Service: Audi TT 2007

Service
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
Workshop Manual
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Fuel supply system, diesel engines
Engine ID
CBB CFG
B B
Edition 06.2010
Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A005TT02320

Audi TT 2007 ➤
Fuel supply system, diesel engines - Edition 06.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Using testers and measuring instruments during a road test . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Removing and installing components from a full or partly full fuel tank . . . . . . . . . . . . . . . . 2
1.5 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Rules for cleanliness when working on fuel supply system and injection system . . . . . . . . 3
2.2 Test conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Fuel tank with attached components - vehicles with four-wheel drive . . . . . . . . . . . . . . . . 5
1.1 Fuel tank with attached components - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 8
2 Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive . . . . . . . . . . . . 14
2.1 Fuel delivery unit and fuel gauge senders - exploded view . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Fuel system pressurisation pump G6 - electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 Checking fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.6 Checking fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.7 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.8 Suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.9 Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3 Supplementary fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1 Supplementary fuel pump V393 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2 Removing and installing supplementary fuel pump V393 . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.1 Fuel filter - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2 Removing and installing fuel filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5 Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7 Accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.1 Accelerator pedal module - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.2 Removing and installing accelerator pedal module with accelerator position senders . . . . 45
Contents i
Audi TT 2007 ➤
ii Contents
Audi TT 2007 ➤
00 – Technical data
1 Safety precautions
Overview
♦ ⇒ “1.1 Working on the fuel system”, page 1
♦ ⇒ “1.2 Using testers and measuring instruments during a road
test”, page 2
♦ ⇒ “1.3 Working on vehicles with start/stop system”,
page 2
♦ ⇒ “1.4 Removing and installing components from a full or partly
full fuel tank”, page 2
♦ ⇒ “1.5 Removing and installing fuel tank”, page 2
1.1 Working on the fuel system

When working on the fuel system note the following warnings:
WARNING
Risk of injury - fuel system operates under pressure.

♦ Wrap a cloth around the connection before opening the
fuel system. Then release pressure by carefully loosening
the connection.
The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
Observe the following points to prevent personal injuries and

damage to the injection and glow plug system:
♦ Always switch off the ignition before connecting or discon‐
necting tester cables or electrical wiring for the injection or
glow plug system.
♦ Always switch off ignition before washing engine.
♦ Faults are stored in the engine control units if electrical con‐
nectors were unplugged and the engine was started: Inter-
rogate event memory in Guided Functions ⇒ Vehicle
diagnostic tester .
Caution
To prevent damage to the electronic components when dis‐

connecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery.
Disconnect battery ⇒ Electrical system; Rep. Gr. 27 .
1. Safety precautions 1
Audi TT 2007 ➤
1.2 Using testers and measuring instru‐

ments 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.
1.3 Working on vehicles with start/stop sys‐

tem
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 when performing repairs (switch off
ignition, if required switch on ignition again).
1.4 Removing and installing components

from a full or partly full fuel tank
When removing and installing components
with respect to from a full or
the correctness partly full
of information in this document. Copyright by AUDI AG.
fuel tank, note the following:
♦ Fuel tank must not be full. The amount of fuel which can be
left in the fuel tank is indicated in the corresponding procedure
description. Drain fuel tank if necessary ⇒ page 6 .
♦ Before commencing work, switch on exhaust extraction sys‐
tem and place an extraction hose close to the sender opening
in the fuel tank to extract escaping petrol fumes. If no exhaust
extraction system is available, a radial fan with a displacement
of at least 15 m3/h can be used (the fan motor must be clear
of the air stream).
♦ Avoid skin contact with fuel. Wear fuel-resistant gloves.
1.5 Removing and installing fuel tank

♦ Fuel tank must be empty to reduce weight. Drain fuel tank if
necessary ⇒ page 6 .
2 Rep. Gr.00 - Technical data

Audi TT 2007 ➤
2 General repair instructions

Overview
♦ ⇒ “2.1 Rules for cleanliness when working on fuel supply sys‐
tem and injection system”, page 3
♦ ⇒ “2.2 Test conditions”, page 3
♦ ⇒ “2.3 Contact corrosion!”, page 3
2.1 Rules for cleanliness when working on

fuel supply system and injection system
Even small amounts of dirt can cause malfunctions. For this rea‐
son, please observe the following rules when working on the fuel
supply system and injection system:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal off open pipes/lines and connections immediately with
clean plugs, e.g. from engine bung set -VAS 6122- .
♦ Place parts that have been removed on a clean surface and
cover them over. Use only lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have not been stored in their packing (e.g. in tool boxes
etc.).
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
2.2 Test conditions

• Battery voltage at least 12.5 V
• Fuel pump fuse OK ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
• Fuel pump relay -J17- OK ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.
• Fuel pump control unit -J538- Ok; checking in Guided Fault
Finding ⇒ vehicle diagnostic tester .
• Fuel tank at least 1/4 full.

• Fuel filter OK.
• Fuel lines OK (not obstructed
permitted or crushed).
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2.3 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.
2. General repair instructions 3

Audi TT 2007 ➤
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.

Audi TT 2007 ➤
20 – Fuel supply system

1 Fuel tank with attached components
- vehicles with four-wheel drive
⇒ “1.1 Fuel tank with attached components - exploded view”, page
5
⇒ “1.2 Draining fuel tank”, page 6
⇒ “1.3 Removing and installing fuel tank with attached compo‐
nents”, page 8
1.1 Fuel tank with attached components - exploded view
1 - Nut
❑ 23 Nm
2 - Heat shield for fuel tank
❑ With support bracket
3 - Fuel return line
❑ Blue
❑ From fuel filter
❑ Do not kink
❑ Clip onto fuel tank
4 - Fuel supply line
❑ Black
❑ To fuel filter
❑ Do not kink
❑ Clip onto fuel tank
5 - Electrical connector
❑ For fuel system pressur‐
isation pump -G6- and
fuel gauge sender -G-
6 - Protective plate
❑ For fuel filler neck
7 - Filler cap
❑ Secured to tank flap unit
8 - Earth connection
❑ To eliminate electrostat‐
ic charge
❑ Installation position
⇒ page 6
❑ Make sure that connec‐
tor is securely fitted
❑ After installation, use an
ohmmeter to check the electrical connection between the protective plate -item 6- on the fuel filler neck
and a bare metal part on the body. Specification:
Protectedapprox. 0Copying
by copyright. Ω for private or commercial purposes, in part or in whole, is not
9 - Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 11 Nm
1. Fuel tank with attached components - vehicles with four-wheel drive 5

Audi TT 2007 ➤
10 - Pop rivet
11 - Fuel tank
❑ Removing and installing ⇒ page 8
❑ For fuel gauge sender 2 -G169-
13 - Securing strap
❑ Installation position: Fixing point (hole) points in direction of travel
Earth connection for fuel filler neck and protective plate

– The connections -2- and -4- on filler neck must be free from
corrosion to ensure earth connection to body is not impaired.
– Position the earth connection as illustrated -1-.
– Ensure that connectors -arrows- for earth connection are prop‐
erly seated on protective plate -5- and on fuel filler neck -3-.
WARNING
Risk of explosion caused by electrostatic discharge.

♦ After installation, use an ohmmeter to check the electrical
connection between the metal ring on the fuel filler neck
and a bare metal part on the body:
• Specification: approx. 0 Ω
1.2 Draining fuel tank

Special tools and workshop equipment required
♦ Wrench -T10202-
♦ Fuel extractor -VAS 5190-
6 Rep. Gr.20 - Fuel supply system

Audi TT 2007 ➤
Procedure
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .
– Release the tank flap.
– Detach tapered adapter -2- from shaft end -1- of fuel extractor
-VAS 5190- .
– Use insulating tape to mark the extraction hose -arrow- at a
distance of -a- = 1,370 mm from the end of the hose.
– Remove filler cap from fuel filler neck.

– Screw shaft end of fuel extractor -VAS 5190- onto fuel filler
neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
Note
♦ The procedure when using a fuel extractor without shaft end

is basically the same.
♦ In this case, make a mark -arrow- on the extraction hose at
distance -a- = 1,305 mm from the end of the hose using insu‐
lating tape. The extraction hose has been properly inserted
when the affixed mark is level with the edge of the filler neck.
♦ If hose is difficult to insert, apply a thin coat of engine oil. DO
NOT use silicone-based lubricant.
– Drain fuel tank as much as possible through fuel filler neck.

– Carefully remove extraction hose.
TT Coupé:
– Remove rear seat bench ⇒ Rep. Gr. 72 .
TT Roadster:
– Remove back panel side trim (left-side) ⇒ Rep. Gr. 70 .
All vehicles (continued):

– Unclip the retaining tabs -arrows- for the flange cover (left-
side).

Audi TT 2007 ➤
– Unplug electrical connector -1- at flange.

– Disengage electrical connector -2- and move it clear to the
side.
– Unscrew locking ring using wrench -T10202- .
– Carefully pull fuel gauge sender 2 -G169- -item 1- with suction-

jet pump just slightly out of aperture in fuel tank.
Note
When removing, make sure you do not bend float arm of fuel
gauge sender 2 -G169- .
– Extract fuel from left fuel tank chamber through fuel tank open‐
ing using fuel extractor -VAS 5190- .
– Push hose into right-hand chamber of fuel tank and extract
remaining fuel.
– Re-install fuel gauge sender 2 -G169- ⇒ page 29 ; observe
notes on procedure for connecting battery.
1.3 Removing and installing fuel tank with

attached components
♦ Engine and gearbox jack -V.A.G 1383 A-

Audi TT 2007 ➤
♦ Hook -3004-
Removing
– Release the tank flap.
WARNING
Risk of accident caused by weight of fuel tank

♦ Fuel tank must be empty when it is removed.
– Drain fuel tank ⇒ page 6 .

