cause bearing dam‐
age.
♦ If the bearing cap bolts are loosened, the cylinder block
must be renewed together with the crankshaft.
♦ Crankshaft bearing clearance cannot be measured using
workshop equipment.
3.2 Renewing needle bearing in crankshaft

♦ Centring mandrel - 3176-
♦ Internal puller Kukko 21/2

Audi A1 2011 ➤
♦ Counter-support Kukko 22/1
Important
• Gearbox removed ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox .
• The needle bearing -arrow- must always be renewed if the
engine is separated from the gearbox.
• The front edges of the internal puller must not be chipped.
Removing
– Pull needle bearing -1- out of crankshaft -2- using commer‐
cially available internal puller (e.g. Kukko - 21/2- ) and counter-
support (e.g. Kukko - 22/1- ).
– Internal puller must be positioned behind needle roller
-arrow-.
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Clean bearing seat in crankshaft and grease lightly. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Drive in needle bearing until flush using centring mandrel -

3176- .
3. Crankshaft 61
Audi A1 2011 ➤
4 Pistons and conrods

⇒ “4.1 Exploded view - pistons and conrods”, page 62
⇒ “4.2 Removing and installing pistons”, page 64
⇒ “4.3 Checking pistons and cylinder bores”, page 65
⇒ “4.4 Checking radial clearance of conrod bearings”,
page 66
4.1 Exploded view - pistons and conrods
1 - Circlip
2 - Piston pin
stalling pistons”,
page 64
3 - Piston
❑ Mark installation posi‐
tion and cylinder num‐
ber ⇒ page 63
⇒ page 64
❑ Checking pistons and
cylinder bores
⇒ page 65
4 - Compression rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to
remove and install com‐
pression rings
❑ Inscription “TOP” faces
towards piston crown
❑ Measuring ring gap
⇒ page 65
❑ Measuring ring-to-
groove clearance
⇒ page 66
5 - Oil scraper rings
❑ Remove and install 3-
part oil scraper rings
carefully by hand
❑ Measuring ring gap
⇒ page 65
❑ Ring-to-groove clearance cannot be checked
6 - Bolts
❑ Usepermitted
old bolts when measuring
by AUDI AG. radial
AUDI AGclearance
unless authorised does not guarantee or accept any liability
❑ Lubricate threads and contact surface
❑ 30 Nm +90°
7 - Conrod bearing cap
❑ Note installation position

Audi A1 2011 ➤
❑ Due to the cracking method used to separate the bearing cap from the conrod in manufacture, the caps
only fit in one position and only on the appropriate conrod
❑ Mark cylinder and conrod allocation in colour -A-
❑ Installation position: Marking -A- on conrod bearing cap faces towards pulley end. Mark before removing
(if no marking is present)
8 - Bearing shell
❑ Installation position ⇒ page 63
❑ Renew used bearing shells
9 - Pressure relief valve
❑ Opening pressure: 1.8 ... 2.2 bar
❑ 27 Nm
10 - Oil spray jet
❑ For piston cooling
11 - Conrod Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Only renew as awith complete set

❑ Mark cylinder and conrod bearing cap allocation in colour -A-
❑ Installation position: Marking -A- on conrod bearing cap faces towards pulley end Mark before removing
(if no marking is present)
❑ Separating parts of new conrod ⇒ page 64
Installation position of pistons and allocation of piston/cylinder
Caution
Risk of damage to piston crown.

♦ If you intend to reinstall used pistons, mark the cylinder
number on the piston crown using paint. Do not attempt to
mark the piston crown with a centre punch or by making
a scratch, notch or similar.
• Arrow on piston crown points to pulley end -arrow-.
Installation position of bearing shell

– Insert bearing shells centrally in conrod and conrod bearing
cap.
• Dimension -a- = 2.5 mm
4. Pistons and conrods 63

Audi A1 2011 ➤
Separating parts of new conrod

It is possible that the two parts of a new conrod are not completely
separated as intended. If it is not possible to take off the conrod
bearing cap by hand, proceed as follows:
– To avoid any risk of damage, the conrod should only be clam‐
ped lightly in a vice using jaw covers as shown in illustration.
• The conrod is clamped in position below the dotted line.
– Unscrew bolts -arrows- approx. 5 turns.
– Using a plastic hammer, carefully knock conrod bearing cap

loose -arrow-.
4.2 Removing and installing pistons

♦ Drift - 10-14-
♦ Piston ring clamp, commercially available

Removing
– Remove cylinder head ⇒Protected
page 103 .
by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove sump ⇒ page 133with
. respect to the correctness of information in this document. Copyright by AUDI AG.
– Mark installation position and cylinder number of piston.
– Mark installation position and matching of cylinder and conrod
bearing cap to conrod ⇒ Item 11 (page 63) .
– Remove conrod bearing cap and pull out piston and conrod
upwards.
Note
If piston pin is difficult to remove, heat piston to approx. 60 °C.

Audi A1 2011 ➤
– Take circlip out of piston pin boss.

– Use drift - 10-14- to drive out piston pin.
Installing
Note

angle.
– Oil running surfaces ofunless
permitted bearing shells.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Install piston using commercially available piston ring clamp;
note installation position ⇒ page 63 .
– Install conrod bearing cap; note installation position
⇒ Item 7 (page 62) .
– Install cylinder head ⇒ page 103 .
Tightening torques
♦ ⇒ “4.1 Exploded view - pistons and conrods”, page 62
4.3 Checking pistons and cylinder bores

Checking piston
– Using a micrometer, measure approx. 10 mm from the lower
edge, perpendicular to the piston pin axis.
• Maximum deviation from nominal dimension: 0.04 mm.
Piston ∅ mm
Nominal dimension 74.461 … 74.499 1)
• 1) Dimensions including coating (thickness 0.015 ± 0.005 mm
on each side)
Measuring 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
of cylinder.
– To do so, use a piston without rings.
Piston ring new Wear limit
mm mm
1st compression ring 0.20 … 0.35 1.0
2nd compression ring 0.50 … 0.70 1.0
Oil scraper ring 0.20 … 0.90 No data availa‐
ble

Audi A1 2011 ➤
Measuring ring-to-groove clearance

– Clean groove in piston before checking clearance.
Piston ring new Wear limit
mm mm
1st compression ring 0.04 … 0.08 0.15
2nd compression ring 0.03 … 0.07 0.15
Oil scraper rings Cannot be measured
Measuring cylinder bore
Caution
Risk of damage to the surface of the cylinder bore.

♦ Do not machine cylinder bore (reboring, honing, grinding)
with workshop equipment.
– Use a cylinder gauge - VAS 6078- to take measurements at 3

points in transverse direction -A- and in longitudinal direction
-B-.
Cylinder bore ∅ mm
Nominal dimension with respect to the74.5
correctness of information in this document. Copyright by AUDI AG.
Maximum dimension 74.515

Minimum dimension 74.505
Note
Measuring the cylinder bores must not be done when the cylinder
block is mounted to the engine and gearbox stand - VAS 6095- ,
as incorrect measurements may result.
4.4 Checking radial clearance of conrod

bearings
♦ Plastigage
Procedure
– Remove conrod bearing cap.
– Clean bearing cap and bearing journal.
– Place a length of Plastigage corresponding to the width of the
bearing on the bearing journal or in the bearing shell.
– Fit conrod bearing cap and secure with old bolts
⇒ Item 6 (page 62) without rotating crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with measurement scale.
Radial clearance
• New: 0.02 ... 0.06 mm

Audi A1 2011 ➤
• Wear limit: 0.07 mm

– Renew conrod bolts.

Audi A1 2011 ➤
15 – Cylinder head, valve gear

1 Toothed belt drive
⇒ “1.1 Exploded view - toothed belt cover”, page 68
⇒ “1.2 Exploded view - toothed belt”, page 69
⇒ “1.3 Detaching toothed belt from camshaft”, page 71
⇒ “1.4 Removing and installing toothed belt”, page 84
1.1 Exploded view - toothed belt cover
1 - Toothed belt cover (bottom)

2 - Bolt
❑ 8 Nm
3 - Bracket
4 - Bolt
❑ 20 Nm
5 - Engine support
⇒ page 43
6 - Bolt
7 - Toothed belt cover (top)
8 - Bolt
❑ 8 Nm
9 - Bracket
❑ For fuel hose and cool‐
ant hose
10 - Coolant pipe
11 - Bolt
68 Rep. gr.15 - Cylinder head, valve gear

Audi A1 2011 ➤
1.2 Exploded view - toothed belt
1 - Toothed belt
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen
❑ Check for wear
❑ Removing ⇒ page 84
❑ Installing (adjusting
valve timing)
⇒ page 97
2 - Bolt
❑ 25 Nm
3 - Tensioning roller
❑ Removal and installa‐
tion involve taking out
engine support
⇒ page 43
4 - Bolt
❑ 8 Nm +45° permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
5 - Sealing cap
6 - O-ring
7 - Bolt
❑ 50 Nm +135°
8 - Camshaft sprocket, ex‐
haust side
❑ With camshaft adjuster
9 - Diamond-coated washer
10 - Guide sleeve
11 - Guide sleeve
12 - Diamond-coated washer
13 - Camshaft sprocket, inlet side
❑ With camshaft adjuster
14 - Bolt
❑ 50 Nm +135°
15 - O-ring
16 - Screw plug
❑ 20 Nm
17 - O-ring
❑ Captive
1. Toothed belt drive 69

Audi A1 2011 ➤
18 - Spacer sleeve
19 - Idler roller
20 - Bolt
❑ 45 Nm
21 - Crankshaft sprocket
❑ Contact surface between sprocket and crankshaft must be free of oil
❑ Can only be installed in one position
Plug for “TDC” drilling in cylinder block - tightening torque
Note
Renew O-ring if damaged.

– Tighten bolt -arrow-
with respect to 30ofNm.
to the correctness information in this document. Copyright by AUDI AG.

Audi A1 2011 ➤
1.3 Detaching toothed belt from camshaft

equipment required
♦ Torque wrench - VAS
6583-
♦ Counterhold tool -
T10172A-
♦ Counterhold tool - T10475-
♦ Special wrench, 30 mm -
T10499-
♦ Insert tool, 13 mm -
T10500-
♦ Socket Torx T30 - T10405-

Audi A1 2011 ➤
♦ Assembly tool - T10476A-

♦ Camshaft clamp - T10494-

Audi A1 2011 ➤
Procedure
G31- and move wiring clear.
pipe.
– Press release tabs and disconnect hose -2- for activated char‐
coal filter.
– Remove bolts -arrows- and detach crankcase breather hose
-1-.
– Move electrical wiring harness -2- and coolant hose -4- clear
and push to one side.
– Unscrew bolt -1- using socket Torx T30 - T10405- .
– Detach resonator -3- from turbocharger to left side and press
it inwards.
– Unscrew bolts -arrows- and remove cover -1- for toothed belt
for coolant pump.

Audi A1 2011 ➤
– Unscrew bolts -arrows- and detach sealing cap -1-.

– Release clips -arrows- and detach toothed belt cover (top)
-1-.
Caution
Risk of damage to engine due to oil on toothed belt.

♦ Place a cloth underneath to catch escaping engine oil.

– Detach cover from camshaft sprocket of exhaust camshaft.
Note
To remove all bolts, rotate crankshaft via vibration damper in di‐

rection of engine rotation -arrow-.

insulation .
– Remove front wheel (right-side) ⇒ Running gear, axles, steer‐
ing; Rep. gr. 44 ; Wheels, tyres .

Audi A1 2011 ➤
– Unscrew nuts -arrows- for swivel joint (right-side).

– Detach swivel joint from wishbone.
Note

– Detach drive shaft (right-side) from gearbox and move to‐

wards rear ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft; Removing and installing drive shaft .

– Rotate crankshaft in normal direction of rotation -arrow- as far

as stop.
Note
The crankshaft must be turned in direction of normal engine ro‐

tation for the crank web to make contact with the locking pin -
Caution

♦ Screw locking pin - T10340- into cylinder block as unless
permitted far as authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
stop and tighten to 30 Nm. with respect to the correctness of information in this document. Copyright by AUDI AG.

far as stop.

Audi A1 2011 ➤
• On both camshafts, asymmetrically positioned grooves

-top and bottom arrows- on gearbox end must now face up‐
wards, as shown in illustrations.
• On exhaust camshaft -A-, grooves -top arrows- are accessible
via openings in coolant pump drive sprocket.
• On inlet camshaft -E-, grooves -bottom arrows- are directly
accessible.
Note
The camshafts have two pairs of grooves: onepermitted
positioned sym‐ by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
metrically and one positioned asymmetrically. Inwith
TDC position,
the asymmetrically positioned pair of grooves must be above the
imaginary horizontal centre line.
– If camshafts are not positioned as described, unscrew locking

pin - T10340- , turn crankshaft one rotation further and return
to TDC position.
Note
♦ It should be possible to insert the camshaft clamp - T10494-

easily.
♦ Do not knock camshaft clamp into place with any kind of tool.
– When camshafts are positioned as described, insert camshaft

clamp - T10494- into camshafts as far as stop and hand-tight‐
en bolt -arrow-.
Note
♦ If it is not possible to insert the camshaft clamp - T10494-

easily:
♦ Press down toothed belt -arrow- using assembly tool -
T10487- and then insert camshaft clamp - T10494- into cam‐
shafts as far as stop and hand-tighten bolt.

Audi A1 2011 ➤
Caution
Avoid damage to camshaft.

♦ The camshaft clamp - T10494- must not be used as a
counterhold tool.
– Unscrew plug -1- on camshaft sprocket on intake side using

counterhold tool - T10172A- with adapters -T10172/1- .
– Loosen bolts -1, 2- approx. 1 turn using counterhold tool -

T10172A- with adapters -T10172/1- .
– Fit special wrench, 30 mm - T10499- onto eccentric adjuster

-2- of tensioning roller.
– Loosen bolt -1- using insert tool, 13 mm - T10500- .
– Release tensioning roller on eccentric adjuster -2- using spe‐
cial wrench, 30 mm - T10499- .
– Detach toothed belt from camshaft sprockets.
Installing (adjusting valve timing)
Caution
Risk of damage to toothed belt if it is kinked.

♦ The bending radius of the toothed belt must be at least 25
mm by
Protected (corresponds
copyright. Copyingto
fordiameter of thepurposes,
private or commercial crankshaft
in part sprocket).
or in whole, is not
Note

angle.
– Check “TDC” position of camshaft and crankshaft:

Audi A1 2011 ➤
• Camshaft clamp - T10494- must be fitted to camshaft housing.
• Locking pin - T10340- is screwed into cylinder block as far as

stop and tightened to 30 Nm.
• Crankshaft is turned in normal direction of rotation until it
makes contact with locking pin - T10340- = “TDC” position.
Caution
Avoid damage to camshafts.

counterhold tool.
– Fit new bolts -1, 2- for camshaft sprockets, but do not tighten.
• It should just be possible to turn the adjusters on the camshafts
without axial movement.
Note
♦ The camshaft sprockets are tri-oval in shape.

♦ If you have loosened one or both of the camshaft sprockets,
they must be re-aligned with one another using the assembly
tool - T10476A- .
– Align markings -3- on camshaft sprocket on inlet side -1- with

rib -2- on camshaft housing.

Audi A1 2011 ➤
– Align marking -3- on camshaft sprocket on exhaust side -1-

with rib -2- on camshaft housing.
• The dot markings -2- and -3- on the camshaft sprockets are
slightly offset.
Note
Groove -1- helps to ensure that assembly tool -T10476A- is ap‐

plied correctly.
– Insert assembly tool - T10476A- between camshaft sprockets.

• Markings -1- on -T10476A- must be aligned with dot markings
-2- on camshaft sprockets.
• It should be possible to insert assembly tool - T10476A- easily

as far as stop.
• The projection -2- of -T10476A- must engage in groove -1- in
camshaft sprocket on exhaust side.

Audi A1 2011 ➤
• Metal lug -arrow- of tensioning roller must engage in cast re‐

cess on cylinder head.
Note correct sequence for fitting toothed belt:

– Pull toothed belt upwards and fit onto idler roller -1-, tensioning
roller -2- and camshaft sprockets -3, 4-.
– Using special wrench, 30 mm - T10499- , turn eccentric ad‐

juster -2- of tensioning roller in direction of -arrow- until ad‐
justment indicator -3- is positioned approx. 10 mm to the right
of adjustment window.
– Turn eccentric adjuster back until adjustment indicator is posi‐
tioned exactly in adjustment window.
Caution
Risk of damage to engine if tightening torque is incorrect.

♦ Torque wrench - VAS 6583- must be used to tighten the
bolts.
♦ When setting the tightening torque on the torque wrench
- VAS 6583- , the reading on the insert tool, 13 mm -
T10500- must be entered in the torque wrench.
– Hold eccentric adjuster in this position and tighten bolt -1- us‐
ing insert tool, 13 mm - T10500- with torque wrench - VAS
6583- .
Note
Turning the engine further or running the engine may lead to slight
differences in the position of the adjustment indicator -3- in rela‐
tion to the adjustment window. This does not affect the toothed
belt tension.

Audi A1 2011 ➤
Caution

counterhold tool.
– Tighten bolts -1, 2- initially to 50 Nm using counterhold tool -

– Remove locking pin - T10340- .
– Remove bolt -arrow- and detach camshaft clamp - T10494- .
Check valve timing:
Note
The assembly tool - T10476A- is not needed to check the valve

timing.
– Turn crankshaft 2 rotations in normal direction of engine rota‐

tion -arrow-.