TT Coupé:
– Remove rear seat bench ⇒ Rep. Gr.by72
Protected .
copyright. Copying for private or commercial purposes, in part or in whole, is not
TT Roadster: with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove back panel trim (right and left) ⇒ Rep. Gr. 70 .

– Unclip the retaining tabs -arrows- for the flange cover (right-
side).
– Unplug electrical connector -arrow- at flange.

Audi TT 2007 ➤
side).

– Unplug electrical connector -2- for Haldex coupling.
– Clean area around fuel filler neck.

– Remove filler cap -arrow- from fuel filler neck.
– Seal opening of fuel filler neck with a piece of clean foam or
similar to prevent dirt from dropping into the tank.
– Remove rear right wheel housing liner ⇒ Rep. Gr. 66 .

– Detach electrical wire -1- for ABS speed sensor from bracket
on fuel filler neck.
– Remove bolts -2- and -3- for fuel filler neck.
– Move overflow hose -4- on fuel filler neck clear.
TT Roadster:
– Remove diagonal struts ⇒ Rep. Gr. 42 .

Audi TT 2007 ➤
Caution
Risk of damage to flexible joints in front exhaust pipe

♦ The flexible joints in the front exhaust pipe must not be
bent more than 10°.
♦ Before slackening clamp on exhaust pipe, secure front
section of exhaust system to underbody of vehicle with a
chain.
– Separate exhaust system at clamp -arrows-.
– Secure front section of exhaust system with a chain. To do so,

engage hooks -3004- into openings on underside of vehicle
(remove plugs if fitted).
– Push the clamp back in order to separate the exhaust system.
Note
A second person will be required for detaching rear section of

exhaust system.
– Disengage rear silencer at the rubber mountings and remove

rear section of exhaust system.
– Remove propshaft ⇒ Rear final drive 02D/0AV; Rep. Gr. 39 .
WARNING
Risk of injury - fuelpermitted
system operates
unless authorisedunder
by AUDI pressure.
AG. AUDI AG does not guarantee or accept any liability
♦ Wrap a clean cloth around the connection before opening
the fuel system. Then release pressure by carefully loos‐
ening the connection.
– Press release tab and disconnect fuel supply pipe -1- and re‐
turn pipe -2- at front right of fuel tank.

Audi TT 2007 ➤
WARNING
Risk of accident caused by weight of fuel tank

♦ Fuel tank must be empty when it is removed.
– First remove bolts -2, 5, 6-.

– If fitted, unhook wiring harness -arrows- and move it clear.
– Position engine and gearbox jack -V.A.G 1383 A- below vehi‐
cle to support tank.
– Remove bolts -1, 3, 4, and 7-.
– Then lower fuel tank using engine and gearbox jack -V.A.G
1383 A- , simultaneously guiding fuel tank down by hand.
– Remove fuel tank downwards (turning it sideways as re‐
quired).
– In addition, a 2nd mechanic will be required to guide the fuel
filler neck on trailing arm out by hand.
Installing
• Tightening torques ⇒ page 5
Installation is carried out in the reverse order; note the following:
– Position fuel tank with securing straps on underbody, using
engine and gearbox jack -V.A.G 1383 A- .
– Attach wiring harness at top of fuel tank.
– When installing fuel tank, make sure that the fuel filler neck is
correctly inserted into the opening on the body.
– Secure fuel tank by first tightening bolts at points -1, 3, 4, 7-,

then at points -2, 5, 6-.

Audi TT 2007 ➤
– The connections -2- and -4- on filler neck must be free from
corrosion to ensure earth connection to body is not impaired.
– Tighten bolts -2- and -4- for fuel filler neck.
– Check the earth wiring at both ends for traces of oxidation and
remove oxidation if necessary.
– Position the earth connection as illustrated -1-.
– Ensure that connectors -arrows- for earth connection are prop‐
erly seated on protective plate -5- and on fuel filler neck -3-.
WARNING
Risk of explosion caused by electrostatic discharge.

♦ After installation, use an ohmmeter to check the electrical
connection between the metal ring on the fuel filler neck
and a bare metal part on the body:
• Specification: approx. 0 Ω
– Attach electrical wire for ABS speed sensor to bracket on fuel

filler neck.
– Install rear right wheel housing liner ⇒ Rep. Gr. 66 .
– Install propshaft ⇒ Rear final drive 02D/0AV; Rep. Gr. 39 .
– Install rear section of exhaust system ⇒ Rep. Gr. 26 .
– Install diagonal struts ⇒ Rep. Gr. 42 .
TT Coupé:
– Install rear seat bench ⇒ Rep. Gr. 72 .
TT Roadster:
– Install back panel trim (right and left) ⇒ Rep. Gr. 70 .

Audi TT 2007 ➤
2 Fuel delivery unit and fuel gauge

senders - vehicles with four-wheel
drive
⇒ “2.1 Fuel delivery unit and fuel gauge senders - exploded view”,
page 14
⇒ “2.2 Fuel system pressurisation pump G6 - electrical test”, page
16
⇒ “2.3 Removing and installing fuel delivery unit”, page 18
⇒ “2.4 Checking fuel gauge sender G ”, page 22
⇒ “2.5 Removing and installing fuel gauge sender G ”,
page 24
⇒ “2.6 Checking fuel gauge sender 2 G169 ”, page 25
⇒ “2.7 Removing and installing fuel gauge sender 2 G169 ”, page
27
⇒ “2.8 Suction-jet pump”, page 31
⇒ “2.9 Removing and installing suction-jet pump”, page 31
2.1 Fuel delivery unit and fuel gauge senders - exploded view
1 - Fuel gauge sender -G-

❑ Checking resistance
values ⇒ page 22
❑ Removing and installing
⇒ page 24
2 - Fuel delivery unit with
flange
❑ Checking fuel system
pressurisation pump -
G6- (electrical test)
⇒ page 16
⇒ page 18
❑ Put at least 5 litres of
fuel into tank after instal‐
ling
3 - Seal
❑ Renew Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Install dry with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Black
❑ To fuel filter
❑ Do not kink
❑ Attached to connection
marked “V” on flange
❑ To disconnect from
flange, press release
tab on connection
❑ Blue
❑ Do not kink

Audi TT 2007 ➤
❑ Attached to connection marked “R” on flange

❑ To disconnect from flange, press release tab on connection
❑ For fuel system pressurisation pump -G6- and fuel gauge sender -G-
7 - Locking ring
❑ Remove and install using wrench -T10202-
❑ 110 Nm
8 - Supply pipe for suction-jet pump
❑ From fuel pump to suction-jet pumppermitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Press release tab on pipe connector to disconnect
❑ For fuel gauge sender 2 -G169-
10 - Locking ring
❑ Remove and install using wrench -T10202-
❑ 110 Nm
11 - Seal
❑ Renew
❑ Install dry
12 - Fuel gauge sender 2 -G169-
❑ Only available together with -item 13-.
❑ Checking resistance values ⇒ page 25
❑ Installation position ⇒ page 30
13 - Suction-jet pump
❑ Only available together with -item 12-.
14 - Fuel supply pipe
❑ From suction-jet pump to fuel delivery unit
❑ Inserted in baffle housing of fuel delivery unit
2. Fuel delivery unit and fuel gauge senders - vehicles with four-wheel drive 15
Audi TT 2007 ➤
2.2 Fuel system pressurisation pump -G6- - electrical test
Special tools and workshop

equipment required
♦ Remote control -
V.A.G 1348/3 A- with
adapter cable -
V.A.G 1348/3-3-
♦ Hand-held multimeter -
V.A.G 1526C-
♦ Auxiliary measuring set -
V.A.G 1594C-
Procedure
Observe test conditions ⇒ page 3 .
TT Coupé:
TT Roadster:
– Remove back panel side trim (right-side) ⇒ Rep. Gr. 70 .

Audi TT 2007 ➤

– Unclip retaining tabs -arrows- for flange cover.
– Connect remote control -V.A.G 1348/3 A- with adapter cable

-V.A.G 1348/3-3- to contact -1- using a test lead from auxiliary
measuring set -V.A.G 1594C- .
– Tape off 2nd connector contact of the adapter cable -
V.A.G 1348/3-3- with insulating tape -arrow- to prevent short
circuits.
– Connect contact -5- to the body (earth) using a test lead from
auxiliary measuring set -V.A.G 1594C- .
– Connect crocodile clip to positive (+) terminal of battery.
– Press remote control button.
• Pump
permittedshould start running
by AUDI AG.audibly.
unless authorised AUDI AG does not guarantee or accept any liability
Note
The fuel pump runs very quietly. Where possible, avoid noisy sur‐
roundings for this test.
Audi TT 2007 ➤
If no noise can be heard from pump:

– Remove fuel delivery unit ⇒ page 18 .
– Check that the electrical wires between flange and fuel pump
are connected and test for continuity.
If no fault is found in wiring, fuel pump is defective. Renew fuel
delivery unit.
– Install fuel delivery unit ⇒ page 20 .
2.3 Removing and installing fuel delivery with respect to the correctness of information in this document. Copyright by AUDI AG.
unit
♦ Wrench -T10202-
Removing
TT Roadster:
Caution
• On the TT Roadster, the fuel tank must first be removed

before removing the fuel delivery unit.
– Removing fuel tank ⇒ page 8 .