Audi A1 2011 ➤

– Rotate crankshaft further in normal direction of rotation as far
as stop.
• The crank web is now in contact with the locking pin.
Note

Note

easily.
– Insert camshaft clamp - T10494- into camshafts as far as stop

and hand-tighten with bolt -arrow-.
Note

easily:
♦ Press down toothed belt -arrow-Protected
usingbyassembly tool -T10487-
and then insert camshaft clamp -with

T10494- into camshafts as in this document. Copyright by AUDI AG.
respect to the correctness of information
far as stop and hand-tighten bolt.
If it is not possible to insert camshaft clamp - T10494- , valve tim‐

ing is not OK.
– Adjust valve timing again ⇒ page 77 .
If it is possible to insert camshaft clamp - T10494- , valve timing

is OK.

Audi A1 2011 ➤
– Tighten bolts -1, 2- to final tightening torque ⇒ page 69 using


Audi A1 2011 ➤
– Tighten plug -1- using counterhold tool - T10172A- with adapt‐

ers -T10172/1- .
Caution

♦ After completing work, check that locking pin - T10340-
and camshaft clamp - T10494- have been removed.
Further installation is carried out in the reverse order; note the

following:
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
Tightening torques
que”“ , page 70
♦ ⇒ “2.2 Exploded view - camshaft housing”, page 101
♦ ⇒ “3.1 Exploded view - crankcase breather system”,
page 140
♦ ⇒ “2.1 Exploded view - coolant pump and thermostat”,
page 157
♦ ⇒ “1.1 Exploded view - turbocharger”, page 181
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Lower wish‐
bone, swivel joint; Exploded view - lower wishbone, swivel joint
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres
1.4 Removing and installing toothed belt

Audi A1 2011 ➤

equipment required
♦ Torque wrench - VAS
6583-
♦ Counterhold tool -
T10172A-
♦ Counterhold tool - T10475-
with adapters -T10475/1-
and -T10475/2-
♦ Special
permitted wrench,
unless authorised 30AG.
by AUDI mmAUDI- AG does not guarantee or accept any liability
T10499-
♦ Insert tool, 13 mm -
T10500-

Audi A1 2011 ➤
♦ Assembly tool - T10476A-
♦ Camshaft clamp - T10494-

Audi A1 2011 ➤
Preparing adapter - T10475- :

– Fit adapters -T10475/1- and -T10475/2- onto counterhold tool
- T10475- , as shown in illustration.
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove air cleaner housing ⇒ page
with respect 203 . of information in this document. Copyright by AUDI AG.
to the correctness

electrical wiring.
pipe.
coal filter.
-1-.
it towards rear.

Audi A1 2011 ➤
for coolant pump.
– Unscrew bolts -arrows- and detach sealing cap -1-.

– Remove bolt -2-.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Release clips -arrows- andtodetach
with respect toothed
the correctness belt cover
of information (top) Copyright by AUDI AG.
in this document.
-1-.
Caution
Risk of damage to engine due to oil on toothed belt.

♦ Place a cloth underneath to catch escaping engine oil.

– Detach cover from camshaft sprocket of exhaust camshaft.

Audi A1 2011 ➤
Note
To remove all bolts, rotate crankshaft via vibration damper in di‐

rection of engine rotation -arrow-.

insulation .
– Remove front wheel (right-side) ⇒ Running gear, axles, steer‐
ing; Rep. gr. 44 ; Wheels, tyres .
– Unscrew nuts -arrows- for swivel joint (right-side).

– Detach swivel joint from wishbone.
Note

– Detach drive shaft (right-side) from gearbox and move to‐

wards rear ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft; Removing and installing drive shaft .
Note

Audi A1 2011 ➤

– Rotate crankshaft in normal direction of rotation as far as stop.
Note

Caution with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Screw locking pin - T10340- into cylinder block as far as
stop and tighten to 30 Nm.
far as stop.
• On both camshafts, asymmetrically positioned grooves

-top and bottom arrows- on gearbox end must now face up‐
wards, as shown in illustrations.
• On exhaust camshaft -A-, grooves -top arrows- are accessible
via openings in coolant pump drive sprocket.
• On inlet camshaft -E-, grooves -bottom arrows- are directly
accessible.
– If camshafts are not positioned as described, unscrew locking
pin - T10340- , turn crankshaft one rotation further and return
to TDC position.

Audi A1 2011 ➤
Note

easily.
– When camshafts are positioned as described, insert camshaft

clamp - T10494- into camshafts as far as stop and hand-tight‐
en bolt -arrow-.
Note

easily:
♦ Press down toothed belt -arrow- using assembly tool -T10487-
and then insert camshaft clamp - T10494- into camshafts as
– Unscrew bolt -arrow- for vibration damper using counterhold

– Remove vibration damper.
Caution
Avoid damage to camshaft.

counterhold tool.
– Unscrew plug -1- on camshaft sprocket on intake side using


Audi A1 2011 ➤
– Loosen bolts -1, 2- approx. 1 turn using counterhold tool -

– Remove bolts -arrows- and detach toothed belt cover (bot‐

tom).
– Fit special wrench, 30 mm - T10499- onto eccentric adjuster

-2- of tensioning roller.
– Loosen bolt -1- using insert tool, 13 mm - T10500- .
– Release tensioning roller on eccentric adjuster -2- using spe‐
cial wrench, 30 mm - T10499- .
Caution

♦ Before removing, mark direction of rotation of toothed belt
– Take off toothed belt.
– Detach crankshaft sprocket -1- -arrow-.

Audi A1 2011 ➤
Installing (adjusting valve timing)
Note

angle.
– Check “TDC” position of camshaft and crankshaft:

• Camshaft clamp - T10494- must be fitted to camshaft housing
-arrow-.

Caution

counterhold tool.
– Fit new bolts -1, 2- for camshaft sprockets, but do not tighten.
• It should just be possible to turn the adjusters on the camshafts
without axial movement.
Note
♦ The camshaft sprockets are tri-oval in shape.

♦ If you have loosened one or both of the camshaft sprockets,
they must be re-aligned with one anther using the assembly
tool - T10476A- .

Audi A1 2011 ➤
– Align markings -3- on camshaft sprocket on inlet side -1- with

– Align marking -3- on camshaft sprocket on outlet side -1- with

• The dot markings -2- and -3- on the camshaft sprockets are
slightly offset.
Note
Groove -1- helps to ensure that assembly tool -T10476A- is ap‐

plied correctly.
– Insert assembly tool - T10476A- between camshaft sprockets.

• Markings -1- on -T10476A- must be aligned with dot markings
-2- on camshaft sprockets.

Audi A1 2011 ➤
• It should be possible to gently insert assembly tool - T10476A-

as far as stop.
• The projection -2- of -T10476A- must engage in groove -1- in
camshaft sprocket on outlet side.
• Metal lug -arrow- of tensioning roller must engage in cast re‐

cess on cylinder head.
– Fit crankshaft sprocket onto crankshaft.

• Contact surface between vibration damper and crankshaft
sprocket must be free of oil and grease.
• Machined surface -arrow- of crankshaft sprocket must be posi‐
tioned over machined surface of crankshaft journal.
– Fit toothed belt in the specified sequence.

1 - Crankshaft sprocket
2 - Idler roller
3 - Tensioning roller
4 - Camshaft sprocket, exhaust side
5 - Camshaft sprocket, inlet side
– Install toothed belt cover (bottom section).
– Bring vibration damper into installation position and tighten in‐
itially to 40 Nm ⇒ page 45 .

Audi A1 2011 ➤
– Using special wrench, 30 mm - T10499- , turn eccentric ad‐

juster -2- of tensioning roller in direction of -arrow- until ad‐
justment indicator -3- is positioned approx. 10 mm to the right
of adjustment window.
– Turn eccentric adjuster back until adjustment indicator is posi‐
tioned exactly in adjustment window.
Caution
Risk of damage to engine if tightening torque is incorrect.

♦ Torque wrench - VAS 6583- must be used to tighten the
bolts.
♦ When setting the tightening torque on the torque wrench
- VAS 6583- , the reading on the insert tool, 13 mm -
T10500- must be entered in the torque wrench.
– Hold eccentric adjuster in this position and tighten bolt -1- us‐
ing insert tool, 13 mmby- copyright.
Protected T10500- withfortorque
Copying private orwrench
commercial-purposes,
VAS in part or in whole, is not
6583- . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
Turning the engine further or running the engine may lead to slight
differences in the position of the adjustment indicator -3- in rela‐
tion to the adjustment window. This does not affect the toothed
belt tension.
Caution

counterhold tool.
– Tighten bolts -1, 2- initially to 50 Nm using counterhold tool -


Audi A1 2011 ➤
Checking valve timing:
Note
The assembly tool - T10476A- is not necessary to check the valve

timing.
– Tighten bolt -arrow- for vibration damper using counterhold

– Turn crankshaft 2 rotations in normal direction of engine rota‐

tion -arrow-.

– Rotate crankshaft further in normal direction of rotation as far
as stop.
• The locking pin is now in contact with thebycrank
Protected web.
Note


Audi A1 2011 ➤
Note

easily.
– Insert camshaft clamp - T10494- into camshafts as far as stop

and hand-tighten with bolt -arrow-.
Note

easily:
♦ Press down toothed belt -arrow- using assembly tool -T10487-
and then insert camshaft clamp - T10494- into camshafts as
If it is not possible to insert camshaft clamp - T10494- , valve tim‐

ing is not OK.
– Adjust valve timing again ⇒ page 93 .
If it is possible to insert camshaft clamp - T10494- , valve timing

is OK.

Audi A1 2011 ➤
– Tighten bolts -1, 2- to final tightening torque ⇒ page 69 using

– Tighten plug -1- using counterhold tool - T10172A- with adapt‐

ers -T10172/1- .
Caution

♦ After completing work, check that locking pin - T10340-
and camshaft clamp - T10494- have been removed.
Further installation is carried out in the reverse order; note the

following:
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
Tightening torques
♦ ⇒ “1.2 Exploded view - toothed belt”, page 69
♦ ⇒ “2.2 Exploded view - camshaft housing”, page 101
que”“ , page 70
page 157
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Lower wish‐
bone, swivel joint; Exploded view - lower wishbone, swivel joint
♦ ⇒ General body repairs,
permitted exterior;
unless authorised Rep.
by AUDI AG.gr.
AUDI66AG;does
Noise insula‐or accept any liability
not guarantee
tion; Exploded with
view - noise
respect insulation
to the correctness of information in this document. Copyright by AUDI AG.
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres

Audi A1 2011 ➤
2 Cylinder head
⇒ “2.1 Exploded view - cylinder head”, page 100
⇒ “2.2 Exploded view - camshaft housing”, page 101
⇒ “2.3 Removing and installing cylinder head”, page 103
⇒ “2.4 Removing and installing camshaft housing”, page 106
⇒ “2.5 Checking compression”, page 109
2.1 Exploded view - cylinder head
1 - Cylinder head gasket

❑ Note installation posi‐
tion: part number must
face cylinder head Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Cylinder head with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ page 103
❑ Checking for distortion
⇒ page 101
3 - Bolt
❑ Correct sequence when
slackening ⇒ page 105
4 - Gasket
5 - Camshaft housing
⇒ page 106
6 - Bolt
7 - Dowel pins
8 - Dowel sleeve
❑ 2x

Audi A1 2011 ➤
Cylinder head - tightening torque and sequence
Note

angle.

1. -1 … 8- 30 Nm
Checking cylinder head for distortion

– Use straight edge 500 mm - VAS 6075- and feeler gauge -1-
to measure cylinder head for distortion at several points.
• Max. permissible distortion: 0.05 mm.
2.2 Exploded view - camshaft housing
2. Cylinder head 101

Audi A1 2011 ➤
1 - Gasket
2 - Oil seal
❑ For inlet camshaft
3 - Oil seal
❑ For exhaust camshaft
(pulley end)
4 - Camshaft housing
⇒ page 106
5 - Bolt
sequence ⇒ pageProtected
103 by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - O-ring with respect to the correctness of information in this document. Copyright by AUDI AG.
7 - Camshaft control valve

❑ Inlet side: camshaft con‐
trol valve 1 - N205-
❑ Exhaust side: exhaust
camshaft control valve 1
- N318-
⇒ page 118
8 - Bolt
❑ 8 Nm
9 - Seal
❑ For sealing cap
10 - Sealing cap
11 - Hall sender
❑ Inlet side: Hall sender - G40-
❑ Exhaust side: Hall sender 2 - G163-
❑ Exploded view ⇒ page 243
12 - Bolt
❑ Tightening torque ⇒ page 243
13 - O-ring
14 - Oil seal
❑ For exhaust camshaft, gearbox end
15 - Toothed belt sprocket
❑ For coolant pump
16 - Bolt
❑ Tightening torque ⇒ Item 8 (page 158)
17 - Sealing cap
18 - Bolt
❑ 8 Nm

Audi A1 2011 ➤
19 - O-ring
20 - Dowel pins
Camshaft housing - tightening torque and sequence
Note

angle.

StageProtected byBolts Tightening
copyright. Copying torque/angle
for private or commercial specification
purposes, in part or in whole, is not
1. -1 … 12- 10 Nm
2. -1 … 12- Turn 180° further
2.3 Removing and installing cylinder head

♦ Socket XZN 10 - 3410-
Removing
Note
Reinstall heat insulation sleeves in the same locations when in‐

stalling.
– Remove camshaft housing ⇒ page 106 .

– Remove intake manifold ⇒ page 205 .
– Remove turbocharger ⇒ page 182 .

Audi A1 2011 ➤
– Unplug electrical connectors:

1- For fuel pressure sender - G247-
2- For oil pressure switch - F1-
3- For injectors -N30- ... -N32-
– Remove bolts -arrows- and detach heat shield -1-.
– Detach heat shield sleeve.

– Unplug electrical connector -arrow- for coolant temperature
sender - G62- .
– Remove bolt -1- on engine support.


Audi A1 2011 ➤
– Slacken cylinder head bolts in the sequence -1 ... 8- and re‐

move.
– Take off cylinder head and set it down on a soft surface (foam
plastic).
Installing
Caution
Avoid damage to sealing surfaces.

♦ Carefully remove sealant residue from cylinder head and
cylinder block.
♦ Ensure that no long scores or scratches are made on the
surfaces.
Avoid damage to cylinder block.
♦ No oil or coolant must be allowed to remain in the blind
holes for the cylinder head bolts in the cylinder block.
Ensure that cylinder head gasket seals properly:
♦ Carefully remove any remaining emery and abrasive ma‐
terial.
♦ Do not remove new cylinder head gasket from packaging
until it is ready to be fitted.
♦ Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
Note

angle.
♦ Renew self-locking nuts, as well as seals, gaskets and O-rings
after removing.
♦ Note expiry date of cylinder head gasket.
♦ When installing an exchange cylinder head, the contact sur‐
faces between the hydraulic compensation elements, roller
rocker fingers and cams must be oiled before installing the
camshaft housing.
♦ After fitting a new cylinder head or cylinder head gasket,
change the engine oil and the coolant in the entire cooling
system.

Audi A1 2011 ➤
– Fit cylinder head gasket -1-.

♦ Note position of dowel sleeves in cylinder block -arrows-.
♦ Note installation position of cylinder head gasket. Part number
-2- should be legible from inlet side.
– If crankshaft has been rotated: set No. 1 cylinder piston to top
dead centre and then turn crankshaft back slightly.
– Fit cylinder head.
– Insert and hand-tighten cylinder head bolts.
– Tighten cylinder head bolts ⇒ page 101 .
Note
Cylinder head bolts do not have to be torqued down again later

after repair work.

note the following:
– Install turbocharger ⇒ page 182 .
– Install camshaft housing ⇒ page 106 .
– Change engine oil ⇒ Maintenance ; Booklet 819 .
– Fill cooling system with fresh coolant ⇒ page 150 .
Tightening torques
♦ ⇒ “2.1 Exploded view - cylinderProtected
head”, by page 100
♦ ⇒ Fig. ““Engine support - tightening torque
with respect and
to the sequence”“
correctness , in this document. Copyright by AUDI AG.
of information
page 31
2.4 Removing and installing camshaft hous‐

ing
Removing
– Remove coolant pump ⇒ page 163 .
– Remove ignition coils ⇒ page 244 .
– Detach toothed belt from camshafts ⇒ page 71 .
– Remove high-pressure pipe ⇒ page 227 .
– Release hose clip -2- and disconnect hose.
Note

Audi A1 2011 ➤
– Unplug electrical connector -1- at activated charcoal filter sol‐

enoid valve 1 - N80- .
– Press release tabs -3- on both sides and disconnect line -2-
for activated charcoal filter system.
– Push line for activated charcoal filter slightly to right.
– Unplug electrical connectors:

2 - For camshaft control valve 1 - N205- / exhaust camshaft con‐
trol valve 1 - N318-
4 - For Hall sender - G40- / Hall sender 2 - G163-
– Remove bolt -3-, move wiring harness clear and place to left
side.
– Pull out oil dipstick -1-.

– Release hose clips -3- and disconnect coolant hoses.
– Move coolant lines -2- towards front.
Note
Disregard -item 1-.

Audi A1 2011 ➤
– Loosen and remove bolts for camshaft housing in the se‐

quence -1 ... 12-.
– Lift camshaft housing straight upwards off cylinder head.
– Detach gasket.
– If not already marked, mark original positions of roller rocker
fingers and compensation elements for reinstallation.
– Remove roller rocker fingers together with compensation ele‐
ments and put down on a clean surface.
Installing
Note

angle.
♦ Renew seal and O-ring after removal.
– Make sure that all roller rocker fingers -2- make contact with
the valve ends -1- correctly and are clipped into their respec‐
tive support elements -4- with
Protected retaining
by copyright. clip
Copying for -3-.
private or commercial purposes, in part or in whole, is not
– Clean surfaces; they must be free
with respect to the of oil andof information
correctness grease. in this document. Copyright by AUDI AG.
– Fit new gasket -1- onto dowel pins -2-.