Audi TT 2007 ➤
TT Coupé:
WARNING
Large amounts of fuel can escape.

♦ The fuel tank must not be more than 1/3 full when remov‐
ing the fuel delivery unit, otherwise a large amount of fuel
will escape.
– Drain fuel tank if necessary ⇒ page 6 .

side).
– Mark fuel supply line -1- and fuel return line -2-.
WARNING
♦ In extreme cases the fuel lines and the fuel can reach a
temperature of 100 °C. Allow the fuel to cool down before
disconnecting the lines - danger of scalding.
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.
– Detach both pipes from flange (press release tabs).
Audi TT 2007 ➤
TT Roadster:
– With fuel tank removed, mark fuel supply line -1- and fuel re‐
turn line -2-.
TT Coupé: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
WARNING

ing the fuel delivery unit, otherwise a large amount of fuel
will escape.

– Take flange (right-side) and seal of fuel delivery unit out of
opening in fuel tank and move clear, leaving pipes connected.
– In opening in fuel tank, press release tab to disconnect supply

pipe -1- to suction-jet pump.
– Detach fuel supply pipe -2- from fuel delivery unit.
– Remove fuel delivery unit.
Note
♦ When removing fuel delivery unit, make sure you do not bend
float arm of fuel gauge sender -G- .
♦ Keep in mind that the fuel delivery unit still contains fuel.
Installing
• Tightening torque ⇒ page 14
Note
♦ Renew seal.
♦ Take care not to bend the fuel gauge sender -G- when fitting
the fuel delivery unit.
♦ Ensure that fuel hoses are securely seated.

Audi TT 2007 ➤
– Insert fuel delivery unit in fuel tank with flange still detached.
– Push fuel supply pipe -2- into hole in fuel delivery unit so that
it engages audibly.
– Connect ends of supply pipe -1- leading to suction-jet pump
together so that they engage audibly.
Note
The fuel delivery unit is shown without the fuel tank in the next
two illustrations.
– Install new seal for flange (seal must be installed dry).

– Insert guide tubes -1- and -2- on flange into corresponding
holes -arrows- in fuel delivery unit.
– Make sure that electrical wiring -1- and fuel supply line -3- are
positioned as shown so they do not obstruct lever -2- of fuel
gauge sender.
Audi TT 2007 ➤
– Press flange down against spring pressure, and turn flange to

installation position.
• Lug -2- on flange points towards arrow marking, and must be
between tabs -1- and -3- on fuel tank.
Note
The -arrow- points in direction of travel.
– Tighten locking ring.

TT Coupé: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

TT Roadster:
– Install fuel tank ⇒ page 12 .
– Put at least 5 litres of fuel into tank after installing fuel delivery
unit.
2.4 Checking fuel gauge sender -G-

♦ Hand-held multimeter -V.A.G 1526C-
♦ Auxiliary measuring set -V.A.G 1594C-

Audi TT 2007 ➤
Procedure
TT Coupé:
TT Roadster:
– Remove back panel side trim (right-side) ⇒ Rep. Gr. 70 .
side).
Audi TT 2007 ➤
– Connect multimeter (resistance test) between contacts -2- and

-3-.
Fuel gauge sender -G- installed:
• Sender at lower stop: approx. 270 Ω.
• Sender at upper stop: approx. 70 Ω.
Note
♦ To test the maximum and minimum resistance values for “tank

full” and “tank empty”, remove the fuel delivery unit
⇒ page 18 and move the sender float all the way to its top or
bottom position.
♦ If the resistance is 0 Ω, there is a short circuit. If the resistance
is ∞ Ω, there is an open circuit
Protected in the Copying
by copyright. wiring.for private or commercial purposes, in part or in whole, is not
♦ The following values are
withobtained
respect to thewith the fuel
correctness gaugein sender
of information this document. Copyright by AUDI AG.
-G- removed, due to the greater travel of the float arm:
Fuel gauge sender -G- removed:

-4-.
Fuel gauge sender -G- installed or removed:
• Sender in any position: approx. 340 Ω.
TT Coupé:
TT Roadster:
– Install back panel side trim (right-side) ⇒ Rep. Gr. 70 .
2.5 Removing and installing fuel gauge

sender -G-
Removing
TT Roadster:
Caution

before removing the fuel delivery unit.

– Remove fuel delivery unit ⇒ page 18 .

Audi TT 2007 ➤
– Use screwdriver to release retaining tabs -arrows- and lift out

fuel gauge sender -G- .
Caution
Risk of damage.
♦ First release retainer tabs on connector contact before
detaching electrical connectors on fuel gauge sender -G- .
– Release retainer tabs on electrical connectors -1 ... 3- and then

detach electrical connectors.
Installing
Installation is carried out in the reverse
Protectedorder; note
by copyright. the for
Copying following:
private or commercial purposes, in part or in whole, is not
– Insert fuel gauge sender -G- intowith
guides onthefuel
respect to delivery
correctness unit in this document. Copyright by AUDI AG.
of information
and press upwards until it clicks into place.
– Plug in electrical connectors and check that they have engag‐
ed properly.
– Install fuel delivery unit ⇒ page 20 .
2.6 Checking fuel gauge sender 2 -G169-

Audi TT 2007 ➤
Procedure
TT Coupé:
TT Roadster:
– Remove back panel side trim (left-side) ⇒ Rep. Gr. 70 .
side).
Note
Disregard -item 2-.

Audi TT 2007 ➤

-2-.
With fuel gauge sender 2 -G169- installed:
Note
♦ In order to test the maximum and minimum values for “tank

full” and “tank empty”, remove the fuel gauge sender 2 -G169-
⇒ page 27 and move the float all the way to its top or bottom
position.
♦ If the resistance is 0 Ω, there is a short circuit. If the resistance
is ∞ Ω, there is an open circuit in the wiring.
♦ The following values are obtained with the fuel gauge sender 2
-G169- removed, due to the greater travel of the float arm:
With fuel gauge sender 2 -G169- removed:



-3-.
With fuel gauge sender 2 -G169- installed or removed:
• Sender in any position: approx. 340 Ω.
TT Coupé:
TT Roadster:
– Install back panel side trim (left-side) ⇒ Rep. Gr. 70 .
2.7 Removing and installing fuel gauge

sender 2 -G169-
♦ Wrench -T10202-
Removing
Audi TT 2007 ➤
TT Roadster:
Caution

before removing the fuel gauge sender 2 -G169- .

TT Coupé:
WARNING

ing the fuel gauge sender 2 -G169- , otherwise a large
amount of fuel will escape.

– Briefly open filler cap for fuel tank and close again.
side).

side.

Audi TT 2007 ➤
WARNING

ing the fuel gauge sender 2 -G169- , otherwise a large
amount of fuel will escape.

– Carefully pull fuel gauge sender 2 -G169- -item 2- together

with suction-jet pump -1- just slightly out of opening in fuel
tank.
– Detach seal.
– Unclip suction-jet pump from flange -arrows-.
Note
Installing
Note
♦ Renew seal.
♦ When installing, make sure you do not bend float arm of fuel
– Carefully insert fuel gauge sender 2 -G169- into opening in fuel

tank. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Clip suction-jet with
pump -1-
respect onto
to the flange,
correctness so that inyou
of information hear it click
this document. Copyright by AUDI AG.
into place.
Audi TT 2007 ➤
Caution
Leakage risk
♦ The seal must not be pinched or damaged when installing
the flange.
– Press flange down against spring pressure and move flange

into installation position.
Note
– Tighten locking ring. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
TT Coupé: with respect to the correctness of information in this document. Copyright by AUDI AG.

TT Roadster:

Audi TT 2007 ➤
2.8 Suction-jet pump

On vehicles with four-wheel drive the fuel tank is divided into a
left and a right chamber. A so-called suction-jet pump -1- is used
for delivering the fuel from the left fuel tank chamber -3- to the
baffle housing of the fuel delivery unit -2- on the right.
Suction-jet pump: operation
The suction-jet pump operates according to the principle of fluid
entrainment: the stream of fuel from the electric fuel pump is
passed through a nozzle in the suction-jet pump, and is thus ac‐
celerated. The accelerated stream of fuel draws off the surround‐
ing fuel and delivers it to the baffle housing of the fuel delivery
unit.
Faults caused by defective suction-jet pump
Caution
The engine can stop due to fuel starvation if the suction-jet

pump is defective.
♦ If the suction-jet pump is defective, the engine can stop
due to fuel starvation when the tank is still 1/4 full.
If the suction-jet pump is not working, up toProtected

15 litres of fuelCopying
by copyright. (up tofor private or commercial purposes, in part or in whole, is not
about 1/4 of tank capacity) may remain in the left chamber of the of information in this document. Copyright by AUDI AG.
with respect to the correctness
tank, from where it cannot be drawn into the fuel delivery unit.
If the engine stops due to fuel starvation with the tank up to about
1/ full, proceed as follows:
4
– Check fuel system pressurisation pump -G6- ⇒ page 16 .
If fuel pump is OK, but no fuel is delivered:
– Put another 5 litres (approx.) of fuel into tank.
– Start engine.
If engine now starts:
– Renew suction-jet pump ⇒ page 31 .
2.9 Removing and installing suction-jet

pump
♦ Wrench -T10202-
Removing
Audi TT 2007 ➤

TT Roadster:
Caution

before removing the suction-jet pump.

TT Coupé:
WARNING

ing the suction-jet pump, otherwise a large amount of fuel
will escape.

side).

Audi TT 2007 ➤
– Mark fuel supply line -1- and fuel return line -2-.
WARNING

side).

side.
Audi TT 2007 ➤
TT Roadster:
– With fuel tank removed, mark fuel supply line -1- and fuel re‐
turn line -2-.
TT Coupé:
WARNING

ing the suction-jet pump, otherwise a large amount of fuel
will escape.

– Unscrew locking ring (right-side) using wrench -T10202- .
– Take flange (right-side) and seal of fuel delivery unit out of

opening in fuel tank and move clear, leaving pipes connected.
– In opening in fuel tank, press release tab to disconnect supply
pipe -1- to suction-jet pump.
– Detach fuel supply pipe -2- from fuel delivery unit.
– Unscrew locking ring (left-side) using wrench -T10202- .

Audi TT 2007 ➤
– Carefully pull fuel gauge sender 2 -G169- -item 2- together

with suction-jet pump -1- just slightly out of opening in fuel
tank.
– Detach seal.
– Unclip suction-jet pump from flange -arrows-.
Note
– Reach into fuel tank opening on left side of vehicle and pull out
suction-jet pump, with pipes pointing towards the left.
Installing with respect to the correctness of information in this document. Copyright by AUDI AG.

Note
♦ Renew seals.
♦ When installing, make sure you do not bend float arm of fuel
– Push suction-jet pump (with pipes attached) into fuel tank

opening on left side of vehicle.
– Reach into fuel tank opening on right side of vehicle and pull
suction-jet pump with pipes into the installation position.
– Push fuel supply pipe -2- into hole in fuel delivery unit so that
it engages audibly.
– Connect ends of supply pipe -1- leading to suction-jet pump
together so that they engage audibly.
Audi TT 2007 ➤
Note
The fuel delivery unit is shown without the fuel tank in the next
two illustrations.

– Insert guide tubes -1- and -2- on flange into corresponding
holes -arrows- in fuel delivery unit.
– Make sure that electrical wiring -1- and fuel supply line -3- are
positioned as shown so they do not obstruct leverby-2-
Protected of fuel
gauge sender. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Caution
Leakage risk
the flange.

Note

Audi TT 2007 ➤
– Carefully insert fuel gauge sender 2 -G169- into opening in fuel

tank.
– Clip suction-jet pump -1- onto flange -2-, so that you hear it
click into place.
Caution
Leakage risk
the flange.

Note

TT Coupé:
TT Roadster:
– Put at least 5 litres of fuel into tank after installing suction-jet
pump
Audi TT 2007 ➤
3 Supplementary fuel pump

⇒ “3.1 Supplementary fuel pump V393 - exploded view”,
page 38
⇒ “3.2 Removing and installing supplementary fuel pump V393 ”,
page 39
3.1 Supplementary fuel pump -V393- - exploded view
Caution
Running when dry causes irreparable damage to high-pres‐

sure pump.
♦ If the fuel filter, the fuel lines or the supplementary fuel
pump -V393- are renewed, it is important to bleed the fuel
system before the engine is started for the first time.
– Bleed fuel system ⇒ Rep. Gr. 23 ; Performing first fuel filling

after installing high-pressure pump .
2 - Bolt
❑ 9 Nm
3 - Bracket permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4 - Bolt
❑ 20 Nm
5 - Rubber mounting
6 - Fuel supply hose
❑ White marking
7 - Bolt
❑ 9 Nm
8 - Bracket
9 - Supplementary fuel pump -
V393-
⇒ page 39
10 - Rubber mounting
❑ To high-pressure pump
❑ White marking

Audi TT 2007 ➤
3.2 Removing and installing supplementary

fuel pump -V393-
Removing
– Disengage fuel hose -3- at bracket -arrow-.
– Press release tab and unplug electrical connector -1-.
– Remove bolts -2, 4- and detach bracket with supplementary
fuel pump.
– Detach electrical connector -1- from bracket.

– Unscrew bolts -2, 3, 5- and remove bracket -4-.
– Move electrical wiring clear -arrow-.

– Take supplementary fuel pump -5- with rubber mountings
-4, 6- out of bracket -2-.
– Detach fuel hoses -1- and -3-.
Installing
Note
Secure all hose connectionspermitted
with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .

– Connect fuel hoses to fuel pipes and supplementary fuel pump

according to markings.
– Engage fuel hoses carefully in mounting bracket.
3. Supplementary fuel pump 39

Audi TT 2007 ➤
4 Fuel filter
⇒ “4.1 Fuel filter - exploded view”, page 40
⇒ “4.2 Removing and installing fuel filter housing”, page 41
4.1 Fuel filter - exploded view
Caution

sure pump.
– Bleed fuel system ⇒ Rep.Protected

Gr. 23by ;copyright.
Performing
Copying first fuelor filling
for private commercial purposes, in part or in whole, is not
after installing high-pressure pump
permitted . authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
unless
Note
Secure all hose connections with the correct type of hose clips

Audi TT 2007 ➤
1 - Bolt
❑ 9 Nm
2 - Nut
❑ 9 Nm
3 - Bolt
❑ 9 Nm
4 - Seal
5 - Cover with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ For filter housing

6 - Fuel return hose
❑ To fuel tank
❑ Blue marking
❑ From fuel tank
❑ White marking
8 - Bolt
❑ 5 Nm
❑ From high-pressure
pump
❑ Blue marking
❑ From supplementary
fuel pump -V393-
❑ White marking
11 - Filter element
❑ Renewing ⇒ Mainte‐
nance tables
12 - Fuel filter housing
4.2 Removing and installing fuel filter hous‐

ing
♦ Hose clip pliers -V.A.G 1921-
4. Fuel filter 41
Audi TT 2007 ➤
Removing
– Mark positions of fuel hoses for re-installation.
– Detach fuel hoses -4, 5, 6, 7- from fuel filter.
– Remove bracket -arrow- for coolant hose at fuel filter.
– Slacken bolt -1- a few turns.
– Remove bolt -3- and nut -2-.
– Detach fuel filter housing -8-.
Installing
Note
– Engage fuel filter carefully on mounting bracket.

– Connect fuel hoses to fuel filter according to markings.

Audi TT 2007 ➤
5 Bleeding fuel system
Caution

sure pump.

5. Bleeding fuel system 43

Audi TT 2007 ➤
6 Checking fuel system for leaks

A leaking fuel system can cause:
♦ Foam build-up or air bubbles in the supply pipe.
♦ Lack of power, misfiring.
♦ Starting problems.
Checking fuel system and fuel lines for leaks
– Check whether the seals on the flanges are damaged and
whether the union nuts on the fuel tank flanges are properly
tightened. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Perform a visual check on all fuel lines, fuel tank components
and hose connections:
♦ Fuel lines to engine
♦ Fuel lines to fuel tank
♦ Fuel cooler
♦ Fuel filter
♦ Fuel tank

Audi TT 2007 ➤
7 Accelerator pedal module

⇒ “7.1 Accelerator pedal module - exploded view”, page 45
⇒ “7.2 Removing and installing accelerator pedal module with ac‐
celerator position senders”, page 45
7.1 Accelerator pedal module - exploded view
1 - Cover cap
2 - Bolt permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 9 Nm
4 - Accelerator pedal module
❑ With accelerator posi‐
tion sender -G79- and
accelerator position
sender 2 -G185-
⇒ page 45
7.2 Removing and installing accelerator

pedal module with accelerator position
senders
7. Accelerator pedal module 45

Audi TT 2007 ➤
♦ For LHD vehicles: release tool -T10238-
♦ For RHD vehicles: release tool -T10240-
Removing
– Remove cover for steering column -arrows-.
– Pull out release tab -2- as far as stop in direction of -arrow-

and unplug electrical connector -1- at accelerator pedal mod‐
ule -3-.
– Use screwdriver to prise off cap -4-.
– Remove bolt -5-.

Audi TT 2007 ➤
– Push release tool -T10238- (or release tool -T10240- for RHD
vehicles) fully into the slots provided, as illustrated -arrow-,
and take off accelerator pedal module.
Installing
– Plug in electrical connector -2- at accelerator pedal module
-5-.
• The connector must audibly engage.
– Press accelerator pedal module onto
Protected retaining
by copyright. studs
Copying -6-.or commercial purposes, in part or in whole, is not
for private
– Insert centring pin -7- into holewithinrespect
underbody.
to the correctness of information in this document. Copyright by AUDI AG.
– Secure accelerator pedal module with bolt -3- and press on

cap -4-.
Note
Disregard -item 1-.
Vehicles with dual clutch gearbox:

– After renewing, perform kick-down adaption in “Guided Func‐
tions” mode ⇒ Vehicle diagnosis, testing and information sys‐
tem VAS 5051.
7. Accelerator pedal module 47

Service
Workshop Manual
Audi TT 2007 ➤ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-

valve common rail)

Engine ID
CBB
B
Edition 03.2010

Service
Repair Group
23 - Mixture preparation - injection
28 - Glow plug system


Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail) - Edition 03.2010
Contents
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety precautions and rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Rules for cleanliness and instructions for working on fuel system . . . . . . . . . . . . . . . . . . . . 1
1.3 Safety precautions for vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 To avoid any risk of injuries to persons and/or damage to the injection and glow plug system,
always observe the following safety precautions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Fuel system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Performing fuel filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Air cleaner - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4 Removing air cleaner (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 Intake manifold with attached components Protected -byexploded viewfor private
copyright. Copying . . . .or. commercial
. . . . . . purposes,
. . . . . .in .part
. . or. in. .whole,
. 24 is not
6.2 Removing and installing intake manifold . . . . to. the