• The part number -3- of the gasket is legible from above.
– Check “TDC” position of camshafts and crankshaft:

• Camshaft clamp - T10494- must be fitted to camshaft housing.

Audi A1 2011 ➤

Caution
Risk of roller rocker fingers slipping off the ends of the valve
stems and compensation elements.
♦ The camshaft housing must not be tilted when fitting it onto
the cylinder head.
– Carefully fit the camshaft housing vertically onto the dowel

pins -arrows- from above.
Note
Note different bolt lengths.
– Tighten camshaft housing bolts ⇒ page 103 .

note the following:
– Install high-pressure pipe ⇒ page 227 .
– Install ignition coils ⇒ page 244 .
– Install coolant pump ⇒ page 163 .
Caution
Avoid damage to valves and piston crowns after working on

valve gear. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Turn the engine carefully at least 2 rotations to ensure that
none of the valves make contact when the starter is op‐

erated.
Tightening torques
♦ ⇒ “3.1 Exploded view - valve gear”, page 111
2.5 Checking compression


Audi A1 2011 ➤
♦ Spark plug socket and extension - 3122 B-
♦ Compression tester - V.A.G 1763-
Procedure
• Engine oil temperature at least 30 ℃.
• Battery voltage at least 12.5 V.
– Remove ignition coils ⇒ page 244 .
– Remove spark plugs with spark plug spanner - 3122 B- .
– Unplug electrical connector for engine speed sender - G28-
⇒ page 248 .
– Check compression pressure with compression tester -
V.A.G 1763- (see ⇒ operating instructions for details of how
to use tester).
– Have a 2nd mechanic press down the accelerator pedal com‐
pletely and at the same time operate the starter until the
pressure on the tester display no longer increases.
– Repeat procedure on each cylinder.

Compression pressure bar
When new 10.0 … 15.0
Wear limit 7.0
Maximum difference between cylinders 3.0
Assembling
– Install spark plugs ⇒ Maintenance ; Booklet 819 .
– Install ignition coils ⇒ page 244 .
– Erase any entries in event memory resulting from testing ⇒ Ve‐
hicle diagnostic tester, Guided Functions , Generate read-
iness code .

Audi A1 2011 ➤
3 Valve gear
⇒ “3.1 Exploded view - valve gear”, page 111
⇒ “3.2 Measuring axial clearance of camshaft”, page 112
⇒ “3.3 Removing and installing camshaft oil seal”, page 113
⇒ “3.4 Removing and installing camshaft control valve N205 /
N318 ”, page 118
⇒ “3.5 Removing and installing valve stem oil seals”, page 119
3.1 Exploded view - valve gear
1 - Exhaust valve
❑ Do not machine, only
grinding-in is permitted
❑ Valve dimensions
⇒ page 129
❑ Checking valve guides
⇒ page 128
2 - Cylinder head
3 - Valve stem oil seal
4 - Valve spring
❑ Installation position
⇒ page 112
5 - Valve spring plate Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - Valve cotters permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
7 - Roller rocker finger
stalling camshaft hous‐
ing”, page 106
❑ Mark installation posi‐
tion for re-installation
❑ Check roller bearings
for ease of movement
❑ Lubricate contact surfa‐
ces before installing
8 - Securing clip
❑ For hydraulic compen‐
sation element
9 - Hydraulic valve compensa‐
tion element
❑ Do not interchange
❑ Lubricate contact surface
10 - Inlet valve
❑ Do not machine, only grinding-in is permitted
❑ Valve dimensions ⇒ page 129
❑ Checking valve guides ⇒ page 128
3. Valve gear 111

Audi A1 2011 ➤
Position of valve spring

• The smaller ∅ -a- faces the valve spring plate.
• The larger ∅ -b- faces the cylinder head.
3.2 Measuring axial clearance of camshaft


♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge - VAS 6079-
Procedure
– Secure universal dial gauge bracket - VW 387- with dial gauge
- VAS 6080- to camshaft housing, as shown in illustration.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
Axial clearance:
• Wear limit: 0.25 mm.

Audi A1 2011 ➤
3.3 Removing and installing camshaft oil

seal
⇒ “3.3.1 Removing and installing inlet camshaft oil seal”,
page 113
⇒ “3.3.2 Removing and installing exhaust camshaft oil seal, pulley
end”, page 115
⇒ “3.3.3 Removing and installing exhaust camshaft oil seal, gear‐
box end”, page 116
3.3.1 Removing and installing inlet camshaft

oil seal
♦ Assembly tool - T10478 B-
Removing
– Unscrew bolt -2- and remove camshaft sprocket.
Note
Disregard -item 1-.
3. Valve gear 113

Audi A1 2011 ➤
– Pull out oil seal -1- using extractor tool -T20143/1- .
Installing
Note
sleeve -T10478/2- .
– Fit guide sleeve -T10478/2- with oil seal -1- onto camshaft.
– Use thrust piece -T10478/1A- and bolt -1- for camshaft sprock‐
et to pull in oil seal onto stop.

Audi A1 2011 ➤
3.3.2 Removing and installing exhaust cam‐

shaft oil seal, pulley end
♦ Assembly tool - T10478 B-
Removing
– Remove engine support ⇒ page 43 .
– Unscrew bolt -1- and detach camshaft adjuster.
Note
Disregard -item 2-.
– Pull out oil seal -1- using extractor tool -T20143/1- .
3. Valve gear 115

Audi A1 2011 ➤
Installing
Note
sleeve -T10478/2- .
– Fit guide sleeve -T10478/2- with oil seal -1- onto camshaft.
– Pull in thrust piece -T10478/1A- with bolt -T10478/5- as far as

stop.
– Install engine support ⇒ page 43 .
3.3.3 Removing and installing exhaust cam‐

shaft oil seal, gearbox end

Audi A1 2011 ➤
Removing
– Remove toothed belt sprocket for coolant pump
⇒ page 169 .
– Carefully slide extractor tool -T20143/1- between camshaft
and oil seal -1-.
– Pry out oil seal.
Installing
– If necessary, use fine sandpaper (grit 220 ... 1000) to remove
any permitted
burrs thatunlesshave formed
authorised onAG.the
by AUDI outside
AUDI AG does ofnot the outer
guarantee grooves
or accept any liability
on thewith
exhaust camshaft
respect to the correctness-arrows-.
of information in this document. Copyright by AUDI AG.
Note
3. Valve gear 117

Audi A1 2011 ➤
sleeve -T10479/2- .
– Fit guide sleeve -T10479/2- with oil seal -2- onto camshaft so
that it is centred.
– Secure guide sleeve onto camshaft using bolt -1- for coolant
pump drive sprocket.
– Slide oil seal onto camshaft and unbolt guide sleeve.
– Pull in oil seal onto stop -arrow- using press tool -T10479/1-
and bolt -T10479/4- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Install toothed belt sprocket for coolant

withpump
respect ⇒ page 169 .of information in this document. Copyright by AUDI AG.
to the correctness
3.4 Removing and installing camshaft con‐

trol valve -N205- / -N318-

Audi A1 2011 ➤
Removing
electrical wiring.
– Release fasteners
Protected using
by copyright. release
Copying toolor -commercial
for private T10527- and detach
purposes, in part or inair
whole, is not
pipe. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Unplug relevant electrical connector -2- or -3-.

– Remove bolt -1- and remove exhaust camshaft control valve
1 - N318- .
– Unscrew bolt -4- and remove camshaft control valve 1 -
N205- .
Installing
Note
Renew O-rings after removing.
Tightening torques
♦ ⇒ “3.1 Exploded view - valve gear”, page 111
3.5 Removing and installing valve stem oil

seals
⇒ “3.5.1 Removing and installing valve stem oil seals (cylinder
head installed)”, page 119
⇒ “3.5.2 Removing and installing valve stem oil seals (cylinder
head removed)”, page 123
3.5.1 Removing and installing valve stem oil

seals (cylinder head installed)
3. Valve gear 119

Audi A1 2011 ➤
♦ Spark plug socket and extension - 3122 B-
♦ Valve stem seal fitting tool - 3365-
♦ Removal and installation device for valve cotters - VAS 5161

A- with set -VAS 5161 A/32-
♦ Adapters - T40012-

Audi A1 2011 ➤
♦ Valve shaft pliers - VAS 6770-
Procedure
– Remove spark plugs with spark plug socket and extension -
3122 B- .
– Set piston of appropriate cylinder to “bottom dead centre”.
– Fit guide plate -VAS 5161 A/32- onto cylinder head and secure
with knurled screws -VAS 5161/12- .
– Screw adapter - T40012- with seal hand-tight into the corre‐
sponding spark plug thread.
– Connect adapter to compressed air line using a commercially
available connection piece, and apply constant air pressure.
• Minimum pressure: 6 bar
– Apply drift -VAS 5161/3A- to guide plate and use plastic-head‐
ed hammer to release sticking valve cotters.
3. Valve gear 121

Audi A1 2011 ➤
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Insert assembly cartridge -VAS 5161 A/32-1- (slide on sleeve
-VAS 5161 A/32-2- ) in guide plate.
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips 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 pressure fork.
– Take out assembly cartridge.
– Detach guide plate and turn to one side.
• The compressed air hose remains connected.
– Detach valve spring with valve spring plate.
– Pull off valve stem oil seal with valve shaft pliers - VAS 6770- .
Caution
Make sure valve stem oil seals are not damaged when instal‐
ling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.
– Lightly oil sealing lip of valve stem oil seal.

– Slide valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.

Audi A1 2011 ➤
If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161 A/32-3- .
• Larger diameter of valve cotters faces upwards.
– Press assembly cartridge onto insertion device from above
and pick up valve cotters.
– Insert valve spring and valve spring plate; installation position
of valve spring ⇒ page 112 .
– Secure guide plate -VAS 5161 A/32- back onto cylinder head.
– Insert assembly cartridge -VAS 5161 A/32-1- with sleeve -VAS
5161 A/32-2- into guide plate.
– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Assembling
– Install spark plugs ⇒ Maintenance ; Booklet 819 .
– Install camshaft housing ⇒ page 106 .
3.5.2 Removing and installing valve stem oil

seals (cylinder head removed)
♦ Valve stem seal fitting tool - 3365-
3. Valve gear 123

Audi A1 2011 ➤
♦ Removal and installation device for valve cotters - VAS 5161

A- with set -VAS 5161/32-
♦ Engine and gearbox support - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-
♦ Valve shaft pliers - VAS 6770-

Audi A1 2011 ➤
Procedure
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Secure cylinder head in cylinder head tensioning device, as
shown in illustration.
– Connect cylinder head tensioning device to compressed air.
– Using lever -arrow-, slide air pad under combustion chamber
where valve stem oil seals are to be removed.
– Apply just enough compressed air to bring air pad into contact
with valve heads.
– Fit guide plate -VAS 5161 A/32- onto cylinder head and secure
with knurled screws -VAS 5161/12- .
– Apply drift -VAS 5161/3A- to guide plate and use plastic-head‐
ed hammer to release sticking valve cotters.
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Insert assembly cartridge -VAS 5161 A/32-1- (slide on sleeve
-VAS 5161 A/32-2- ) in guide plate.
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips 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 pressure fork.
– Take out assembly cartridge.
– Detach guide plate and turn to one side.
– Detach valve spring with valve spring plate.
3. Valve gear 125

Audi A1 2011 ➤
– Pull off valve stem oil seal with valve shaft pliers - VAS 6770- .
Caution
Make sure valve stem oil seals are not damaged when instal‐
ling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.
– Lightly oil sealing lip of valve stem oil seal.

– Slide valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.
If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161 A/32-3- .
• Larger diameter of valve cotters faces upwards.
– Press assembly cartridge onto insertion device from above
and pick up valve cotters.
– Insert valve spring and valve spring plate; installation position
of valve spring ⇒ page 112 .

Audi A1 2011 ➤
– Secure guide plate -VAS 5161 A/32- back onto cylinder head.
– Insert assembly cartridge -VAS 5161 A/32-1- with sleeve -VAS
5161 A/32-2- into guide plate.
– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
3. Valve gear 127

Audi A1 2011 ➤
4 Inlet and exhaust valves

⇒ “4.1 Checking valve guides”, page 128
⇒ “4.2 Checking valves”, page 128
⇒ “4.3 Valve dimensions”, page 129
4.1 Checking valve guides

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge - VAS 6079-
Test sequence
– Insert valve into guide. End of valve stem must be flush with
guide. Only insert inlet valve into inlet valve guide and exhaust
valve into exhaust valve guide, as the stem diameters are dif‐
ferent.
– Measure the amount of sideways play.
• Wear limit: 0.5 mm.
– If the wear limit is exceeded, repeat the measurement with
new valves.
– Renew cylinder head if wear limit is still exceeded.
Note
Valve guides cannot be renewed.
4.2 Checking valves

– Visually inspect for scoring on valve stems and valve seat sur‐
faces.
– Renew valve if scoring is clearly visible.

Audi A1 2011 ➤
4.3 Valve dimensions
Note
Inlet and exhaust valves must not be machined. Only grinding-in

is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 28.5 25.0
∅b mm 4.973 4.963
c mm 110.25 110.09
α ∠° 45 30
4. Inlet and exhaust valves 129

Audi A1 2011 ➤
17 – Lubrication
1 Sump/oil pump
⇒ “1.1 Exploded view - sump/oil pump”, page 130
⇒ “1.2 Engine oil”, page 133
⇒ “1.3 Removing and installing sump”, page 133
⇒ “1.4 Removing and installing oil pump”, page 136
⇒ “1.5 Removing and installing oil level and oil temperature send‐
er G266 ”, page 137
1.1 Exploded view - sump/oil pump
Note
♦ If large quantities of metal shavings or abrasion are found when performing engine repairs, this may be an
indication of damage to the crankshaft or conrod bearings. To prevent further damage, the following steps
are required after completion of repair work: clean the oil galleries carefully and renew the oil spray jets,
engine oil cooler and oil filter.
♦ Oil spray jet and pressure relief valve ⇒ page 62
130 Rep. gr.17 - Lubrication

Audi A1 2011 ➤
1 - Sump
⇒ page 133
2 - Bolt
❑ Tightening sequence
⇒ page 132
3 - Seal
❑ Renew (for oil drain plug
with separate seal)
4 - Oil drain plug
❑ With attached seal on
new vehicles
⇒ page 132
❑ Renewed when first oil
change is performed
⇒ page 132
❑ The oil drain plug with
separate seal (fitted
when first oil change is
performed) can be re-
used ⇒ page 133
❑ 30 Nm
5 - Oil intake pipe
❑ Clean strainer if dirty
6 - Bolt
❑ 8 Nm
7 - Gasket
8 - Seal
9 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
with respect and sequence
to the correctness ⇒inpage
of information 132 Copyright by AUDI AG.
this document.
10 - Oil pump
11 - Dowel sleeve
❑ 2x
12 - Gasket
13 - Baffle plate
14 - Dowel pin
15 - Seal
16 - Oil level and oil temperature sender - G266-
17 - Bolt
❑ 9 Nm
1. Sump/oil pump 131

Audi A1 2011 ➤
Sump - tightening torque and sequence

2. -1 … 18- 12 Nm
Oil pump - tightening torque and sequence
Note

angle.

1. -1, 2- 8 Nm
2. -1- Turn 90° further
3. -2- 20 Nm
Oil drain plug with attached seal (fitted at factory)

– Discard oil drain plug with captive seal -1- when performing
first oil change.
– Fit new oil drain plug -3- with exchangeable seal -2-.

Audi A1 2011 ➤
Oil drain plug with exchangeable seal (all further oil changes)
– Unscrew oil drain plug -2- and discard used seal -3-.
– New seal -1- can be renewed separately when performing fu‐
ture oil changes.
1.2 Engine oil

Refer to ⇒ Maintenance tables for engine oil capacity, oil speci‐
fications and viscosity grades.
Caution
Risk of damage to catalytic converter.

♦ The oil level must not be above the “MAX” mark on the
dipstick. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1.3 Removing and installing sump

♦ Allen key, long reach - T10058-
♦ Electric drill with plastic brush attachment

♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue
Removing
• Engine oil drained, oil filter removed ⇒ Maintenance ; Booklet
819
– Detach air conditioner compressor from bracket and tie up ⇒
Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Detaching and attaching air conditioner compressor
at bracket .

Audi A1 2011 ➤
– Unplug electrical connector -1- at oil level and oil temperature

sender - G266- .
– Remove bolts -arrows- securing gearbox to sump.
– Loosen bolts -arrows- in diagonal sequence and remove.
– Unscrew bolts -arrows- at gearbox end using Allen key, long

reach - T10058- .

Audi A1 2011 ➤
– Use assembly lever to prise sump off cylinder block at recess‐

es -arrow- (front and rear).
– Remove sump. To do so, it may be necessary to strike sump
lightly with a rubber hammer to loosen it from bonded joint.
Installing
Caution
Protect lubrication system against contamination.

♦ Cover exposed parts of the engine.
WARNING
Risk of eye injury.

♦ Wear safety goggles.
– Remove sealant residue from sump -1- and cylinder block us‐
ing rotating plastic brush or similar.
– Clean surfaces; they must be free of oil and grease.
Note
Note expiry date of sealant.
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 2

mm).

Audi A1 2011 ➤
Caution
Make sure lubrication system is not clogged by excess sealant.

♦ The bead of sealant must not be thicker than specified.
– Apply bead of sealant -arrow- onto clean sealing surface of

sump (bottom section) as shown in illustration.
• Thickness of sealant bead: 2 ... 3 mm
Note
♦ Take particular care when applying sealant bead in area of

sealing flange.
♦ Install sump within 5 minutes after applying the sealant.
– Fit sump and tighten bolts ⇒ page 132 .
Note
After fitting sump assembly, the sealant must dry for approx. 30
minutes. Then (and only then) fill the engine with engine oil.
– Install oil filter, fill up with engine oil and check oil level ⇒ Main‐
tenance ; Booklet 819 .
Tightening torques Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ ⇒ Fig. ““Sump - tightening torque and sequence”“ , page 132 to the correctness of information in this document. Copyright by AUDI AG.
with respect
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐

pressor; Exploded view - air conditioner compressor drive unit
♦ ⇒ Rep. gr. 34 ; Removing and installing gearbox; Tightening
torques for gearbox
1.4 Removing and installing oil pump

Removing
– Remove toothed belt ⇒ page 84 .
– Remove sump ⇒ page 133 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Remove crankshaft oil seal (pulley end) ⇒ page 47 .
– Remove bolts -1, 2- and detach oil pump horizontally from
dowel pins in cylinder block.
– Detach gasket.

Audi A1 2011 ➤
Installing
Note

angle.
♦ Renew gasket after removing.
– Check whether dowel pins -arrows- for centring oil pump and
cylinder block are fitted; insert dowel pins if necessary.
– Fit new gasket -1-.
– Turn oil pump gear so that two opposite recesses are vertically
aligned -arrows-.
– Fit oil pump and tighten bolts ⇒ page
permitted 132 . by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
– Install new crankshaft oil seal (pulley end) ⇒ page 47 .
– Install toothed belt ⇒ page 84 .
Tightening torques
♦ ⇒ Fig. ““Oil pump - tightening torque and sequence”“ ,
page 132
- alternator
1.5 Removing and installing oil level and oil

temperature sender - G266-
Removing
• Engine oil drained ⇒ Maintenance ; Booklet 819
– Remove bolts -1- and detach oil level and oil temperature
sender - G266- -item 3-.
Installing
Note
Renew seal -4- after removing.
– Fill with engine oil and check oil level ⇒ Maintenance ; Booklet
819 .
Tightening torques
♦ ⇒ “1.1 Exploded view - sump/oil pump”, page 130

Audi A1 2011 ➤
2 Engine oil cooler

⇒ “2.1 Exploded view - engine oil cooler”, page 138
⇒ “2.2 Removing and installing engine oil cooler”, page 138
2.1 Exploded view - engine oil cooler
1 - Bolt
❑ 8 Nm + 90°
2 - Engine oil cooler
❑ See note ⇒ page 130
⇒ page 138
❑ If renewed, refill system
with fresh coolant
3 - Seals
2.2 Removing and installing engine oil cool‐

er
Removing

Audi A1 2011 ➤
– Unscrew bolts -arrows- and detach engine oil cooler -1-.

Installing
Note
Renew seals after removing.
– Install intake manifold ⇒ page 205 .
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Tightening torques
♦ ⇒ “2.1 Exploded view - engine oil cooler”, page 138
2. Engine oil cooler 139

Audi A1 2011 ➤
3 Crankcase breather
⇒ “3.1 Exploded view - crankcase breather system”, page 140
⇒ “3.2 Removing and installing oil separator”, page 141
3.1 Exploded view - crankcase breather system
1 - Bolt
❑ Self-locking
❑ 9 Nm
2 - Oil separator
⇒ page 141
❑ Renew if damaged
3 - Cover
❑ For oil separator
4 - Hose
❑ For crankcase breather
5Protected
- O-ringby copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Renew
permitted after removing
6 - Hose
7 - Connection
Oil separator - tightening torque and sequence

– Tighten bolts in the sequence -1 ... 9- to 9 Nm.

Audi A1 2011 ➤
3.2 Removing and installing oil separator

♦ Electric drill with plastic brush attachment
♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue
Removing
– Detach air conditioner compressor from bracket and tie up ⇒
Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Detaching and attaching air conditioner compressor
at bracket .
– Remove bolt -2- and press continued coolant circulation pump
- V51- to side.
Note
Disregard -item 3-.

– Release fasteners -2- -arrow- on cover -1- for oil separator and
detach cover.
– Slacken and remove bolts in the sequence: -9 ... 1-.

– Carefully release oil separator from bonded joint.
Installing
Caution
Risk of leaks if sealing surfaces are damaged.

♦ Do not use a scraper or other tools to clean sealing sur‐
faces.
Protect lubrication system against contamination.
♦ Cover exposed parts of the engine.
3. Crankcase breather 141

Audi A1 2011 ➤
WARNING
Risk of eye injury.

♦ Wear safety goggles.
– Remove sealant residue from oil separator -1- and cylinder

block using rotating plastic brush or similar.
– Clean surfaces; they must be free of oil and grease.
– Screw 2 studs a few turns into holes -arrows-.
Note
Note the use-by date of the sealant.
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 2

mm).
Caution
Make sure lubrication system is not clogged by excess sealant.
♦ The bead of sealant must not be thicker than specified.
– Apply bead of sealant -arrow- onto clean sealing surface of oil

separator as shown in illustration.
• Thickness of sealant bead: 2 ... 3 mm
Note
Install oil separator within 5 minutes after applying the sealant.

Audi A1 2011 ➤
– Place oil separator onto studs -arrows- and position it on cyl‐

inder block.
– Remove studs again.
– Fit and tighten bolts ⇒ page 140 .
The remaining installation steps are carried out in the reverse se‐
quence.
Tightening torques
♦ ⇒ Fig. ““Oil separator - tightening torque and sequence”“ ,
page 140
♦ ⇒ “2.2 Exploded view - electric coolant pump”, page 159
- alternator
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Exploded view - air conditioner compressor drive unit
3. Crankcase breather 143

Audi A1 2011 ➤
4 Oil filter/oil pressure switches

⇒ “4.1 Exploded view - oil filter/oil pressure switches”,
page 144
⇒ “4.2 Removing and installing oil pressure switch F1 ”,
page 144
⇒ “4.3 Checking oil pressure”, page 145
⇒ “4.4 Removing and installing valve for oil pressure control N428
”, page 146
4.1 Exploded view - oil filter/oil pressure switches
1 - Oil filter
❑ See note ⇒ page 130
⇒ Maintenance ; Book‐
let 819
2 - Threaded connection
3 - Oil pressure switch - F1-
❑ Opening/closing pres‐
sure 0.3 ... 0.6 bar
❑ Black insulation
❑ Checking in Guided
Fault Finding ⇒ Vehi‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
cle diagnostic tester permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 144
❑ 20 Nm
4 - Seal
5 - O-rings
6 - Bolt
❑ 8 Nm
7 - Valve for oil pressure con‐
trol - N428-
⇒ page 146
4.2 Removing and installing oil pressure

switch - F1-

Audi A1 2011 ➤
♦ Articulated wrench, 24 mm - T40175-
Removing
– Move fuel hose -2- clear at intake manifold.
Note
Place a cloth underneath to catch escaping engine oil.
– Use articulated wrench, 24 mm - T40175- to unscrew oil pres‐

sure switch - F1- -item 1-.
Installing
Installation is carried out in the reverse order;
Protected note the
by copyright. following:
Copying for private or commercial purposes, in part or in whole, is not
Note
♦ Renew oil pressure switch and seal after removing.

♦ Fit the new oil pressure switch - F1- into the connection im‐
mediately to avoid loss of oil.
– Check oil level ⇒ Maintenance ; Booklet 819 .

Tightening torques
♦ ⇒ “4.1 Exploded view - oil filter/oil pressure switches”,
page 144
- alternator
4.3 Checking oil pressure

4. Oil filter/oil pressure switches 145

Audi A1 2011 ➤
♦ Oil pressure tester - V.A.G 1342-
Procedure
• Oil level OK, checking ⇒ Maintenance ; Booklet 819
• Engine oil temperature at least 80°C (radiator fan must have
run once).
– Remove oil pressure switch - F1- ⇒ page 144 .
– Screw oil pressure tester - V.A.G 1342- into hole for oil pres‐
sure switch.
– Screw oil pressure switch - F1- into hole in oil pressure tester
- V.A.G 1342- to seal hole.
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
– Start engine.
• Oil pressure at idling speed: at least 0.6 bar.
• Minimum oil pressure at 2000 rpm: 1.5 bar.
• Minimum oil pressure at 4500 rpm: 2.8 bar.
Assembling
– Install oil pressure switch - F1- ⇒ page 144 .
4.4 Removing and installing valve for oil

pressure control - N428-
Removing
insulation .
– Remove bolts -1- and nuts -2, 3- and detach bracket -4- for
catalytic converter.

Audi A1 2011 ➤
Note
Place a cloth underneath to catch escaping engine oil.
– Remove bolt -3- and detach valve for oil pressure control -
N428- -item 1-.
Installing
Note
Renew O-ring after removal.
– Move bracket for catalytic converter into installation position.

– Hand-tighten bolts -1- and nuts -2, 3- until they make contact.
– Tighten bolted connections for bracket -4- ⇒ page 239 .
Tightening torques
♦ ⇒ “4.1 Exploded view - oil filter/oil pressure switches”,
page 144 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4. Oil filter/oil pressure switches 147

Audi A1 2011 ➤
19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 148
⇒ “1.3 Draining and filling cooling system”, page 150
⇒ “1.2 Checking cooling system for leaks”, page 149
1.1 Connection diagram - coolant hoses
Note
♦ Blue = Large coolant circuit.

♦ Red = Small coolant circuit.
♦ Orange = Charge air cooling circuit.
♦ Brown = Heating circuit.
♦ Arrows show direction of coolant flow.
1 - Water radiator for charge air

cooling circuit
2 - Non-return valve
3 - Charge air cooler
4 - Cylinder head/cylinder
block
5 - Coolant expansion tank
❑ With filler cap
6 - Filler cap
❑ For coolant expansion Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
tank permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Checking pressure re‐
lief valve ⇒ page 150
7 - Turbocharger
8 - Coolant temperature send‐
er - G62-
9 - Heat exchanger for heater
10 - Coolant pump
❑ With thermostat hous‐
ing
13 - Restrictor
14 - Radiator outlet coolant
temperature sender - G83-
15 - Radiator
16 - Continued coolant circula‐
tion pump - V51-
148 Rep. gr.19 - Cooling

Audi A1 2011 ➤
1.2 Checking cooling system for leaks

♦ Cooling system tester - V.A.G 1274 B-
♦ Adapter for cooling system tester

Protected - V.A.G
by copyright. 1274/8-
Copying for private or commercial purposes, in part or in whole, is not
♦ Adapter for cooling system tester - V.A.G 1274/9-
1. Cooling system/coolant 149

Audi A1 2011 ➤
Procedure
• Engine must be warm.
WARNING

hot.
♦ Cover filler cap on coolant expansion tank with a cloth and
open carefully to dissipate pressure.
Note
Disregard -item 2-.
– Fit cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/8- onto 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 filler cap

V.A.G 1274/9- onto filler cap.
– Build up pressure with hand pump on cooling system tester.
♦ The pressure relief valve should open at a pressure of
1.4 ... 1.6 bar.
1.3 Draining and filling cooling system

Audi A1 2011 ➤

equipment required
♦ Adapter for cooling system
tester - V.A.G 1274/8-
♦ Cooling system charge unit
- VAS 6096-
♦ Coolant collecting system -
VAS 5014- or drip tray for
workshop hoist - VAS
6208-
♦ Hose clip pliers - VAS
6362-
♦ Refractometer - T10007A-
♦ Cooling system tester - V.A.G 1274 B-
♦ Safety goggles with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Protective gloves

Audi A1 2011 ➤
Draining
WARNING

hot.

Disregard -item 2-.

insulation .

– Release hose clip -arrow- and detach coolant hose (bottom
– Release hose clips -1 and 2- and detach coolant hoses (bot‐

tom right) from water radiator for charge air cooling circuit.
Filling
Caution
Always use distilled water for mixing coolant additives as this

ensures optimum corrosion protection.

Audi A1 2011 ➤
Note
♦ The effectiveness of the coolant is greatly influenced by the

quality of the water with which it is mixed. Because water may
contain different substances depending on the country or even
the region, the water quality to be used for cooling systems
has been specified. Distilled water meets all the requirements
and is therefore recommended for use when topping up or fill‐
ing up with coolant.
♦ Use only coolant additives listed in the ⇒ Electronic parts
catalogue (ETKA) . Other coolant additives could seriously
impair in particular the anti-corrosion properties. The resulting
damage could lead to loss of coolant and consequently to se‐
rious engine damage.
♦ Coolant with the recommended mixture ratio prevents frost
and corrosion damage and stops scaling. At the same time it
raises the boiling point of the fluid in the system. For this rea‐
son the cooling system must be filled all year round with the
correct coolant additive.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ The refractometer - T10007A- MUST be used to determine the
current level of frost protection.
♦ The mixture must guarantee frost protection down to at least
-25 ℃ (in countries with arctic climate: down to -36 ℃). The
amount of antifreeze should only be increased if greater frost
protection is required in very cold climates. This must only be
down to -48 ℃, however, as otherwise the cooling efficiency
of the coolant is impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be provided to at least -25 ℃.
♦ Read off the level of frost protection on the scale for the rele‐
vant coolant additive.
♦ The temperature indicated on the refractometer - T10007A-
corresponds to the temperature at which the first ice crystals
can form in the coolant.
♦ Do not reuse coolant.
♦ Only use water/coolant additive as a lubricant for coolant ho‐
ses.
Recommended mixture ratio for coolant

• Coolant (40 %) and water (60 %) for frost protection to -25 ℃
• Coolant (50 %) and water (50 %) for frost protection to -36 ℃
• Coolant ⇒ Electronic parts catalogue

Audi A1 2011 ➤
Procedure
Note
Secure all hose connections with correct type of hose clips (as
– Connect coolant hoses to water radiator for charge air cooling

circuit with hose clips -1 and 2-.
– Connect coolant hose to radiator (bottom) with hose clip

-arrow-.
– Fill reservoir of -VAS 6096- with at least 8 litres of premixed
coolant (according to recommended ratio):
– Fit adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank.
– Attach cooling system charge unit - VAS 6096- to adapter -
V.A.G 1274/8- .
– Run vent hose -1- into a small container -2-.
Note
The vented air draws along a small amount of coolant, which

should be collected.
– Close both valves -A- and -B- (turn lever at right angles to di‐
rection of flow).
– Connect hose -3- to compressed air.
• Pressure: 6 ... 10 bar.

Audi A1 2011 ➤
– Open valve -B- by setting 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.
– Also briefly open valve -A- (turn lever in direction of flow) so
that hose on reservoir of -VAS 6096- can fill with coolant.
– Close valve -A- again.
– Leave valve -B- open for another 2 minutes.
• The suction jet pump continues to generate a partial 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.
Note
♦ If the needle does not reach the green zone, repeat the proc‐
ess.
♦ Check cooling system for leaks if the vacuum is not main‐
tained.
– Detach compressed air hose.

– Open valve -A-.
• The vacuum in the cooling system causes the coolant to be
drawn out of the reservoir of -VAS 6096- ; the cooling system
is then filled.
– Detach cooling system charge unit - VAS 6096- from coolant
expansion tank.
– Top up coolant to “max” mark.

– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Exploded view - noise insulation .
– Set temperature to “HI”. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Switch off air conditioner compressor (press permitted
AC button).
• LED in button should not light up.

– Start engine and run alternately at approx. 1500 rpm and max.
2800 rpm until radiator fan cuts in.
– Top up coolant to overflow hole on expansion tank with engine
running.
– Close filler cap -1- on coolant expansion tank (make sure it
engages).
– Allow engine to run at idling speed until both large coolant ho‐
ses at radiator become warm.
– Switch off ignition and allow engine to cool down.

Audi A1 2011 ➤
– Check coolant level.

V.A.G 1274/8- onto coolant expansion tank.
– Using hand pump on tester, build up a pressure of approx. 1.0
bar.
• The coolant level must be between the “min” and “max” mark‐
ings when the engine is cold.
• The coolant level can be at or above the “max” marking when
the engine is warm.
– Top up with coolant again if necessary.

Audi A1 2011 ➤
2 Coolant pump/thermostat assembly

⇒ “2.1 Exploded view - coolant pump and thermostat”,
page 157
⇒ “2.2 Exploded view - electric coolant pump”, page 159
⇒ “2.3 Exploded view - coolant temperature senders”,
page 161
⇒ “2.4 Removing and installing electric coolant pump”,
page 161
⇒ “2.5 Removing and installing coolant pump”, page 163
⇒ “2.6 Removing and installing thermostat”, page 167
⇒ “2.7 Removing and installing toothed belt sprocket for coolant
pump”, page 169
⇒ “2.8 Removing and installing coolant temperature sender G62
”, page 171
⇒ “2.9 Removing and installing radiator outlet coolant tempera‐
ture sender G83 ”, page 172
2.1 Exploded view - coolant pump and thermostat
1 - Thermostat housing
stalling coolant pump”,
page 163
2 - Thermostat
❑ For small coolant circuit
❑ Starts to open at approx.
87 ℃
⇒ page 169
3 - Gasket
4 - Coolant pump
⇒ page 163
❑ Renew toothed belt as
well when renewing
coolant pump
permitted5 unless
- Boltauthorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Thread-forming
❑ Fit and screw in bolt by
hand so that it is
screwed into old thread.
Then tighten bolt to tor‐
que.
6 - Gasket
7 - Toothed belt cover
❑ For toothed belt for cool‐
ant pump
2. Coolant pump/thermostat assembly 157

Audi A1 2011 ➤
8 - Bolt
❑ 20 Nm + 90°
9 - Toothed belt
❑ Renew toothed belt as well when renewing coolant pump
10 - Toothed belt sprocket
❑ Apply sealant when installing
11 - Bolt
❑ 8 Nm
12 - Bolt
❑ Thread-forming
❑ Fit and screw in bolt by hand so that it is screwed into old thread. Then tighten bolt to torque.
❑withTightening torque and
respect to the correctness sequence
of information ⇒ pageCopyright
in this document. 159 by AUDI AG.
13 - Cover
❑ For thermostat
14 - Gasket
15 - Thermostat
❑ For large coolant circuit
❑ Starts to open at approx. 105 ℃
16 - Bolt
Installation position of thermostat for large coolant circuit

• Must be positioned with centring pin in guide -arrow- in ther‐
mostat housing.