. . correctness
. . . . . . .of .information
. . . . . .in.this
. .document.
. . . . . .Copyright
. . . . .by. AUDI . . AG. 24
with respect
6.3 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2 Performing first fuel filling operation after installing high-pressure pump . . . . . . . . . . . . . . 33
8 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.1 Checking injectors (piezo injectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2 Adaption of injector delivery calibration values and injector voltage calibration values . . . . 35
8.3 Checking return flow rate of injectors (piezo injectors) with engine running . . . . . . . . . . . . 35
8.4 Checking return flow rate of injectors (piezo injectors) at starter cranking speed . . . . . . . . 38
8.5 Checking for injectors sticking open (piezo injectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.6 Removing and installing injectors (piezo injectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9 Components of injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.1 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.2 Removing and installing intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.3 Installing high-pressure pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.4 Checking pressure retention valve in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9.5 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.6 Checking fuel pressure (low pressure) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.7 Checking delivery rate of fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.8 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.9 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 59
9.10 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10 Lambda probe and exhaust gas temperature sensors - exploded view . . . . . . . . . . . . . . . . 65
10.1 Lambda probe and exhaust gas temperature sensors - exploded view . . . . . . . . . . . . . . . . 65
10.2 Removing and installing Lambda probe G39 with Lambda probe heater Z19 . . . . . . . . . . 65
10.3 Removing and installing exhaust gas pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . 67
11 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.1 Wiring and component check with test box V.A.G 1598/42 . . . . . . . . . . . . . . . . . . . . . . . . 68
11.2 Renewing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

1 ...................................................................... 73
Contents i
Audi TT 2007 ➤
1.1 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

1.2 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.3 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
ii Contents
Audi TT 2007 ➤
23 – Mixture preparation - injection

1 Safety precautions and rules for
cleanliness
1.1 Safety precautions

WARNING

erly secured.
secured.
person.
1.2 Rules for cleanliness and instructions

for working on fuel system
To prevent the high-pressure fuel pump from running while it is
empty and to ensure that the engine starts quickly after parts have
been renewed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank and
the high-pressure fuel pump are removed or renewed, the ba‐
sic setting “Checking fuel system pressurisation pump” must
be performed to bleed the fuel system.
♦ If a fuel pump, fuel line or fuel filter are removed or renewed,
the basic setting “Display group 35” must be performed ONCE
before the engine is started for the first time.
♦ If the high-pressure fuel pump is removed or renewed, the ba‐
sic setting “Display group 35” must be performed THREE
TIMES before the engine is started for the first time.
• Clean tools and workbench etc. before working on the injection
system.
• Thoroughly clean all unions and surrounding areas before dis‐
connecting.
• When removing components, plug all open connections im‐
mediately with suitable clean sealing caps.
• Do not remove sealing caps from components until immedi‐
ately prior to installation. After removal, components should
be kept in new, sealable plastic bags (use the original new part
packaging if possible).
• Before installation, check the injectors and their surroundings
visually; they must be undamaged and free of lint. Make sure
the injector bores in the cylinder head are clean. Wipe out if
1. Safety precautions and rules for cleanliness 1

Audi TT 2007 ➤
necessary using a clean cloth, taking care not to cause dam‐

age. Do not use sharp objects of any kind.
• If the high-pressure fuel lines are to be re-used, you must mark
them before removal. High-pressure fuel lines must always be
re-installed in their original positions (i.e. on the same cylin‐
der).
• The following components and seals/O-rings must always be
renewed when the injectors are removed and installed: “cop‐
per seal”, “O-ring for injector bore”, “O-ring for injector return
connection”.
renewed when an injector is renewed: “clamping piece”, “cop‐
connection”.
• Always fit new copper seals for the injectors. Check all new O-
rings for damage before installing. Lubricate O-rings lightly
with assembly oil or clean engine oil before installing. Use as‐
sembly tool for installing the “O-ring for injector return con‐
nection”. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Take care not to damage the injectors when
with respectremoving theofold
to the correctness information in this document. Copyright by AUDI AG.
copper seals.
• Align the high-pressure fuel lines so they are free of tension.
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.
• Press the return lines onto the injectors by hand from above
so that they engage audibly on each injector (do not press in
the release pins when doing this). Then press down the re‐
lease pin after connecting the return line. Check that the return
lines are seated securely by pulling them by hand from above.
Also check that they seal properly (fuel pressure in return line
as far as pressure retention valve: between 8 and 10 bar).
• All cable ties which are released or cut open when removing
must be refitted in the same position when installing.
• When the fuel system is open: Do not work with compressed
air if this can be avoided. Do not move the vehicle unless ab‐
solutely necessary.
• Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
Use release tool -T40138- to unplug connectors that cannot be
accessed easily.
2 Rep. Gr.23 - Mixture preparation - injection

Audi TT 2007 ➤
1.3 Safety precautions for vehicles with

start/stop system
WARNING

start/stop system.
1.4 To avoid any risk of injuries to persons

and/or damage to the injection and glow
plug system, always observe the follow‐
ing safety precautions:
♦ Persons wearing a pacemaker should not lean over the engine
compartment while the engine is running, as the injectors use
high voltage pulses.
♦ Do not open any fuel line connections while the engine is run‐
ning.
necting injection and glow plug system wiring or tester cables.
♦ Always switch off the ignition before cleaning the engine.
necting the battery, otherwise the engine control unit may be
damaged.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. The fault memory should therefore be inter‐
rogated and (if necessary) erased after completing the tests
and any repair work that may be required.
1.5 Checking vacuum system

♦ Hand vacuum pump -VAS 6213-
Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks

Audi TT 2007 ➤
♦ 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 a fault is stored in the fault memory, check the 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.

Audi TT 2007 ➤
2 Overview of fitting locations

Components A to J are not shown on the exploded view.
1 - Exhaust gas pressure sen‐

sor 1 -G450-
❑ Fitting location
⇒ page 10
❑ Adaption must be per‐
formed after renewing
this component
⇒ page 67
2 - Hall sender -G40- (cam‐
shaft position sensor)
⇒ page 10
⇒ page 75
3 - Lambda probe -G39- with
Lambda probe heater Protected
-Z19- by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Fitting location permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 13 with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ page 65
❑ 50 Nm
4 - Engine control unit -J623-
⇒ page 8
⇒ page 68
5 - Injectors (piezo injectors)
⇒ page 12
⇒ page 42
6 - Position sender for charge
pressure positioner -G581-
❑ Fitting location ⇒ page 12
7 - Pressure retention valve
❑ The pressure retention valve maintains a residual pressure of approx. 10 bar in the return lines.
❑ This residual pressure is required for the control function of the piezo injectors.
❑ The pressure retention valve may only be renewed together with the fuel return lines.
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system.
❑ Checking pressure retention valve ⇒ page 54
8 - Fuel pressure regulating valve -N276-
❑ 80 Nm
9 - Charge pressure control solenoid valve -N75-
❑ Electrical connector for exhaust gas temperature sender 3 -G495-
2. Overview of fitting locations 5

Audi TT 2007 ➤
❑ For exhaust gas temperature sender 4 -G648-
❑ For Lambda probe -G39-
11 - Air mass meter -G70-
12 - Coolant temperature sender -G62-
❑ Removing and installing ⇒ Rep. Gr. 19
13 - Engine speed sender -G28-
❑ 4.5 Nm
14 - Variable intake manifold motor -V183-
❑ With variable intake manifold position sender -G513-
❑ Fitting location ⇒ page 11 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
15 - Exhaust gas recirculation cooler change-over
with respectvalve -N345- of information in this document. Copyright by AUDI AG.
to the correctness
16 - Pump for exhaust gas recirculation cooler -V400-
17 - Intake manifold flap motor -V157-
❑ With throttle valve potentiometer -G69-
❑ Intake manifold - exploded view ⇒ page 24
18 - Charge pressure sender -G31-
❑ Combined with intake air temperature sender -G42-
19 - Glow plugs
❑ Glow plug 1 -Q10-
20 - Fuel temperature sender -G81-
21 - Exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212-
22 - Fuel supply line connection from fuel filter
23 - Fuel supply line connection (high-pressure pipe)
24 - High-pressure fuel pump with fuel metering valve -N290-
❑ Do not open fuel metering valve -N290-
❑ After renewing, first fuel filling MUST be performed (it is important not to allow pump to run while it is still
empty) ⇒ page 33

Audi TT 2007 ➤
25 - Fuel pressure sender -G247-

❑ 100 Nm
26 - Radiator outlet coolant temperature sender -G83-
27 - Supplementary fuel pump -V393-
28 - Fuel filter
❑ Fuel filter - exploded view ⇒ Rep. Gr. 20
❑ Renewing fuel filter ⇒ Rep. Gr. 20
A - Low heat output relay -J359- and high heat output relay -J360-
❑ Fitting location ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
B - Brake light switch -F- and brake pedal switch -F47-
❑ In footwell on brake pedal
C - Clutch position sender -G476-
❑ Only fitted on vehicles with manual gearbox
D - Accelerator position sender -G79- and accelerator position sender 2 -G185-
E - Actuator for structure-borne sound -R214-
F - Control unit for structure-borne sound -J869-
G - Exhaust gas temperature sender 3 -G495-
❑ Lambda probes and exhaust gas temperature sensors - exploded view ⇒ page 65
H - Exhaust gas temperature sender 1 -G235-
I - Exhaust gas temperature sender 4 -G648-
J - Particulate filter
❑ Fitted on underbody Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Combined with a catalytic converter