Audi A1 2011 ➤
Thermostat housing to coolant pump - tightening torque and se‐

quence
– Tighten bolts in the sequence -A ... F- to 7 Nm.
Cover for thermostat to thermostat housing - tightening torque

– Tighten bolts for cover -1- in the sequence -A ... D- to 7 Nm.
2.2 Exploded view - electric coolant pump

Audi A1 2011 ➤

tion pump - V51-
❑ With bracket
⇒ page 161
2 - Coolant hose
3 - Bolt
❑ 8 Nm
4 - Coolant hose

Audi A1 2011 ➤
2.3 Exploded view - coolant temperature senders
1 - Radiator
2 - Support ring
3 - O-ring
er - G62-
⇒ page 171
5 - Bolt
❑ 8 Nm
6 - Cylinder head
7 - Radiator outlet coolant tem‐
perature sender - G83-
⇒ page 172
8 - Seal
2.4 Removing and installing electric coolant

pump
♦ Hose clamps, up to 25 mm - 3094-

Audi A1 2011 ➤
♦ Coolant collecting system - VAS 5014- or drip tray for work‐

shop hoist - VAS 6208-
♦ Hose clip pliers - VAS 6362-
Removing
WARNING
hot.
Note
Disregard -item 2-.

insulation .

Audi A1 2011 ➤

– Use hose clamps up to 25 mm - 3094- to clamp off coolant
hoses at continued coolant circulation pump - V51- .
– Remove bolt -2- and detach continued coolant circulation
pump - V51- .
Installing
Note
– Check coolant level ⇒ page 156 .

Tightening torques
2.5 Removing and installing coolant pump

♦ Torque wrench - VAS 6583-


Audi A1 2011 ➤
Removing
– Drain coolant ⇒ page 150 .
– Press release tabs on both sides and disconnect hose -2- for
activated charcoal filter system.
-1-.
– Move clear electrical wiring harness -1- and coolant hose -2-.
– Release hose clips -arrows- and disconnect coolant hoses.

Audi A1 2011 ➤
– Detach resonator -3- from turbocharger to left side and care‐
fully lift it off upwards.
for coolant pump.
– Slacken and remove bolts in the sequence: -5 ... 1-.

– Detach coolant pump with toothed belt.
Installing
Note
♦ Renew seal and O-rings after removal.

♦ If coolant pump is being renewed, renew toothed belt as well.

– Lubricate seal for coolant pump lightly with coolant.

– Fit toothed belt so that it is centred and move coolant pump
into installation position.

Audi A1 2011 ➤
– Pre-tighten bolts in the specified sequence:

2. -1 … 5- 10 Nm
– Loosen all bolts again by one turn.
– Apply torque wrench -VAS 6583- with hexagon key (10 mm)
-item 6- to coolant pump.
Note
For ease of handling, apply torque wrench -VAS 6583- vertically.
– Have a second mechanic apply a torque of 30 Nm to coolant

pump.
Note
♦ Dopermitted
not support torqueby wrench
unless authorised withAGyour
AUDI AG. AUDI other
does not hand.
guarantee or accept any liability
♦ Do not apply excessive force to torque wrench.
– While keeping coolant pump under tension, tighten bolts for

coolant pump in specified sequence:
3. -2, 1, 5- 10 Nm
4. -3, 4, 5, 1, 2- 12 Nm
note the following:
Note

Tightening torques
♦ Coolant pump ⇒ page 166
♦ ⇒ “2.1 Exploded view - charge air system”, page 190

Audi A1 2011 ➤
2.6 Removing and installing thermostat

⇒ “2.6.1 Removing and installing thermostat for large cooling cir‐
cuit”, page 167
⇒ “2.6.2 Removing and installing thermostat for small coolant cir‐
cuit”, page 169
2.6.1 Removing and installing thermostat for

large cooling circuit
♦ Special wrench - T10508-

Removing
– Press release tabs on both sides and disconnect hose -2- for
activated charcoal filter system.
-1-.

Audi A1 2011 ➤
– Disconnect coolant hose -3- from connection on turbocharger.

– Release hose clip -4- and detach coolant hose -3- from ther‐
mostat cover.
– Remove bolts -arrows- and detach cover -2- from thermostat
housing -1-.
– Turn thermostat anti-clockwise -arrow- using special wrench -

T10508- and detach.
Installing
Note
Renew seal and O-rings after removal.
– Lubricate gasket lightly with coolant.

• Installation position of thermostat ⇒ page 158 .
– Bring thermostat into position with special wrench - T10508- ,
press down slightly and turn clockwise -arrow- as far as stop.
Note
– Fill up with coolant ⇒ page 152 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Tightening torques with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ ⇒ Fig. ““Cover for thermostat to thermostat housing - tighten‐

ing torque”“ , page 159

Audi A1 2011 ➤
2.6.2 Removing and installing thermostat for

small coolant circuit
Removing
– Remove bolts in the sequence -F … A-.
– Detach coolant pump from thermostat housing.
– Detach thermostat -2- from coolant pump -1-.

Installing
Note
Renew gasket after removing.
– Lubricate gasket lightly with coolant.
– Fit thermostat housing onto coolant pump.

• Centring pins on thermostat must be fitted in guides -arrows-
on coolant pump.
– Tighten bolts for thermostat housing
permitted unless authorised⇒bypage 159
AUDI AG. . AG does not guarantee or accept any liability
AUDI
– Install coolant pump ⇒ page 163 .
Note

Tightening torques
♦ ⇒ Fig. ““Thermostat housing to coolant pump - tightening tor‐
que and sequence”“ , page 159
2.7 Removing and installing toothed belt

sprocket for coolant pump

Audi A1 2011 ➤
♦ Counterhold tool - T10172A- with adapters -T10172/2-
Removing
– Loosen bolt -1- using counterhold tool - T10172A- with adapt‐
ers -T10172/2- .
– Remove bolt and take off toothed belt drive sprocket -2-.
Installing
– Fit toothed belt drive sprocket:
• Grooves -1, 2- in camshaft are arranged asymmetrically.
• Openings -arrows- in toothed belt sprocket are also arranged
asymmetrically.
– Fit toothed belt sprocket onto camshaft so that asymmetrical
grooves are positioned exactly in centre of openings.
Tightening torques
page 157

Audi A1 2011 ➤
2.8 Removing and installing coolant temper‐

ature sender - G62-
Removing
• Engine cold.
Note

stalling.
– To relieve residual pressure in cooling system,
with respectopen filler cap
-1- on coolant expansion tank briefly and then close cap again
(it should click into place).
Note
Disregard -item 2-.

insulation .
Note
Place a cloth underneath to catch escaping coolant.
– Remove bolt -arrow- and detach coolant temperature sender

- G62- -item 1-.
– Open heat insulation sleeve.
Note
♦ If O-ring with support ring remains lodged in cylinder head, lift

it out using a piece of wire.
♦ Insert new coolant temperature sender - G62- immediately in‐
to cylinder head to avoid loss of coolant.
Installing
Note

Tightening torques
♦ ⇒ “2.3 Exploded view - coolant temperature senders”,
page 161

Audi A1 2011 ➤
2.9 Removing and installing radiator outlet

coolant temperature sender - G83-
Removing
• Engine cold.
– To relieve residual pressure in cooling system, open filler cap
-1- on coolant expansion tank briefly and then close cap again
(it should click into place).
Note
Disregard -item 2-.
– Unplug electrical connector -arrow-.
Note
– Unscrew radiator outlet coolant temperature sender - G83- .

Installing
Note
♦ Renew O-ring after removal.

♦ To avoid loss of coolant, screw in new radiator outlet coolant
temperature sender - G83- immediately.

Tightening torques
♦ ⇒ “2.3 Exploded view - coolant temperature senders”,
page 161

Audi A1 2011 ➤
3 Coolant pipes
⇒ “3.1 Exploded view - coolant pipes”, page 173
⇒ “3.2 Removing and installing coolant pipes”, page 173
3.1 Exploded view - coolant pipes
Note
The arrow markings on coolant pipes and on ends of hoses must align.
1 - Coolant hose
2 - Coolant pipe
⇒ page 173
3 - Bolt
❑ 8 Nm
4 - Coolant hose
5 - Coolant hoses
6 - Coolant pipes
❑ Clipped onto intake
manifold (top)
7 - Bolt
❑ 9 Nm
8 - Bolt
9 - Coolant hose
3.2 Removing and installing coolant pipes
Removing
3. Coolant pipes 173

Audi A1 2011 ➤
Caution
Danger of damage to intake manifold and coolant pipe.

♦ Proceed very carefully when performing this work.
– Carefully release catches -arrows- and disconnect coolant

pipe -2- from intake manifold -1-.
Installing
– Push coolant pipe onto intake manifold so that it engages au‐
dibly.

Audi A1 2011 ➤
4 Radiators/radiator fan
⇒ “4.1 Exploded view - radiators/radiator fan”, page 175
⇒ “4.2 Removing and installing radiator”, page 177
⇒ “4.3 Removing and installing radiator cowl”, page 179
⇒ “4.4 Removing and installing radiator fan V7 ”, page 180
4.1 Exploded view - radiators/radiator fan

Radiators
1 - Coolant hoses
❑ For charge air cooling
circuit
2 - Air duct
3 - Water radiator for charge air
cooling circuit
❑ Remove together with
radiator
stalling radiator”,
page 177
with fresh coolant
4 - Coolant hose (bottom)
5 - Radiator outlet coolant tem‐
perature sender - G83-
⇒ page 172
❑ 35 Nm
6 - Seal
7 - Coolant hose (top)
8 - Air duct
9 - Coolant hose
❑ To coolant expansion
tank
10 - Radiator
⇒ page 177
with fresh coolant
11 - Condenser
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing and
installing condenser
12 - Bolt
❑ Tightening torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Exploded view - con‐
denser
13 - Bolt
❑ 5 Nm
4. Radiators/radiator fan 175

Audi A1 2011 ➤
14 - Bracket
❑ Note installation position
15 - Bracket
❑ For water radiator for charge air cooling circuit
Connecting coolant hose with plug-in connector
Note
If damaged, renew retaining clip -4-.
– Remove old O-ring -2- from coolant hose -3-.

– Lubricate new O-ring with coolant and fit O-ring in coolant
hose.
– Press coolant hose onto coolant pipe -1- until it engages with
a click.
– Press coolant hose in again and then pull to check that plug-
in connector is correctly engaged.
Radiator cowl and radiator fan
1 - Pin
❑ For spreader clip
2 - Air flow ring
❑ Depending on version
3 - Radiator fan - V7-
❑ With radiator fan control
unit - J293-
⇒ page 180
4 - Radiator cowl
⇒ page 179
5 - Air flow flap
6 - Clip
❑ For coolant hose
7 - Bracket
❑ For electrical connector

Audi A1 2011 ➤
8 - Bolt
❑ 1.5 Nm
4.2 Removing and installing radiator
Note
Radiator and water radiator for charge air cooling circuit are re‐
moved together.

Removing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove bumper cover ⇒ General body repairs, exterior; Rep.
gr. 63 ; Bumper (front); Removing and installing bumper cov‐
er .
– Remove radiator cowl ⇒ page 179 .
– Release hose clips -1 and 2- and detach coolant hoses (top

– Swivel top edge of radiator slightly to rear.
– Lift radiator, disengage it from bottom mounting points and
press it to the rear.

Audi A1 2011 ➤
Vehicles with air conditioning:
WARNING
Risk of injury caused by refrigerant.

♦ The air conditioner refrigerant circuit must not be opened.
Caution
Danger of damage to refrigerant lines and hoses.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Move condenser to front and place in lock carrier, then secure

with cable ties to prevent from dropping.

– Release fasteners at water radiator for charge air cooling cir‐
cuit -1- -arrows A-.
– Pull water radiator for charge air cooling circuit off radiator
-2- -arrowProtected
B- and by disengage -arrow
copyright. Copying C-.
for private or commercial purposes, in part or in whole, is not
– Detach bothwithradiators.
Installing
Note
♦ If there are slight impressions on the fins, refer to ⇒ page 9 .

– Vehicles with air conditioning: Install condenser ⇒ Heating, air

conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing and
installing condenser .
– Install bumper cover (front) ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front); Exploded view - bumper cover .
Note

Tightening torques
♦ ⇒ “4.1 Exploded view - radiators/radiator fan”, page 175

Audi A1 2011 ➤
4.3 Removing and installing radiator cowl

Removing
rier.
– Release hose clip -1- and detach air hose.
– Remove bolts -arrows- and detach air duct -1-.
– Unplug electrical connector -arrow- for radiator outlet coolant

temperature sender - G83- .
– Move coolant hose -1- clear at radiator cowl -arrows-.

Audi A1 2011 ➤
WARNING
Risk of injury as the radiator fan may start up automatically.

♦ Unplug electrical connectors before performing work on
radiator cowl.
– Unplug electrical connector -1- for radiator fan at bottom of

radiator cowl.
– Press locking tabs on left and right sides of radiator cowl
-arrow- and at the same time lift radiator cowl off radiator.
Installing
Install in reverse order.
Tightening torques
4.4 Removing and installing radiator fan -

V7-
Removing
– Remove radiator cowl ⇒ page 179 .
– Press out pins -arrows- of fasteners and detach ring -1- from
fan.
– Take electrical wiring -1- out of cable guide.
– Unscrew nuts -arrows- and detach radiator fan - V7- .
Installing
Tightening torques
♦ ⇒ “4.1 Exploded view - radiators/radiator fan”, page 175

Audi A1 2011 ➤
21 – Turbocharging/supercharging
1 Turbocharger
⇒ “1.1 Exploded view - turbocharger”, page 181
⇒ “1.2 Removing and installing turbocharger”, page 182
⇒ “1.3 Removing and installing charge pressure positioner V465
”, page 187
1.1 Exploded view - turbocharger

Part 1
1 - Connection
2 - Bolt
❑ 8 Nm
3 - O-ring
4 - Gasket
5 - Bracket
❑ For coolant pipes
6 - Bolt
❑ 20 Nm
7 - Turbocharger
⇒ page 182
8 - Nut
❑ 25 Nm
9 - Lock nut
❑ For charge pressure po‐
sitioner - V465-
❑ 10 Nm
10 - Operating lever
sitioner - V465-
11 - Securing clip
12 - Securing clip
13 - Operating lever
sitioner - V465-
14 - Charge pressure positioner - V465-
Protected by❑ Removing
copyright. Copying forand
privateinstalling
or commercial⇒ purposes,
page 187 in part or in whole, is not
15 - Bolt
❑ 9 Nm
Part 2
1. Turbocharger 181
Audi A1 2011 ➤
1 - Turbocharger
⇒ page 182
2 - O-ring
3 - Bolt
❑ 9 Nm
4 - Bolt
❑ 20 Nm
5 - Oil supply line
6 - O-ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Renew after with
removing
7 - Bolt
❑ 9 Nm
8 - O-ring
9 - Bolt
❑ 8 Nm
10 - Hose
11 - Bolt
❑ 8 Nm
12 - O-rings
13 - Gasket
14 - Coolant pipes
❑ Supply and return
15 - Bolt
❑ 8 Nm
16 - O-ring
17 - Oil return line
18 - Bolt
❑ 9 Nm
19 - O-ring
1.2 Removing and installing turbocharger

182 Rep. gr.21 - Turbocharging/supercharging

Audi A1 2011 ➤
♦ Engine bung set - VAS 6122-
1. Turbocharger 183
Audi A1 2011 ➤
Removing
Note
♦ Observe rules for cleanliness ⇒ page 7 .

♦ Reinstall heat insulation sleeves in the same locations when
installing.
Caution
If the turbocharger has suffered mechanical damage (e.g.

damaged compressor wheel), it is not sufficient merely to fit a
new turbocharger. The following work must be performed in
order to avoid further damage:
♦ Check air cleaner housing, air filter element and air hoses
for dirt and foreign

with particles.
♦ Check the entire charge air system (including the charge

air cooler) for foreign matter.
♦ If foreign matter is found in the charge air system, clean
all relevant ducts and hoses and renew charge air cooler
if necessary.

electrical wiring.
pipe.

Audi A1 2011 ➤
coal filter system.
-1-.
it towards rear.
for coolant pump.
– Detach electrical connectors -1, 2- from bracket, unplug con‐

nectors and move electrical wiring clear.
1. Turbocharger 185
Audi A1 2011 ➤

alytic converter.
– Remove nuts -arrows- and tie up catalytic converter.
– Remove bolts -arrows- and detach oil supply line -1- and oil
return line -2-.
– Clamp off coolant hoses -1- with hose clamps, up to 25 mm -

3094- .
– Remove bolts -arrows- and pivot coolant lines -2- to one side.

Audi A1 2011 ➤
– Unscrew nuts -arrows-, detach turbocharger -1- and unplug

electrical connector -2-.
Installing
Note
♦ Renew seals, nuts and O-rings after removal.

♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ After installing the turbocharger, allow the engine to idle for
approx. 1 minute without pressing the accelerator to ensure
that the turbocharger is supplied with oil.
– When reinstalling used turbocharger: Insert screwdriver -2-

into groove -arrow- on turbocharger and lever out seal -1-.
Note

Tightening torques
♦ ⇒ Fig. ““Installing catalytic converter - tightening torque and
page 157
1.3 Removing and installing charge pres‐

sure positioner - V465-

1. Turbocharger 187
Audi A1 2011 ➤
Removing
coal filter system.
-1-.
it towards rear.
for coolant pump.

Audi A1 2011 ➤
– Remove securing clips -3- and detach actuating lever -4-.

– Detach charge pressure positioner - V465- -item 1- and unplug
electrical connector -2-.
Installing
Note
– Adapt engine control unit - J623- to charge pressure positioner

- V465- ⇒ Vehicle diagnostic tester, Guided Functions .
Tightening torques
page 157
1. Turbocharger 189
Audi A1 2011 ➤
2 Charge air system

⇒ “2.1 Exploded view - charge air system”, page 190
⇒ “2.3 Removing and installing charge air cooler”, page 192
⇒ “2.4 Removing and installing charge pressure sender G31 / in‐
take air temperature sender 2 G299 ”, page 194
⇒ “2.5 Checking charge air system for leaks”, page 194
2.1 Exploded view - charge air system
Note
♦ Check that all air pipes and hoses
permitted and
unless vacuum
authorised lines
by AUDI are AG
AG. AUDI correctly fitted and
does not guarantee thatanythere
or accept liability are no leaks before
carrying out tests or repairs.

♦ Observe rules for cleanliness ⇒ page 7 .
1 - Gasket
2 - Sealing lip
3 - Charge air cooler
⇒ page 192
with fresh coolant
4 - Bolt
❑ Thread-forming
hand so that it is
que.
❑ 15 Nm
5 - Coolant hose
6 - Coolant hoses
7 - Intake manifold
⇒ page 205
8 - Bolt
9 - Retaining clip
❑ For air pipe
10 - O-ring
11 - Air pipe
12 - Bolt
❑ Repair method if retaining tabs are broken off
❑ Thread-forming

Audi A1 2011 ➤
❑ 7 Nm
13 - Charge pressure sender - G31- / intake air temperature sender 2 - G299-
14 - O-ring
15 - O-ring
16 - Connection
17 - O-ring
18 - Bolt
19 - O-ring
20 - Intake air temperature sender - G42- / intake manifold pressure sender - G71-
21 - Bolt
❑ Tightening torque ⇒ Item 13 (page 205)
22 - Coolant hose
23 - Hose
❑ For crankcase breather Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2.2 Exploded view - hose connections for

charge air system
Note
♦ To ensure that the air hoses can be properly secured at their
connections, spray rust remover onto the worm thread of used
hose clips before installing.
Tightening torque for

1- Hose clip -a- = 13 mm wide: 5.5 Nm
2- Hose clip -b- = 9 mm wide: 3 Nm
2. Charge air system 191

Audi A1 2011 ➤
2.3 Removing and installing charge air cool‐

er
Removing

Audi A1 2011 ➤
Note
– Clamp off coolant hoses on charge air cooler with hose clamps
up to 25 mm - 3094- .
– Release hose clips -1, 2- and disconnect coolant hoses.
– Remove bolts -arrows- and detach charge air cooler.
Installing
Note
♦ If there are slight impressions on the fins, refer to ⇒ page 9 .

♦ Renew gasket after removing.
Note

Tightening torques
♦ ⇒ “2.1 Exploded view - charge air system”, page 190

Audi A1 2011 ➤
2.4 Removing and installing charge pres‐

sure sender - G31- / intake air tempera‐
ture sender 2 - G299-
Removing
Version A:
– Release catches -arrows- and detach charge pressure sender
- G31- / intake air temperature sender 2 - G299- .
Version B:
– Unscrew bolts -2- and remove charge pressure sender - G31- /
intake air temperature sender 2 - G299- .
Installing
Note

♦ If fasteners on air pipe have broken off, secure charge pres‐
sure sender - G31- / intake air temperature sender 2 - G299-
with bolts -2-; for bolts, refer to ⇒ Electronic parts catalogue .
2.5 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-
Procedure
– Attach end piece - V.A.G 1687/6- to connection.
– Connect hose -1- of charge air system tester -V.A.G 1687- to
end piece.

Audi A1 2011 ➤
Prepare charge air system tester - V.A.G 1687- as follows:

– Unscrew pressure control valve -2- completely and close
valves -3- and -4-.
• Make sure knob is pulled out before turning pressure control
valve -2-.
– Using a commercially available connection piece, connect
charge air system tester - V.A.G 1687- to compressed air -1-.
Note
If there is water in sight glass, remove drain plug -6- and drain
water.
– Open valve -3-.
Caution
Risk of damage if pressure is set too high.

♦ The pressure must not exceed 0.5 bar.
– Adjust pressure to 0.5 bar via pressure control valve -2-.

– Open valve -4- and wait until test system is pressurised. If
necessary, adjust pressure to 0.5 bar again.
– Check charge air system for audible leaks or leaks that can be
felt with the hand; apply commercially available leak detecting
spray or use ultrasonic tester - V.A.G 1842- .
Note
♦ For operation of ultrasonic tester -V.A.G 1842- , refer to ⇒not guarantee or accept any liability
permitted unless authorised by AUDI AG. AUDI AG does
Operating instructions
with. respect to the correctness of information in this document. Copyright by AUDI AG.
♦ A small amount of air escapes through the valves and enters

the engine. Therefore it is not possible to perform a pressure
retention test.
♦ Release pressure in test circuit by detaching hose coupling
from adapter before removing adapter.
Assembling
Note
♦ Renew seal and O-rings after removal.

Tightening torques

Audi A1 2011 ➤
24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview of fitting locations - injection system”,
page 196
⇒ “1.2 Reducing fuel pressure in high-pressure section”,
page 200
1.1 Overview of fitting locations - injection system

Overview of fitting locations - engine compartment
1 - Charge pressure sender -

G31- / intake air temperature
sender 2 - G299-
❑ Exploded view
⇒ page 190
2 - Lambda probe - G39- and
Lambda probe heater - Z19-
❑ Exploded view
⇒ page 229
3 - Lambda probe after catalyt‐
ic converter - G130- and Lamb‐
da probe heater 1 after catalyt‐
ic converter - Z29-
❑ Exploded view
⇒ page 229
4 - Accelerator position sender
- G79- and accelerator position
sender 2 - G185-
❑ Fitting location
⇒ page 197
5 - Brake light switch - F- /
brake pedal switch - F47-
⇒ page 197
6 - Engine control unit - J623-
⇒ page 231
7 - Clutch position sender -
G476-
⇒ page
Protected197
8 - Gearbox neutral
with respect toposition
the correctness of information in this document. Copyright by AUDI AG.
sender - G701- / reversing light
switch - F4-
❑ Fitting location ⇒ page 197
9 - Radiator outlet coolant temperature sender - G83-
10 - Brake servo pressure sensor - G294-
❑ Fitting location ⇒ page 198
196 Rep. gr.24 - Mixture preparation - injection

Audi A1 2011 ➤
Accelerator position sender - G79- and accelerator position send‐

er 2 - G185-
♦ In accelerator pedal module
2 - Electrical connector for accelerator pedal module
Note
The accelerator position sender - G79- and accelerator position

sender 2 - G185- are integrated in the accelerator pedal module
and cannot be renewed individually.
Removing and installing ⇒ Fuel supply system, petrol engines;

Rep. gr. 20 ; Accelerator mechanism; Removing
Protected by copyright. and
Copying for installing
private or commercial purposes, in part or in whole, is not
accelerator pedal module with accelerator
permitted position
unless authorised sender
by AUDI AG. AUDI-G79-
AG does / not guarantee or accept any liability
-G185- with respect to the correctness of information in this document. Copyright by AUDI AG.
Fitting location of brake light switch - F- / brake pedal switch - F47-

♦ -Item 3- on brake master cylinder
Removing and installing ⇒ Brake system; Rep. gr. 45 ; Sensors;
Removing and installing brake light switch
Fitting location of clutch position sender - G476-

♦ On clutch master cylinder, next to brake servo
Removing and installing ⇒ Rep. gr. 30 ; Clutch mechanism; Re‐
moving and installing clutch position sender - G476-
♦ At plenum chamber partition panel -arrow-.
Fitting location of gearbox neutral position sender - G701- / re‐

versing light switch - F4-
♦ On gearbox (front left)
3 - Electrical connector for gearbox neutral position sender -
G701-
4 - Electrical connector for reversing light switch - F4-
1. Injection system 197

Audi A1 2011 ➤
Fitting location of brake servo pressure sensor - G294-

♦ In vacuum line
1- Electrical connector for brake servo pressure sensor -
G294-
Overview of fitting locations - engine (view from above)
1 - Camshaft control valve 1 -

N205-
❑ Exploded view
⇒ page 111
2 - Exhaust camshaft control
valve 1 - N318-
❑ Exploded view
⇒ page 111
3 - Activated charcoal filter sol‐
enoid valve 1 - N80-
4 - Ignition coil 1 with output
stage - N70-
❑ Exploded view
⇒ page 243
stage - N127-
❑ Exploded view
⇒ page 243
stage - N291-
❑ Exploded view
⇒ page 243
7 - Hall sender 2 - G163-
❑ Exploded view
⇒ page 243 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
8 - Hall sender - G40- (cam‐
shaft position sensor)
❑ Exploded view
⇒ page 243
9 - Fuel metering valve - N290-
❑ Exploded view
⇒ page 224
10 - Injector, cylinder 3 - N32-

Audi A1 2011 ➤
Overview of fitting locations - engine (inlet side)
1 - Oil pressure switch - F1-

❑ Exploded view
⇒ page 144
2 - Fuel pressure sender -
G247-
❑ Exploded view
⇒ page 211
3 - Throttle valve module -
J338-
❑ Including throttle valve
drive for electric throttle
- G186- , throttle valve
drive angle sender 1 for
electric throttle - G187-
and throttle valve drive
angle sender 2 for elec‐
tric throttle - G188-
❑ Exploded view
⇒ page 204
4 - Intake air temperature
sender - G42- / intake manifold
pressure sender - G71-
❑ Exploded viewProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 204
5 - Engine speed sender -

G28-
❑ Exploded view
⇒ page 243
tion pump - V51-
❑ Exploded view
⇒ page 159
Overview of fitting locations - engine (exhaust side)

Audi A1 2011 ➤
1 - Oil level and oil temperature

sender - G266-
❑ Exploded view
⇒ page 130
2 - Knock sensor 1 - G61-
❑ Exploded view
⇒ page 243
er - G62-
❑ Exploded view
⇒ page 161
4 - Charge pressure positioner
- V465-
❑ Exploded view
⇒ page 181
5 - Valve for oil pressure con‐
trol - N428-
❑ Exploded view
⇒ page 144
1.2 Reducing fuel pressure in high-pressure

section
WARNING

cause injury.
♦ The injection system consists of a high-pressure section
(maximum approx. 120 bar) and a low-pressure section
(approx. 7 bar).
♦ Prior to opening the high-pressure section (e.g. when re‐
moving the high-pressure pump, fuel rail, injectors, fuel
pipes or fuel pressure sender - G247- ), the fuel pressure
in the high-pressure section must be reduced to a residual
pressure of approx. 7 bar. The procedure is described be‐with respect to the correctness of information in this document. Copyright by AUDI AG.
low.

♦ Vehicle diagnostic tester

Audi A1 2011 ➤
Reducing fuel pressure in high-pressure section:

– Connect vehicle diagnostic tester and perform function “Re‐
duce fuel pressure” in “Guided Functions”.
• Fuel pressure will drop to a specified value.
– Switch off ignition.
The fuel rail is still filled with fuel, however it is no longer under
high pressure.
WARNING
There is a risk of injury: avoid skin contact with fuel.

♦ Wear safety goggles and protective clothing when open‐
ing the fuel system.
♦ Before opening the high-pressure section of the fuel sys‐
tem, place a clean cloth around the connection to catch
escaping fuel.
– The high-pressure system must be opened »immediately« af‐

ter reducing the fuel pressure; wrap a clean cloth around the
connection. Catch the escaping fuel.
Note
♦ The pressure will increase again due to the effect of residual

heat if the high-pressure system is not opened immediately.
♦ The ignition must not be switched on again from this point on
as this would increase the pressure again.
Additional steps required

– Erase event memory and generate readiness code in engine
control unit in “Guided Functions” mode.

Audi A1 2011 ➤
2 Air cleaner
⇒ “2.1 Exploded view - air cleaner housing”, page 202
⇒ “2.2 Removing and installing air cleaner housing”, page 203
2.1 Exploded view - air cleaner housing
1 - Air duct (front section)

❑ On lock carrier
2 - Bolt
❑ 4.5 Nm
3 - Air duct (rear section)
❑ On lock carrier
4 - Air hose
5 - Air cleaner (bottom section)
❑ Clean out dirt, leaves
and salt deposits
6 - Air filter element
❑ Use genuine air filter el‐
ement ⇒ Electronic
parts catalogue
❑ Change intervals ⇒ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Maintenance tables permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
let 819
7 - Hose
system
8 - Air cleaner (top section)
❑ Check for dirt
9 - Rubber buffer
10 - Bolt
❑ 1.5 Nm
11 - Water drain pipe
❑ With water drain valve
❑ Clean
12 - Rubber grommet
13 - Bolt
❑ 9 Nm

Audi A1 2011 ➤
2.2 Removing and installing air cleaner

housing
Removing
rier.
Note
Disregard -item 1-.

– Move vacuum line -5- clear.
– Loosen hose clip -4-.
– Lift air cleaner housing -3- off ball studs and detach.
Installing
Note
♦ Use a silicone-free lubricant when installing the air hoses.
Tightening torques
2. Air cleaner 203

Audi A1 2011 ➤
3 Intake manifold
⇒ “3.1 Exploded view - intake manifold”, page 204
⇒ “3.2 Removing and installing intake manifold”, page 205
⇒ “3.3 Removing and installing throttle valve module J338 ”, page
208
⇒ “3.4 Cleaning throttle valve module”, page 209
3.1 Exploded view - intake manifold
1 - Coolant pipe
❑ Clipped onto intake
manifold
2 - Bolt
3 - Intake manifold
❑ Combined with charge
air cooler
⇒ page 205
4 - O-ring
5 - Vacuum line
6 - Throttle valve module -
J338-
⇒ page 208
❑ Cleaning ⇒ page 209
❑ After throttle valve mod‐
ule - J338- has been re‐
newed, it must be re-
adapted to engine con‐
trol unit - J623- . Use
vehicle diagnostic tester
7 - Bolt permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Thread-forming
hand so that it is
que.
❑ 7 Nm
8 - Retaining clip
❑ For air pipe
9 - Seal
10 - Gaskets
11 - Bolt

Audi A1 2011 ➤
12 - O-ring
13 - Bolt
❑ Thread-forming
❑ 7 Nm
14 - Intake air temperature sender - G42- / intake manifold pressure sender - G71-
15 - Vacuum line
16 - O-ring
17 - Hose
Intake manifold - tightening torque and sequence

1. -arrows- Starting in centre, screw in bolts alter‐
nately by hand until they make contact
2. -arrows- Starting in centre, screw in bolts alter‐
nately: 8 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
3.2 Removing and installing intake manifold

3. Intake manifold 205

Audi A1 2011 ➤
Removing
WARNING
Risk of injury caused by fuel.

♦ To allow the fuel pressure to dissipate, wrap a clean cloth
around the connection and carefully loosen the connec‐
tion before opening the fuel system.
Caution
Risk of malfunctions caused by dirt.

♦ Observe ⇒ “3.1 Rules for cleanliness”, page 7 .
– Release catch -arrow- and disconnect vacuum hose -1-.

electrical wiring.
pipe.

Audi A1 2011 ➤
– Press release tabs -3- on both sides and disconnect line -2-
for activated charcoal filter system.
Note
Disregard -item 1-.
– Unplug electrical connector -1- for throttle valve module -

J338- .
Note
Disregard -item 2-.

– Release hose clips -arrows- and disconnect coolant hoses.

– Move coolant line -1- and fuel line -2- clear at intake manifold.

Audi A1 2011 ➤
– Unplug electrical connector -2- for intake air temperature

sender - G42- .

– Detach intake manifold -1-.
Installing
Note
Renew seals and O-rings after removal.

Note

Tightening torques
♦ ⇒ “3.1 Exploded view - intake manifold”, page 204
3.3 Removing and installing throttle valve

module - J338-

Audi A1 2011 ➤
Removing
electrical wiring.
pipe.

– Remove bolts -2- and detach throttle valve module - J338- .
Installing
Note
– If throttle valve module - J338- has been renewed, adapt en‐

gine control unit - J623- to throttle valve module - J338- in
⇒ Vehicle diagnostic tester, Guided Functions .
Tightening torques
♦ ⇒ “3.1 Exploded view - intake manifold”, page 204
3.4 Cleaning throttle valve module
Note
♦ Carbon deposits and dirt in the limit stop can lead to incorrect
adaption values.
♦ Take care not to scratch the throttle valve housing when clean‐
ing it.