❑ Adaption must be performed after renewing this component

Audi TT 2007 ➤
Adaption must be performed after renewing exhaust gas pressure

sensor 1 -G450- and/or particulate filter. The adaption procedure
is described in the Guided Fault Finding or Guided Functions; use
a vehicle diagnostic tester.
Fitting location of engine control unit -J623-
Removing and installing ⇒ page 70
Accelerator position sender -G79- and accelerator position send‐

er 2 -G185-
Removing and installing ⇒ Rep. Gr. 20
Note
The accelerator position sender -G79- and accelerator position

sender 2 -G185- are integrated in the accelerator pedal module
and cannot be renewed individually.
Brake light switch -F- and brake pedal switch -F47- -1-

Audi TT 2007 ➤
Clutch position sender -G476-

Integrated functions: clutch pedal switch for engine start -F194-
and clutch pedal switch -F36- (manual gearbox only)
Fuel pump control unit -J538-

1 - Connector for fuel pump control unit -J538-
2 - Fuel pump control unit -J538-
3 - Fuel system pressurisation pump -G6-
Sound package
1 - Actuator for structure-borne sound -R214-
2 - Control unit for structure-borne sound -J869-

Audi TT 2007 ➤
Fitting locations
3 - Variable intake manifold motor -V183- with variable intake
manifold position sender -G513-
4 - Exhaust gas recirculation cooler change-over valve -N345-
5 - Intake manifold flap motor -V157- with throttle valve potenti‐
ometer -G69-
6 - Exhaust gas recirculation valve -N18- with exhaust gas recir‐
culation potentiometer -G212-
8 - Fuel metering valve -N290-
Pump for exhaust gas recirculation cooler -V400- -arrow-
Hall sender -G40-
Exhaust gas pressure sensor 1 -G450-


Audi TT 2007 ➤
Radiator outlet coolant temperature sender -G83-
Engine speed sender -G28- -arrow-
Components at front of engine

1 - Electrical connector for Hall sender -G40-
3 - Variable intake manifold motor -V183- with variable intake
manifold position sender -G513-
Components at front of engine

3 - Exhaust gas recirculation valve -N18- with exhaust gas recir‐
culation potentiometer -G212-
4 - Intake manifold flap motor -V157- with throttle valve potenti‐
ometer -G69-
5 - Charge pressure sender -G31- with intake air temperature
sender -G42- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi TT 2007 ➤
Components on engine
1 - Exhaust gas pressure sensor 1 -G450-
2 - Position sender for charge pressure positioner -G581-
4 - Injectors (N30 to N32)
Injectors
1 - Injector, cylinder 1 -N30-
Fitting locations and connectors

1 - Electrical connector for charge pressure control solenoid valve
-N75-
2 - Electrical connector for exhaust gas temperature sender 4 -
G648-
G235-
4 - Electrical connector for Lambda probe -G39-
G495-
Coolant temperature sender -G62- -2-

Audi TT 2007 ➤
Components in particulate filter

1 - Exhaust gas temperature sender 3 -G495-
3 - Lambda probe -G39-
Components at rear of engine

1- Exhaust gas temperature sender 1 -G235-
2- Exhaust gas temperature sender 4 -G648-
3- Vacuum unit for exhaust gas recirculation cooling system

Audi TT 2007 ➤
3 Fuel system - exploded view
WARNING
♦ Always read rules for cleanliness and instructions for

working on fuel system ⇒ page 1 .
♦ Follow these instructions and rules for cleanliness before
starting work and while working on the fuel system.
Caution
The high-pressure fuel pump has very close tolerances and

must not be allowed to run without fuel. To prevent this and to
enable the engine to start quickly after parts have been re‐
newed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank
and the high-pressure fuel pump are removed or renewed,
the first fuel filling must be performed.
♦ If a fuel pump, fuel line (between fuel tank and high-pres‐
sure fuel pump) or fuel filter is removed or renewed, the
fuel system must be bled before the engine is started for
the first time.
♦ If the high-pressure fuel pump is removed or renewed, the
fuel system must be bled before the engine is started for
the first time.
♦ Performing first fuel filling after installing high-pressure
pump ⇒ page 33
Note
The high-pressure pump will be damaged if the first fuel filling

procedure is not performed.

Audi TT 2007 ➤
1 - Bolt
❑ 10 Nm
2 - High-pressure pipe
❑ 25 Nm
❑ Between high-pressure
pump and fuel rail
3 - Fuel return lines (from in‐
jectors)
❑ To fuel tank
❑ Fuel return line must not
be kinked, damaged or
clogged Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ The fuel return lines to the correctness of information in this document. Copyright by AUDI AG.
with respect
must not be dismantled;
if necessary they must
be renewed complete
with pressure retention
valve.
❑ The pressure retention
valve maintains a resid‐
ual pressure of approx.
10 bar in the return lines.
❑ This residual pressure is
required for the control
function of the piezo in‐
jectors.
❑ Checking pressure re‐
tention valve
⇒ page 54
❑ After replacement, en‐
gine must be run at
idling speed for approx.
2 minutes to bleed fuel
system. Then check fuel
return lines for leaks.
4 - Bolt
❑ 10 Nm
5 - High-pressure pipes
❑ 25 Nm
❑ Between fuel rail and injectors
❑ Do not interchange
❑ Install free of stress
❑ 80 Nm
❑ Cannot be re-installed
7 - Fuel rail
9 - High-pressure fuel pump
❑ With fuel metering valve -N290- (do not open)
❑ After renewing, first fuel filling operation MUST be performed (it is important not to allow pump to run
while it is still empty) ⇒ page 33
3. Fuel system - exploded view 15

Audi TT 2007 ➤
10 - Bolt
❑ 20 Nm
11 - Bolt
❑ 1st stage: 15 Nm
❑ 2nd stage: 20 Nm + 1/4 turn (90 °) further
12 - High-pressure pump sprocket
13 - Nut
❑ 95 Nm
14 - Hub
❑ With sender wheel
❑ Use counterhold tool -T10051- to loosen and tighten
❑ To remove, use puller -T40064-
❑ 100 Nm
16 - Bolt
❑ 22 Nm
17 - Clamping piece
❑ If they are to be re-installed, the injectors and clamping pieces must always be re-fitted on the same
cylinder. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ When an injector is renewed, the corresponding clamping
permitted piece by
unless authorised must
AUDI beAG. renewed
AUDI AG doesat notthe same
guarantee time.any liability
or accept
18 - Hexagon flange nut
❑ For clamping piece
❑ 10 Nm
19 - Cover for injector
20 - Bolt
❑ 5 Nm
21 - Injector (piezo injectors)
❑ When removing and installing, always renew the following components and seals/O-rings: “copper seal”,
“O-ring for injector bore”, “O-ring for injector return connection”.
❑ The following components and seals/O-rings must always be renewed when an injector is renewed:
“clamping piece”, “copper seal”, “O-ring for injector bore”, “O-ring for injector return connection”.
❑ When re-installing “high-pressure injector pipe” check taper seats visually for damage, scores and cor‐
rosion (always renew if damaged)
❑ If they are to be re-installed, the injectors, high-pressure fuel pipes and clamping pieces must always be
re-fitted in their original positions (i.e. on the same cylinder).

Audi TT 2007 ➤
Installation position of clamping piece
3. Fuel system - exploded view 17

Audi TT 2007 ➤
4 Performing fuel filling
Caution
If a fuel pump, fuel line (between fuel tank and high-pressure

fuel pump) or fuel filter is removed or renewed, the fuel system
must be bled before the engine is started for the first time.
After installation, the high-pressure pump must first be filled
with fuel before the engine is started (the pump must NOT be
allowed to run while still empty).
– Connect a vehicle diagnostic tester.

– Switch on ignition.
– Select “Engine electronics” in vehicle self-diagnosis.
– Then select “Basic setting”.
– Select “Display group 35”.
– Press “activate” button.
– The fuel pumps start running.
– The fuel pumps must run for approx. 1 minute to ensure that
the high-pressure pump is filled with sufficient fuel.
Note
To repeat basic setting, switch ignition off and on once. Then start
basic setting again.
– Start engine after filling fuel system.

– Run engine at moderate speed for several minutes and then
switch off.
– Checkpermitted
fuel system
with respect to thefor leaks.of information in this document. Copyright by AUDI AG.
correctness
– Erase fault in fault memory using diagnostic tester.

– After completing the repair, road-test the vehicle over a dis‐
tance of at least 20 km. Accelerate with full throttle at least
once. Then inspect the high-pressure section of the fuel sys‐
tem again for leaks.
Note
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the engine and erase the fault memory. Then con‐
tinue the road test.
– Interrogate fault memory.

Audi TT 2007 ➤
5 Air cleaner
5.1 Air cleaner - exploded view
1 - Spring-type clip
2 - Air hose
❑ To turbocharger
❑ Check air intake hose
for dirt and leaves
❑ 1.5 Nm
⇒ page 49
4 - Bolts
❑ For air cleaner (top sec‐
tion)
❑ 1.5 Nm
5 - Bolts
tion)
❑ 1.5 Nm
6 - Air cleaner (top section)
❑ Clean any salt residue,
leaves and dirt out of air
cleaner (top section)
7 - Filter element
❑ Always use genuine
part for air filter element
⇒ page 21
❑ Observe change inter‐
vals ⇒ Maintenance ;
Booklet 810
8 - Bolt
❑ For air cleaner (bottom
section)
❑ 8 Nm
9 - SnowProtected
screen by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Notpermitted
installed
unlessin all vehicles
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
10 - Air cleaner (bottom section)
❑ Clean any salt residue, leaves and dirt out of air cleaner (bottom section)
❑ On vehicles for cold climates, air cleaner (bottom section) with hot-air-intake hose is installed
11 - Connection for water drain hose
❑ Clean connection
12 - Water drain hose
❑ Clean water drain hose
13 - Flutter valve
❑ Clean and re-install
5. Air cleaner 19
Audi TT 2007 ➤
14 - Intake air duct

❑ To lock carrier
❑ Clean any leaves and dirt out of intake air duct
5.2 Removing and installing engine cover

panel
Removing
– Carefully pull engine cover panel off retaining pins one after
the other “arrows”. Do not jerk the cover panel away, and do
not try to pull on one side only.
Installing
– To avoid damage, do not strike the engine cover panel with
your fist or with any kind of tool. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Position engine cover panel on engine (note locations of oil

filler neck and oil dipstick).
– Press engine cover panel with both hands into the rubber
grommets at the rear and then into the grommets at the front.

Audi TT 2007 ➤
5.3 Removing and installing air filter ele‐

ment
Removing
– Unscrew bolts -arrows- from air cleaner (top section).
Note
Disregard items 1 to 3.
– Lift up air cleaner (top section) and take out air filter element.
Installing
To ensure the proper function of the air mass meter -G70- it is
important to observe the following notes and instructions.
Note
♦ If the air filter element is very dirty or wet, dirt or water could
reach the air mass meter -G70- and affect the air mass value.
This would lead to loss of power, since aProtected
smaller injection
by copyright. Copying for private or commercial purposes, in part or in whole, is not
quantity is calculated. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Always use genuine part for air filter element.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. Do not use any lubri‐
cants containing silicone when assembling.
♦ Both sections of the air cleaner housing MUST be clean.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue
♦ To prevent malfunctions, cover all critical parts of the engine
air intake tract (air mass meter, intake pipes, etc.) with a clean
cloth when blowing out the air cleaner housing with com‐
pressed air.
♦ Please observe requirements for disposal.
– Remove snow screen -1- and clean it.
Note
The snow screen is not fitted on all vehicles.
5. Air cleaner 21
Audi TT 2007 ➤
– Clean water drain -arrow- and air cleaner (bottom section).

– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections); use a vacuum cleaner if necessary.
– Check for salt residue, dirt and leaves in air mass meter and
air intake hose (engine intake side).
– Check for dirt and leaves in air duct going from lock carrier to
air cleaner housing.
– When installing the air filter element, check that it is properly
centred in the retainer in the air cleaner (bottom section).
– Fit the top section of the air cleaner carefully on the bottom
section, without using force. Make sure the top section of the
air cleaner is fitted straight on the air filter element (note posi‐
tion of sealing lip on air filter element).
– Ensure secure fit of intake hose at air mass meter -G70- .
The remaining installation steps are carried out in the reverse se‐
quence.
5.4 Removing air cleaner (bottom section)

Removing
– Remove air duct leading from lock carrier to air cleaner hous‐
ing -2 and 3-.
– Slacken bolt -1-.
– Carefully lift air cleaner (bottom section).
Installing
important to observe the following instructions.
Note
This would lead to loss of power, since a smaller injection
quantity is calculated.
♦ Use a silicone-free lubricant when installing the intake hose.

Audi TT 2007 ➤
Note
– Disconnect water drain hose -arrow- from air cleaner (bottom

section) and clean any dirt or leaves out of connection and
hose.
– Fit the top section of the airpermitted
cleaner carefully
unless authorised on theAG.
by AUDI bottom
AUDI AG does not guarantee or accept any liability
section, without using force. with
Make sure
respect to thethe top section
correctness of the
air cleaner housing is fitted straight on the air filter element
(note position of sealing lip on air filter element).
quence.
5. Air cleaner 23
Audi TT 2007 ➤
6 Intake manifold
6.1 Intake manifold with attached components - exploded view
1 - Intake manifold
❑ With variable intake
manifold motor -V183-
and variable intake
manifold position send‐
er -G513- (combined in
one component)
❑ Must not be dismantled
⇒ page 24
2 - Bolt
❑ 8 Nm
3 - Gasket Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Renew permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4 - Seal
❑ Renew
5 - Connecting pipe
❑ To exhaust gas recircu‐
lation cooler
6 - Bolt
❑ 20 Nm
7 - Gasket
❑ Renew
8 - Bolt
❑ 10 Nm
9 - Intake manifold flap motor -
V157-
⇒ page 49
10 - Bolt
❑ 10 Nm
11 - Bolt
❑ 10 Nm
12 - Oil dipstick
13 - Exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212-
6.2 Removing and installing intake manifold


Audi TT 2007 ➤
♦ Torque wrench -V.A.G 1331-
♦ Ratchet -V.A.G 1331/1-
♦ Bit XZN 8 -T40159-
Removing
WARNING

– Remove engine cover panel ⇒ page 20 .

– Take noise insulation off cylinder head cover.
6. Intake manifold 25
Audi TT 2007 ➤
– Remove noise insulation -1- ⇒ Rep. Gr. 50 .
– Loosen hose clip -2- and remove air hose.
Removing air hoses with plug-in connectors

– Release tab -A- on plug-in connector by lifting retaining clip
-arrow-.
– Disconnect air pipes and hoses by hand (do not use a tool).

Audi TT 2007 ➤
– Remove bolts -1- and -3-.

– Slacken hose clip -5- at intake manifold flap motor -V157- ,
detach air pipe -2- but do not remove.
Note
Disregard item -4-.
– Unplug electrical connectors -5- from glow plugs.
– Unscrew union nuts at high-pressure pumpby -6-
permitted unless authorised AUDIand fuelAG
AG. AUDI rail
does not guarantee or accept any liability
-1- and remove high-pressure fuel pipe.
– Remove bolts -arrows- securing retainers for high-pressure

fuel pipe.
– Move wiring harness -2- clear.
– Detach fuel return lines -1, 2 and 3-.

– Remove securing bolt -arrow- and take out return line.
– Remove bolt from bracket -4- for exhaust gas recirculation
cooler change-over valve -N345- .
– Unplug connectors -9- from exhaust gas recirculation valve -
N18- and throttle valve module -J338- -7-.
– Remove bolts -6- from connecting pipe for exhaust gas recir‐
culation.
Audi TT 2007 ➤
– Open hose clip -8- securing air hose and disconnect hose
downwards from intake manifold flap motor -V157- .
– Remove bolt -9- on bracket for oil dipstick.
– Remove bolts securing intake manifold in diagonal sequence
starting from outside and working inwards using bit XZN 8 -
T40159- .
– Remove intake manifold.
Installing
– Renew seals and/or gaskets.
– Tighten bolts securing intake manifold in diagonal sequence
starting from outside and working inwards.
• Tightening torque for intake manifold: refer to exploded view
of intake manifold ⇒ Item 2 (page 24) .
– Install air pipe: Charge air cooler - exploded view ⇒ Rep. Gr.
21 .
Installing air hoses with plug-in connectors
Note
♦ Renew seal if damaged.

♦ Make sure that the seal is correctly seated in the groove on
the complete circumference of the air pipe/hose.
♦ Apply a thin coating of silicon-free lubricant to the sealing area
and the seal.
– Release retaining clip (position -1-).

– Push air pipe/hose in as far as stop and press retaining clip to
lock -2-.by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
– Press air pipe/hose
with respect again
to the correctness and pullin this
of information again to check
document. that
Copyright plug-in
by AUDI AG.
connector is correctly engaged.
– Install noise insulation ⇒ Rep. Gr. 50 .
6.3 Removing and installing fuel rail


Audi TT 2007 ➤
♦ Tool insert, AF 17 -V.A.G 1331/6-
♦ Socket -T40055-
Removing
WARNING


Audi TT 2007 ➤
– Unscrew union nuts at high-pressure pump -6- and fuel rail

-1- and remove high-pressure fuel pipe.
– Remove bolts -arrows- for high-pressure fuel pipe.
– Detach fuel return hose -3-.
– Move wiring harness -2- clear.
– To do so, unplug the following electrical connectors:

- Injectors
- Glow plugs
Caution
♦ Mark cylinder numbers on high-pressure pipes. They must

always be re-installed on the same cylinders.
♦ Observe rules for cleanliness when working on the injec‐
tion system.
♦ Plug open connections with suitable sealing caps imme‐
diately.
– Loosen union nuts for high-pressure pipes at injectors using

socket -T40055- (17 mm).
– Loosen union nuts for high-pressure pipes at fuel rail using tool
insert, AF 17 -V.A.G 1331/6- .
– After removal, lay high-pressure pipes on a clean cloth.
– Unscrew both bolts and remove fuel rail.
Installing
– Install high-pressure pipes free of stress.
• Tightening torques: refer to exploded view of fuel system
⇒ page 14

Audi TT 2007 ➤
7 High-pressure pump
7.1 Removing and installing high-pressure

pump
♦ Counterhold tool -T10051-
♦ Puller -T40064- with T40064/1
♦ Torque wrench -V.A.G 1331- with ratchet -V.A.G 1331/1-
Removing
Caution
♦ Always observe rules for cleanliness and instructions for

♦ Running
permittedwhen dry causesby AUDIirreparable damage to high-
unless authorised AG. AUDI AG does not guarantee or accept any liability
pressure pump.
♦ The high-pressure pump must first be filled with fuel before

the engine is started. The high-pressure pump must not
be allowed to run while still empty (performing first fuel
filling ⇒ page 33 ).
– Remove toothed belt from camshaft and high-pressure pump

⇒ Rep. Gr. 15 .
7. High-pressure pump 31
Audi TT 2007 ➤
– Unplug electrical connector -1- at fuel metering valve -N290- .