♦ Acetone (commercially available)
♦ Brush
Procedure
– Remove throttle valve module - J338- ⇒ page 208 .

Audi A1 2011 ➤
– Open throttle valve by hand and lock it in open position with a

wedge (plastic or wood) -arrow-.
WARNING
Acetone is highly flammable.

♦ Observe all accident prevention regulations and safety
precautions when handling flammable liquids.
♦ Do not use compressed air when cleaning the throttle
valve.
♦ Wear safety goggles and protective clothing to avoid any
contact with skin and risk of injury.
– Clean throttle valve housing thoroughly, especially around the

points -arrows- where the throttle valve closes, using com‐
mercially available acetone and a small brush.
– Wipe out throttle valve housing with a lint-free cloth.
– Allow acetone to flash off completely.
– Install throttle valve module - J338- ⇒ page 208 .
– Erase learnt values and adapt engine control unit - J623- to
throttle valve module - J338- in Guided Functions mode
⇒ Vehicle diagnostic tester.

Audi A1 2011 ➤
4 Injectors
⇒ “4.1 Exploded view - fuel rail with injectors”, page 211
⇒ “4.2 Removing and installing fuel rail”, page 212
⇒ “4.3 Removing and installing injectors”, page 213
⇒ “4.4 Cleaning injectors”, page 217
4.1 Exploded view - fuel rail with injectors
1 - Fuel rail
⇒ page 212
2 - Bolt
❑ Tighten alternately in
stages; final torque 9
Nm
3 - Fuel pressure sender -
G247-
❑ Checking ⇒ page 220
⇒ page 219
❑ Lubricate taper lightly
with clean engine oil; do
not lubricate thread
❑ 22 Nm
4 - Support ring
❑ Via this support ring, the
fuel rail exerts the
clamping force that
holds the injector in the
cylinder head
❑ Clipped to -item 8-
5 - O-ring
❑ Lubricate lightly withwith respect to the correctness of information in this document. Copyright by AUDI AG.
clean engine oil
6 - Spacer ring
7 - Injector
⇒ page 213
8 - Combustion chamber ring seal
❑ Do not apply grease or use any other lubricants
❑ Renewing ⇒ “4.3 Removing and installing injectors”, page 213
4. Injectors 211
Audi A1 2011 ➤
9 - High-pressure pipe
WARNING
The fuel system oper‐
ates at extremely high
pressure. This can
cause injury.
The
♦ fuel pressure in the
high-pressure section of
the injection system must
be reduced to a residual
pressure prior to opening
the system ⇒ page 200 .
❑ Connections must not be damaged

❑ Do not alter shape
❑ 25 Nm
4.2 Removing and installing fuel rail

Removing
WARNING

cause injury.
prior to opening the system ⇒ page 200 . authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless
Caution



Audi A1 2011 ➤
Note
Place a cloth underneath to catch escaping fuel.
– Remove bolts -arrows- and pull fuel rail off injectors -2-.
– If necessary, unplug electrical connectors at injectors.
Installing
Note

♦ Renew support rings after removing.
– Apply mountings on fuel rail onto injectors.

– Press fuel rail onto injectors as far as stop (first on right side,
then on left side).
– Press fuel rail down firmly in vicinity of bracket and screw in
bolts two turns.
Tightening torques
♦ ⇒ “4.1 Exploded view - fuel rail with injectors”, page 211
4.3 Removing and installing injectors

♦ Tool set for FSI engines - T10133 C- with -T10133/16A- and
-T10133/19-
Removing
Caution

4. Injectors 213
Audi A1 2011 ➤
Note
Injectors must only be installed when the engine is cold.
– Remove fuel rail ⇒ page 212 .

– Unplug electrical connector from corresponding injector.
– Use screwdriver -2- to prise support ring -1- off injector.
– Remove O-ring -4- from injector -2-.
– Slide sleeve -T10133/18- over injector.

– Carefully knock against stop sleeve several times with a plas‐
tic hammer -1- to loosen injector.
Note
♦ Use a torque wrench to pull out injector.

♦ Set torque wrench to 5 Nm.
♦ Observe correct torque to avoid irreparable damage to injec‐
tor.

Audi A1 2011 ➤
– Apply puller -T10133/19- to groove on injector.

– Attach removal tool -T10133/16A- to puller.
– Pull out injector by screwing in bolt -1- on puller.
– If injector does not come loose after torque limit of 5 Nm is
reached, remove puller again.
– Repeat procedure using stop sleeve to loosen injector.
– Repeat procedure for each injector.
Dismantling injector
– Pull support ring -5- and spacer ring -3- off injector -2-.
– Carefully remove old combustion chamber ring seal -1-. To do
so, cut open seal using knife or prise open with small screw‐
driver and then pull off forwards.
Note
Take care not to damage groove on injector. The injector must be

renewed if the groove is damaged.
Installing
Note
♦ Use complete repair set when installing.

♦ Renew support rings after removing.
♦ Renew combustion chamber ring seal before re-installing in‐
jector.
♦ Lightly lubricate O-rings for injectors with clean engine oil.
– Clean bore in cylinder head with nylon cylinder brush -

T10133/4- .
– When re-installing an injector, clean any combustion residue
off groove for combustion chamber ring seal and injector stem
with a clean cloth.
4. Injectors 215
Audi A1 2011 ➤
– Fit assembly cone -T10133/5- with new combustion chamber

ring seal -1- onto injector -2-.
– Using assembly sleeve -T10133/6- , push combustion cham‐

ber ring seal onto assembly cone -T10133/5- as far as it will
go.
– Turn round assembly sleeve -T10133/6- and slide combustion

chamber ring seal into groove. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
The combustion chamber ring seal is widened when it is pushed

onto the injector. After pushing it on, it therefore has to be com‐
pressed again. This is done in two stages, as described below.
– Push calibration sleeve -T10133/7- onto injector as far as it will

go and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/7- off again by turning it in the
opposite direction.

Audi A1 2011 ➤
– Push calibration sleeve -T10133/8- onto injector as far as it will

go and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/8- off again by turning it in the
opposite direction.
– Before installing new injector -1-, lubricate new O-ring -3- light‐
ly with clean engine oil.
Note
The combustion chamber ring seal -1- must not be lubricated.
– Push injector by hand as far as it will go into aperture in cylin‐

der head (do not use oil or grease). Ensure that the injector is
properly seated in the cylinder head.
• Electrical connector of injector must engage in recess in cyl‐
inder head.
Note
It should be possible to insert injector easily. If necessary wait

until the combustion chamber ring seal has contracted sufficient‐
ly.
– Install fuel rail ⇒ page 212 .
4.4 Cleaning injectors

♦ Ultrasonic cleaning unit - VAS 6418-
♦ Mounting plate for injection modules - VAS 6418/1-
♦ Cleaning fluid ⇒ Electronic parts catalogue
Note
♦ Ultrasonic cleaning unit must be filled with cleaning fluid up to

top edge of apertures (see detail in illustration).
♦ Observe safety precautions and operating instructions for ul‐
trasonic cleaning unit.
4. Injectors 217
Audi A1 2011 ➤
Cleaning
– Remove injectors ⇒ page 213 .
– Insert injectors -1- all the way into mounting plate for injection
modules - VAS 6418/1- -item 2-.
– Immerse injectors together with mounting plate for injection
modules - VAS 6418/1- into cleaning fluid - VAS 6418/2- .
– Set rotary knob -4- to a temperature of 50°C.
– Select a cleaning time of 30 minutes with rotary knob -5-.
– Use button -3- to switch on ultrasonic cleaning unit.
Note
The time set starts to elapse as soon as a cleaning temperature

of 50°C has been reached.
– After cleaning, renew combustion chamber ring seal for each

injector ⇒ page 213 .

Audi A1 2011 ➤
5 Senders and sensors

⇒ “5.1 Removing and installing fuel pressure sender G247 ”, page
219
⇒ “5.2 Checking fuel pressure sender G247 ”, page 220
⇒ “5.3 Removing and installing intake air temperature sender
G42 / intake manifold pressure sender G71 ”, page 222
5.1 Removing and installing fuel pressure

sender - G247-
♦ Socket - T40218-
Removing
– Remove bolt -1- for coolant pipe (front).
Note
Disregard -item 2-.
5. Senders and sensors 219

Audi A1 2011 ➤
– Move fuel hose clear and press to one side.

Note
– Unscrew fuel pressure sender - G247- -item 2- using socket,

27 mm - T40218- .
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation is carried out in the reverse order; notewith
therespect
following:
Note
Do not lubricate thread of fuel pressure sender.
Tightening torques
♦ ⇒ “4.1 Exploded view - fuel rail with injectors”, page 211
5.2 Checking fuel pressure sender - G247-

♦ Test instrument adapter/DSO (3-pin) - VAS 5570-
♦ Pressure sensor tester - VAS 6394-

Procedure
WARNING

cause injury.

Audi A1 2011 ➤
Caution

– Remove fuel pressure sender - G247- ⇒ page 219 .

– Lubricate taper seal of adapter -VAS 6394/3- with clean en‐
gine oil and screw into fuel rail (22 Nm).
– Unscrew plug -2- and screw fuel pressure sender - G247- into
tester -VAS 6394/1- .
– Connect pressure line -1- of tester to adapter - VAS 6394/3- .
– Connect vehicle and fuel pressure sender - G247- -item 1-

electrically using test instrument adapter/DSO (3-pin) - VAS
5570- .

Audi A1 2011 ➤
– Switch on tester -VAS 6394/1- by pressing button -A- once

briefly.
Note
♦ You can press and hold button -A- for 2 seconds to switch on
the illumination for 20 seconds.
♦ If tester -VAS 6394/1- does not indicate 0 bar, zero the tester
⇒ Operating instructions .
– Connect a vehicle diagnostic tester .

– Start engine and run at idling speed.
– Select “Engine electronics” in vehicle self-diagnosis.
– Then select “Measured values”.
– Select “Fuel pressure” from the list.
– Compare fuel pressure indicated on tester -VAS 6394/1- with
actual value displayed on vehicle diagnostic tester .
– Observe fuel pressure displayed on vehicle diagnostic tester.
• The pressure readings must not deviate by more than 5 bar.
– If deviation is more than 5 bar, renew fuel pressure sender -
G247- .
– Repeat the test with the new fuel pressure sender - G247- and
compare the two pressure values.
– If measured values are now the same, install new fuel pres‐
sure sender - G247- .
– If measured values are not the same again, check electrical
connection between fuel pressure sender - G247- and engine
control unit - J623- ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
5.3 Removing and installing intake air tem‐

perature sender - G42- / intake manifold
pressure sender - G71-
Removing
rier.

Audi A1 2011 ➤
– Remove water drain pipe -1- by turning it slightly in direction

of -arrow A- and detaching it downwards -arrow B-.

Version A:
– Release catches -arrows- and
Protected by detach
copyright. intake
Copying air ortemperature
for private commercial purposes, in part or in whole, is not
sender - G42- / intake manifold pressure sender - G71- .
Version B:
– Unscrew bolts -2- and detach intake air temperature sender -
G42- / intake manifold pressure sender - G71- .
Installing
Note

♦ If fasteners on intake manifold have broken off, secure intake
air temperature sender - G42- / intake manifold pressure send‐
er - G71- with bolts -2-; for bolts, refer to ⇒ Electronic parts
catalogue .
Tightening torques

Audi A1 2011 ➤
6 High-pressure pump
⇒ “6.1 Exploded view - high-pressure pump”, page 224
⇒ “6.2 Removing and installing high-pressure pump”, page 225
⇒ “6.3 Removing and installing high-pressure pipe”, page 227
6.1 Exploded view - high-pressure pump
1 - Fuel supply hose

2 - Electrical connector
3 - High-pressure pump
❑ With fuel metering valve
- N290-
❑ Do not dismantle
⇒ page 225
4 - Roller tappet
❑ When installing lubri‐
cate lightly with clean
engine oil
5 - O-ring
❑ When installing lubri‐
cate lightly with clean
engine oil
6 - High-pressure pipe
WARNING
Risk of injury - fuel sys‐
tem operates under high
pressure.
The
♦ fuel pressure in the Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
high-pressure section of permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
the injection system must

be reduced to a residual
pressure prior to opening
the system ⇒ page 200 .

⇒ page 227
❑ Check for damage be‐
fore re-installing
❑ Do not alter shape
❑ Connections must not be damaged
❑ Lubricate threads of union nuts with clean engine oil
❑ 25 Nm
7 - Bolt

Audi A1 2011 ➤
High-pressure pump - tightening torque and sequence
Note

angle.
To prevent flange of high-pressure pump from being deformed

during installation, fit high-pressure pump as follows:
1. -1, 4- Screw in by hand until contact is made
2. -1, 4- Tighten one turn alternately until
flange of high-pressure pump makes
contact with camshaft housing
3. -1, 4- 20 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4. -1, 4- Turn 90° further
6.2 Removing and installing high-pressure

pump
♦ Spring type clip pliers - VAS 6922-
Removing
• Engine cold.
WARNING

cause injury.
Caution


6. High-pressure pump 225

Audi A1 2011 ➤
Note
– Release hose clip -2- and detach fuel supply hose.

– Unscrew bolts -1, 4- and detach high-pressure pump and roller
tappet.
Installing
Note
– Check roller tappet for damage and renew if necessary.

– Lubricate roller tappet -1- lightly with clean engine oil.
– Insert lubricated roller tappet -1- into camshaft housing.
– Turn crankshaft in direction of engine rotation until roller tappet
is positioned at lowest point.
– Insert a new, oiled O-ring -2- into groove on high-pressure
pump -3-.
– Tighten bolts hand tight in small steps.
• Final tightening torque for bolts ⇒ page 225
– Then initially tighten bolts alternately to 5 Nm (do not tilt high-
pressure pump).
Note
♦ The high-pressure pump can be damaged if it is tightened too

much on one side (keep it straight).

– Check fuel system for leaks.
Tightening torques
♦ ⇒ Fig. ““High-pressure pump - tightening torque and se‐
quence”“ , page 225

Audi A1 2011 ➤
6.3 Removing and installing high-pressure

pipe
Removing
rier.
– Remove water drain pipe -1- by turning it slightly in direction

of -arrow A- and detaching it downwards -arrow B-.
WARNING

cause injury.
prior to opening the system
⇒ “1.2 Reducing fuel pressure in high-pressure section”,
page 200 .
Caution

6. High-pressure pump 227

Audi A1 2011 ➤
Note
– Unscrew union nuts -arrows- and detach high-pressure pipe.

Installing
Note
– Lubricate threads of union nuts with clean engine oil.

– Hand-tighten union nuts for high-pressure pipe (make sure
that pipe is not under tension).
– Tighten union nuts.
Tightening torques
♦ ⇒ “6.1 Exploded view - high-pressure pump”, page 224

Audi A1 2011 ➤
7 Lambda probe
⇒ “7.1 Exploded view - Lambda probe”, page 229
⇒ “7.2 Removing and installing Lambda probe”, page 230
7.1 Exploded view - Lambda probe
Note
♦ New Lambda probes are coated with an assembly paste. The

paste must not get into the slots on the Lambda probe body.
♦ In the case of a used Lambda probe grease only the thread
with high-temperature paste. The paste must not get into the
slots on the Lambda probe body. High-temperature paste ⇒
Electronic parts catalogue
♦ The electrical wiring of the lambda probe must be secured at
the original locations when installing. The wiring must NOT
come into contact with the exhaust pipe.
1 - Lambda probe after catalyt‐

ic converter - G130- with
Lambda probe 1 heater after
catalytic converter - Z29-
⇒ page 230
❑ 55 Nm
❑ For Lambda probe -
G39- with Lambda
probe heater - Z19-
❑ For Lambda probe after
catalytic converter -
G130- with Lambda
probe 1 heater after cat‐
alytic converter - Z29-
4 - Lambda probe - G39- with
⇒ page 230
❑ 55 Nm
7. Lambda probe 229

Audi A1 2011 ➤
7.2 Removing and installing Lambda probe

♦ Lambda probe open ring spanner set - 3337-
Removing
– Unplug corresponding electrical connector:
1- For Lambda probe - G39- and Lambda probe heater - Z19-
2- For Lambda probe after catalytic converter - G130- and
– Unscrew corresponding Lambda probe using a tool from

Lambda probe open ring spanner set - 3337- .
1- Lambda probe after catalytic converter - G130-
2- Lambda probe - G39-

Installing
Note
♦ New Lambda probes are coated with an assembly paste. The

paste must not get into the slots on the Lambda probe body.
♦ In the case of a used Lambda probe grease only the thread
with high-temperature paste. The paste must not get into the
slots on the Lambda probe body. High-temperature paste ⇒
Electronic parts catalogue
Tightening torques
♦ ⇒ “7.1 Exploded view - Lambda probe”, page 229

Audi A1 2011 ➤
8 Engine control unit

⇒ “8.1 Removing and installing engine control unit J623 ”,
page 231
8.1 Removing and installing engine control

unit - J623-
Note
♦ Not every engine control unit is bolted to a protective housing.

Whether a protective housing is fitted depends on the engine/
gearbox combination.
♦ The engine control unit -1- is bolted to the protective
permitted housing
-5-. To make it more difficult to unscrew thewith
shear bolts
respect to the-3- and of information in this document. Copyright by AUDI AG.
correctness
-4- for locking plate -2-, their threads have been coated with
locking fluid.
♦ The protective housing has to be removed before the connec‐
tors can be unplugged from the engine control unit (e.g. to
connect the test box or renew the engine control unit).

♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle attach‐
ment -2- from wiring harness repair set - VAS 1978 B-

♦ Vice-grip pliers (commercially available)
Removing
– If engine control unit is to be renewed, select test sequence/
function “Replace engine control unit” in “Guided Functions”
mode ⇒ Vehicle diagnostic tester.
– Switch off ignition and take out ignition key.
– Release catch -arrow- and detach engine control unit - J623-
-item 1- from bracket.
8. Engine control unit 231

Audi A1 2011 ➤
Note
♦ The threads of the two shear bolts -4- which are not screwed
into the engine control unit -1- are secured with locking fluid.
To unscrew these two bolts, the threads must therefore be
heated with the hot air blower.
♦ The threads of the two shear bolts -3- which are screwed into
the engine control unit are not secured with locking fluid. Do
not apply heat to the threads in the control unit housing; this
is not necessary and would cause overheating of the control
unit.
Caution
Wiring, connectors, insulation and control units can be burnt

and damaged.
♦ Keep exactly to by
the following procedure. Observe operat‐
permitted unless authorised AUDI AG. AUDI AG does not guarantee or accept any liability
ingrespect
with instructions for hot
to the correctness air blower.
– Select settings on hot air blower -4- as shown in illustration:

2 - Temperature potentiometer to maximum heat output
3 - Two-stage air flow switch to position “3”
Note
♦ Then use hot air blower to heat threaded holes in protective

housing into which shear bolts have been screwed. This re‐
duces the inhibiting action of the locking fluid on the shear bolt
threads and makes it easier to unscrew these bolts.
♦ Cover up all painted parts to avoid any damage caused by hot
air blower or vice-grip pliers.
WARNING
Risk of burns.
♦ Parts of the metal locking plate will become very hot as a
result of heating the shear bolts. Try to ensure that only
the thread is heated and none of the nearby components.
These should be covered if necessary.
– Connect nozzle attachment to hot air blower - VAS 1978/14A- .

– Hold nozzle attachment on hot air blower close to shear bolt
on protective housing.
– Switch on hot air blower and heat bolt for 20 ... 25 seconds.

Audi A1 2011 ➤
– Then grasp bolt head with vice-grip pliers and unscrew shear
bolt.
– Repeat procedure for second shear bolt.
– Detach protective housing from multi-pin connectors.
– Unscrew the two shear bolts screwed into the engine control
unit (they do not need to be heated).
Installing
Note
Renew the shear bolts.
– Re-install protective housing on engine control unit.

– Use thread tap or similar to remove remnants of locking fluid
from tapped holes for shear bolts.
– If engine control unit is to be renewed, select test sequence/
function “Replace engine control unit” in “Guided Functions”
mode ⇒ Vehicle diagnostic tester.
8. Engine control unit 233

Audi A1 2011 ➤
26 – Exhaust system
1 Exhaust pipes/silencers
⇒ “1.1 Exploded view - silencers”, page 234
⇒ “1.2 Separating exhaust pipes/silencers”, page 235
⇒ “1.3 Removing and installing silencers”, page 236
⇒ “1.4 Stress-free alignment of exhaust system”, page 237
⇒ “1.5 Checking exhaust system for leaks”, page 238
1.1 Exploded view - silencers
1 - Rear silencer Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Combined in one unit with respect to the correctness of information in this document. Copyright by AUDI AG.
with centre silencer as
original equipment. Can
be renewed individually
for repair purposes
⇒ page 236
❑ Disconnecting exhaust
pipes/silencers
⇒ page 235
❑ Align exhaust system so
it is free of stress
⇒ page 237
2 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes
⇒ page 236
❑ Disconnecting exhaust
pipes/silencers
⇒ page 235
⇒ page 237
3 - Rubber mounting
4 - Bolt
❑ 23 Nm
5 - Clamp (rear)
❑ Before tightening, align
exhaust system so it is free of stress ⇒ page 237
❑ Tighten bolted connections evenly
6 - Nut
❑ 23 Nm
7 - Mounting
234 Rep. gr.26 - Exhaust system

Audi A1 2011 ➤
8 - Bolt
❑ 23 Nm
9 - Trim
❑ For tailpipe
❑ Slide onto tailpipe as far as stop
Installation position of rear clamp

– Fit clamp in position shown.
• Angle -α- = approx. 20°
• Bolt connections face to rear.
• Nuts facing upwards
1.2 Separating exhaust pipes/silencers

♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.
♦ The cutting point is marked by an indentation on the circum‐
ference of the exhaust pipe.
♦ Chain pipe cutter - VAS 6254-
Procedure Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Cut through exhaust pipe at right angles at the position marked
-arrow 2- using chain pipe cutter - VAS 6254- .

– Position clamp centrally at side marks -arrows 1, 3- when in‐
stalling.
– Fit rear clamp ⇒ page 235 .
– Align the exhaust system so it is free of stress ⇒ page 237 .
1. Exhaust pipes/silencers 235

Audi A1 2011 ➤
1.3 Removing and installing silencers

Removing centre silencer
– Remove tunnel cross-piece (rear) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody trim; Exploded view - un‐
derbody trim .
– Vehicles without connection point: separate exhaust pipes/si‐
lencers ⇒ page 235 .
– Vehicles with connection point: release clamp -arrows- and
push to right side.
– Loosen clamp -arrow- and push towards rear.
– Remove bolt -2- and detach centre silencer.
Removing rear silencer

– Press coupling rod of rear left vehicle level sender -G76- off
ball stud -2- -arrow-.

Audi A1 2011 ➤
– Remove bolt -1- and press bracket -2- with rear left vehicle
level sender - G76- to one side.
– Vehicles without connection point: separate exhaust pipes/si‐

lencers ⇒ page 235 .
– Vehicles with connection point: release clamp -arrows- and
push to right side.
– Unscrew bolts -1- and detach rear silencer -2-.

Installing
Tightening torques
♦ ⇒ “1.1 Exploded view - silencers”, page 234
♦ ⇒ “2.1 Exploded view - emission control system”, page 239
♦ ⇒ Running gear, axles, steering; Rep. gr. 43 ; Vehicle level
sender; Exploded view - rear vehicle level sender
♦ Tunnel cross-piece ⇒ General body repairs, exterior; Rep. gr.
66 ; Underbody trim; Exploded view - underbody trim
1.4 Stress-free alignment of exhaust system

Procedure
• The exhaust system must be aligned when it is cool.
Note
The -arrow- points in direction of travel.
1. Exhaust pipes/silencers 237

Audi A1 2011 ➤
– Loosen bolt connections on front clamp.

– Push exhaust system towards front of vehicle until preloading
at mounting for rear silencer -a- = 15 ... 17 mm.
– Fit front clamp ⇒ page 240 .
Aligning tailpipes
– Adjust rear silencer so that there is an even distance between
bumper cut-out and tailpipes.
• -x- = -x-
– Unfasten rear silencer mounting to align tailpipes.
Tightening torques
1.5 Checking exhaust system for leaks

Procedure Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Start the engine and run at idling speed.
– Plug tailpipes during leak test (e.g. with cloth or plug).
– Listen for noise at the connection points of cylinder head/ex‐
haust manifold, turbocharger/front exhaust pipe etc. to locate
any leaks.
– Rectify any leaks that are found.

Audi A1 2011 ➤
2 Emission control system

⇒ “2.1 Exploded view - emission control system”, page 239
⇒ “2.2 Removing and installing catalytic converter”, page 240
2.1 Exploded view - emission control system
1 - Rubber mounting
2 - Front exhaust pipe with cat‐
alytic converter
❑ Do not bend flexible joint
more than 10° - other‐
wise it can be damaged Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Install flexible joint so with respect to the correctness of information in this document. Copyright by AUDI AG.
that it is not under ten‐
sion.
❑ Take care not to dam‐
age wire mesh on flexi‐
ble joint.
❑ Protect catalytic con‐
verter from damage by
knocks and impact
⇒ page 240
❑ Do not remove protec‐
tive packaging from re‐
placement part until you
are ready to fit the flexi‐
ble joint
⇒ page 237
3 - Bracket
4 - Bolt
❑ 20 Nm
5 - Nut
6 - Bracket
7 - Screw-type clip
8 - Seal
9 - Turbocharger
10 - Nut
11 - Rubber mounting
12 - Clamp (front)
❑ Before tightening, align exhaust system so it is free of stress ⇒ page 237
2. Emission control system 239

Audi A1 2011 ➤
❑ Tighten bolted connections evenly

13 - Nut
❑ 30 Nm
Installation position of front clamp

– Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp -arrow-.
• Bolted connection facing towards right
– Tighten bolted connections evenly
Installing catalytic converter - tightening torque and sequence

1. – Fit catalytic converter to tur‐
bocharger, attach screw-type
clip -arrow- without tightening
2. – Fit nuts -1, 2, 3- by hand with‐ • It must still be pos‐
out tightening sible to move cata‐
lytic converter and
bracket
3. – Tighten screw-type clip 15 Nm

-arrow-
4. – Tighten nuts in the sequence 20 Nm
-1, 2, 3-
2.2 Removing and installing catalytic con‐

verter
Note
The catalytic converter is removed together with the front exhaust

pipe.

Protectedequipment required
♦ High-temperature paste ⇒ Electronic
with respect parts
to the correctness catalogue
Removing
Note
Reinstall all cable ties in the same locations when installing.

Audi A1 2011 ➤
– Detach electrical connectors -1, 2- from bracket, unplug con‐

nectors and move electrical wiring clear.
alytic converter.
– Remove nuts -arrows-.
insulation .
– Detach catalytic converter with front exhaust pipe from rubber

mountings -arrows-.
2. Emission control system 241

Audi A1 2011 ➤
– Loosen clamp -arrow- and push towards rear.

– Detach catalytic converter with front exhaust pipe.
Installing
Note
♦ Renew gasket and self-locking nuts after removal.

♦ Lubricate exhaust manifold studs with high-temperature
paste; for high-temperature paste refer to ⇒ Electronic parts
catalogue .

Tightening torques
♦ ⇒ Fig. ““Installing catalytic converter - tightening torque and

Audi A1 2011 ➤
28 – Ignition system
1 Ignition system
⇒ “1.1 Exploded view - ignition system”, page 243
⇒ “1.2 Test data, spark plugs”, page 244
⇒ “1.3 Removing and installing ignition coils with output stages”,
page 244
⇒ “1.4 Removing and installing knock sensor 1 G61 ”,
page 247
⇒ “1.5 Removing and installing Hall senders”, page 248
⇒ “1.6 Removing and installing engine speed sender G28 ”, page
248
1.1 Exploded view - ignition system
1 - Spark plug
❑ Remove and install with
spark plug socket and
extension - 3122 B-
let 819
❑ Change interval ⇒
Maintenance tables
let 819
2 - Ignition coil with output
stage
♦ Ignition coilpermitted
1 withunless
output
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
stage - N70- with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Ignition coil 2 with output
stage - N127-
♦ Ignition coil 3 with output
stage - N291-
⇒ page 244
3 - Bolt
❑ 8 Nm
4 - Knock sensor 1 - G61-
⇒ page 247
5 - Bolt
❑ Tightening torque influ‐
ences the function of the
knock sensor
❑ 20 Nm
6 - Hall sender 2 - G163-
❑ Camshaft position sensor
7 - Bolt
❑ 8 Nm
1. Ignition system 243

Audi A1 2011 ➤
8 - O-ring
9 - Bolt
❑ 8 Nm
10 - Hall sender - G40-
❑ Camshaft position sensor
11 - O-ring
12 - Sealing flange (gearbox end)
13 - Sender wheel
❑ For engine speed sender - G28-
❑ Removing and installing ⇒ “2.3 Removing and installing sealing flange (gearbox end)”, page 51
14 - Engine speed sender - G28-
❑ Note installation position ⇒ page 250
15 - Bolt
❑ 4.5 Nm
1.2 Test data, spark plugs

Engine data 1.0 ltr. TFSI engine
Idling speed 640 ... 800 rpm
is not adjustable; controlled by the idling speed stabili‐
sation
Engine speed limiter (deactivates injectors/closes throt‐ approx. 6500 rpm
tle valve)
Ignition timing is determined by the control unit. Ignition
timing cannot be adjusted.
Ignition system Multi-coil system with 3 ignition coils (output stages
integrated) connected directly to spark plugs via
spark plug connectors
Spark plugs Designations ⇒ Electronic parts catalogue
Tightening torque ⇒ Maintenance ; Booklet 819
Firing order 1-2-3
1.3 Removing and installing ignition coils

with output stages

244 Rep. gr.28 - Ignition system

Audi A1 2011 ➤
♦ Puller - T10530-
Removing
Ignition coils (cylinders 2 and 3):
Ignition coil (cylinder 1 only):
electrical wiring.
pipe.
All ignition coils (continued):


Audi A1 2011 ➤
– Press puller - T10530- into hole in ignition coil -1- as far as

stop.
– Tighten knurled nut -2- in direction of -arrow-.
– Pull ignition coil out of camshaft housing with puller - T10530-

in direction of -arrow-.
Installing
Note

– Push spark plug with
connector -1- onto ignition coil by hand as far
as stop.
• Vent channel -2- must be positioned so that it is aligned cen‐
trally with connector housing -3-.
– Fit all ignition coils loosely into spark plug holes.
– Align ignition coils with connectors and attach all connectors
onto ignition coils simultaneously.
– Press ignition coils onto spark plugs by hand evenly (do not
use tool).
Tightening torques
♦ ⇒ “1.1 Exploded view - ignition system”, page 243

Audi A1 2011 ➤
1.4 Removing and installing knock sensor 1

- G61-
Removing
Note

stalling. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
insulation .
– Remove bolts -1- and nuts -2, 3- and detach bracket -4- for
catalytic converter.
– Remove bolts -arrows- and detach heat shield -1-.
– Detach heat shield sleeve.

– Unscrew bolt -2- and remove knock sensor 1 - G61- .

Audi A1 2011 ➤
Installing
– Move bracket for catalytic converter into installation position.
– Hand-tighten bolts -1- and nuts -2, 3- until they make contact.
– Tighten bolted connections for bracket -4- ⇒ page 239 .
Tightening torques
1.5 Removing and installing Hall senders

Removing
Hall sender - G40- :
– Unscrew bolt -2- and remove Hall sender - G40- .
Hall sender 2 - G163- :
– Unscrew bolt -4- and remove Hall sender 2 - G163- .
Installing
Note
Tightening torques
1.6 Removing and installing engine speed

sender - G28-
♦ Socket, AF 4 mm - T10370-

Audi A1 2011 ➤
Removing
insulation .
– Remove bolt -2- and press continued coolant circulation pump
- V51- to side.
Note
Disregard -item 3-.
– Release and unplug electrical connector -1-.
– Unscrew bolt -arrow- using socket, AF 4 mm - T10370- and

detach engine speed sender - G28- -item 1-.

Audi A1 2011 ➤
Installing
– Move engine speed sender - G28- into installation position,
ensuring that tab -3- slides into guide slot on sealing flange
-4-, as shown in illustration.
– Tighten bolt -2- and plug in electrical connector -1-.
Tightening torques

CHZE-CHZB-DDHA - 3-Cylinder Direct Petrol Injection Engine (1 0 LTR 4-Valve TFSI EA211)

Uploaded by

Copyright:

Available Formats

CHZE-CHZB-DDHA - 3-Cylinder Direct Petrol Injection Engine (1 0 LTR 4-Valve TFSI EA211)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

CHZE-CHZB-DDHA - 3-Cylinder Direct Petrol Injection Engine (1 0 LTR 4-Valve TFSI EA211)

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

All rights reserved.

Copyright © 2015 Audi AG, Ingolstadt D4B804C90D8

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

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

24 - Mixture preparation - injection . . . . .Protected

8 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

1.1 Engine identification number/engine da‐

♦ The 4-character engine code can be found on the type plate

Code letters CHZB CHZE DDHA

2 Rep. gr.00 - Technical data

2.1 Safety precautions when working on the

The fuel system operates at extremely high pressure. This can

Observe the following to prevent injuries to persons and damage

To prevent irreparable damage to the electronic components

Escaping fuel can cause a risk.

2.2 Safety precautions when working on ve‐

Risk of injury due to automatic engine start on vehicles with

2.3 Safety precautions when using testers

Accidents can be caused if the driver is distracted by test

4 Rep. gr.00 - Technical data

2.4 Safety precautions when working on the

Hot steam/hot coolant can escape - risk of scalding.

Overheating can occur if the filler cap is not fitted properly.

2.5 Safety precautions when working on the

To prevent irreparable damage to the electronic components

6 Rep. gr.00 - Technical data

3.1 Rules for cleanliness

♦ Only install clean components; replacement parts should only

3.2 General notes

3.3 General repair instructions

3.4 Foreign particles in engine

If the turbocharger has suffered mechanical damage

3.5 Contact corrosion

3.6 Routing and attachment of pipes, hoses

8 Rep. gr.00 - Technical data

♦ To prevent damaging pipes, hoses and wiring, ensure suffi‐

3.7 Installing radiators and condensers

3.8 Checking vacuum system

10 – Removing and installing engine

1.1 Removing engine

Special tools and workshop

♦ Engine bung set - VAS

10 Rep. gr.10 - Removing and installing engine

♦ Extension -2024A/1- for lifting tackle - 2024A-

♦ Locking pin - T10060A-

♦ Engine support - T10483-

♦ The engine is removed from underneath together with the

1. Removing and installing engine 11

The fuel system operates at extremely high pressure. This can

Hot steam/hot coolant can escape - risk of scalding.

– Open filler cap -1- on coolant expansion tank.

– Place coolant collecting system -VAS 5014- or drip tray for

12 Rep. gr.10 - Removing and installing engine

– Release hose clips -1 and 2-, disconnect coolant hoses (bot‐

Disregard -item 1-.