– Remove securing bolts for coolant line on intake manifold and
move coolant line to one side.
– Pull fuel pipe connections -2 and 3- off high-pressure pump.

– Unscrew union nuts at high-pressure pump -1- and fuel rail
-5- and remove high-pressure fuel pipe -4-.
Note
Do not bend fuel pipes.
– Remove toothed belt sprocket from high-pressure pump.
– Counterhold hub of high-pressure pump using counterhold

tool -T10051- and unscrew securing nut -1-.
– Apply puller -T40064- with thrust piece -T40064/1- as shown

in illustration and pull hub off high-pressure pump. If neces‐
sary, counterhold using an open-end spanner (24 mm).

Audi TT 2007 ➤
– Unscrew securing bolts -arrows- for high-pressure pump.

– Carefully take out high-pressure pump.
Installing
Install in reverse order.
Note
♦ When installing the high-pressure fuel pump, it is essential to

ensure that no dirt enters the fuel system.
♦ Only remove sealing plugs immediately prior to installation of
fuel pipes.
♦ There must be sufficient fuel in the tank.
• Protected
Tightening torques:
by copyright. refer
Copying for toorexploded
private view of
commercial purposes, fuelor system
in part in whole, is not
⇒ page
permitted 14authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
unless
– Install toothed belt for high-pressure pump ⇒ Rep. Gr. 15 .
– Install high-pressure pipes ⇒ page 52 .
Caution

be allowed to run while still empty. First fuel filling
⇒ page 33
♦ Running when dry causes irreparable damage to high-
pressure pump.
7.2 Performing first fuel filling operation af‐

ter installing high-pressure pump
Caution
After installation, the high-pressure pump must first be filled

with fuel before the engine is started (the pump must NOT be
allowed to run while still empty).
Audi TT 2007 ➤
Proceed as follows to fill high-pressure pump with fuel.

– Connect up the vehicle diagnostic, testing and information
system -VAS 5051B- .
– Fuel pumps will run for approx. 60 seconds.
– Repeat this procedure by selecting “Display group 35” 3 times
to ensure that high-pressure pump is sufficiently filled with fuel.
Note

switch off.
– Check fuel system for leaks.
– Erase fault in fault memory using diagnostic tester.
Note

Audi TT 2007 ➤
8 Injectors
8.1 Checking injectors (piezo injectors)

There are three different tests for checking the operation of the
injectors.
• Checking adaption of “Injector delivery calibration values” and
“Injector voltage calibration values” ⇒ page 35
• Checking return flow rate of injectors with engine running
⇒ page 35
• Checking return flow rate of injectors at starter cranking speed
⇒ page 38
8.2 Adaption of injector delivery calibration

values and injector voltage calibration
values
The “Injector delivery calibration” and “Injector voltage calibration”
functions serve to correct the injection rates for each cylinder of
a common rail system individually across the entire operating
range.
The 7-digit adaption values -1- (details in illustration are only an
example) are marked separately on each injector. They may con‐
sist of letters and/or numbers (ASCII code).
Reference table for reading out letters and/or numbers on each

injector
When a new injector is installed, the adaption value for the new
injector must be written into the engine control unit.
When the engine control unit is renewed, the appropriate “injector
delivery calibration” values with “injector voltage calibration” val‐
ues must be written into the new control unit.
Additionally, check that the “injector delivery calibration values”
with “injector voltage calibration values” are correctly entered for
all the other injectors. Do NOT attempt to re-enter these calibra‐
tion values if the correct values are already stored in the engine
control unit.
The adaption procedure is described in the Guided Fault Finding.
(The procedure is also described under Guided Functions)
8.3 Checking return flow rate of injectors

(piezo injectors) with engine running
8. Injectors 35
Audi TT 2007 ➤
♦ Injection rate comparison meter -V.A.G 1348/2 B-
♦ 4 lengths of hose (made up in the workshop) to fit return line

connections on injectors
Checking return flow rate of all injectors
WARNING


– Remove noise insulation from injectors.
– Disconnect hose connection downstream of pressure reten‐
tion valve -2- in fuel return line.
– Seal off the open return connection with a plug -1-.
– Hold the end of this hose -3- (lengthen if necessary) in a suit‐
able container to measure the total return flow rate.
– Start engine and let it idle for 2 minutes.
• Specification for 2 minutes: 0 ml to 50 ml
– If specification is attained, increase engine speed to 2000 ...
2500 rpm for approx. 2 minutes and then check return flow rate
again.
• Specification for 2 minutes: less than 250 ml
Note
1000 ml = 1 litre
If specification is exceeded, this indicates that one or more injec‐

tors are defective. Check return flow rate from each injector
individually.
Checking return flow rate of individual injectors
Special tools and workshop equipment required permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi TT 2007 ➤
Each injector normally has a relatively low return flow rate. If the
return flow rate at one injector is relatively high compared to the
other injectors, that injector is probably defective.
– Clean all return line connections (with commercial cleaning
solution or similar) before removing.
– Dry all components after cleaning.
– Clamp off fuel return line downstream of pressure retention
valve using hose clamp up to 25 mm -3094- .
8. Injectors 37
Audi TT 2007 ➤
– Pull return line connections off injectors; to do so, press both

tabs down and at the same time pull release pin upwards
-arrow-.
Note
No dirt must be allowed to get into the disconnected return lines

or the open connections on the injectors.
– Connect hoses onto return line connections of all 4 injectors.

– Run the 4 hoses into injection rate comparison meter -V.A.G
1348/2 B- .
– Start engine and let it idle for several minutes.
Caution
Do NOT press the accelerator during this test; the engine must
only run at idling speed.
Running the engine at higher speeds with the return lines dis‐
connected
with respectwill cause damage to the injectors.
– When the engine is warm and running at idling speed, the re‐
turn flow rates at each of the 4 return lines must not differ by
more than a small amount.
– If one injector has a significantly higher return flow rate than
the others it must be renewed ⇒ page 42 .
Installing fuel return lines
– Renew O-rings for all return line connections.
Note
Lubricate all O-rings with engine oil or assembly oil before instal‐
ling.
– Push the return line connections carefully over the new seals
and onto the injectors. The catch should engage audibly. Then
press release pin down carefully.
– Check fuel system for leaks ⇒ page 55 .

(piezo injectors) at starter cranking
speed
If it is not possible to start engine, check return flow rate of injec‐
tors at starter cranking speed.

Audi TT 2007 ➤
WARNING

-arrow-.
Note

8. Injectors 39
Audi TT 2007 ➤
– Detach electrical connector -5- from fuel pressure regulating

valve -N276- .
Note
This prevents fuel from being injected when starter is operated.
– Connect the 4 hoses onto return line connections of all 4 in‐

jectors.
1348/2 B- .
– Operate starter three times. (Wait approx. 20 seconds each
time after operating starter to prevent it from overheating.)
• Specification of return flow rate: 0 ml
– If fuel comes out of one injector, that injector must be renewed.
– Re-attach electrical connector on fuel pressure regulating
valve -N276- .
– Renew O-rings for all return line connections.
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Lubricate all O-rings with engine oil or assembly oil before instal‐
ling.
– Push the return line connections carefully over the new seals
and onto the injectors. The catch should engage audibly. Then
press release pin down carefully.
– Erase fault in fault memory using a diagnostic tester.
8.5 Checking for injectors sticking open

(piezo injectors)

Audi TT 2007 ➤
♦ Socket -T40055-
♦ Screw plug -T40204-
WARNING

– Erase fault memory of engine control unit.

– Clean all connections (with commercial cleaning solution or
similar) before removing.
8. Injectors 41
Audi TT 2007 ➤
Note
♦ Make sure all parts are clean; no dirt must be allowed to enter
the fuel system.
♦ Check all cylinders in turn.

Start with cylinder No. 1.
– Unscrew union nut at fuel rail for cylinder 1 and also loosen
union nut on injector slightly using socket -T40055- . Seal off
open connection on injector pipe.
– Plug open connection using plug -T40204- .
– The electrical connector of the relevant injector must remain
connected.
– Erase all faults in fault memory.
– Perform test drive.
Note
♦ The fault “positive fuel pressure control” should no longer be

indicated when the defective injector has been located.
♦ Other fault messages may possibly be stored in the memory.
These result from previous steps and can be disregarded.
– Interrogate fault memory after road-testing vehicle. If a fault

relating to “positive fuel pressure control” is still being indica‐
ted, repeat the above steps for all rail element connections
until the fault is no longer indicated after the road-test.
Observe all instructions for connecting injector pipes.
– Lubricate threads of union nuts with fuel.
– Hand-tighten union nuts on high-pressure pipes. Make sure
that connections are not under tension.
8.6 Removing and installing injectors (piezo

injectors)

Audi TT 2007 ➤
♦ Tool insert, AF 17 -V.A.G 1331/6- with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Socket -T40055-
♦ Puller -T10055- with adapter -T10055/1-
8. Injectors 43
Audi TT 2007 ➤
♦ Assembly sleeve -T10377-
Removing
WARNING Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Caution
♦ Mark cylinder numbers on injector units. They must al‐

ways be re-installed on the same cylinders.
tion system.
diately.

-arrow-.
Note
Should you not be able to pull the return line connection upwards,
open the connection using a small screwdriver.

Audi TT 2007 ➤
– Unplug electrical connectors -1- at injectors which are to be

removed.
– Loosen union nuts for high-pressure pipes at injectors using
socket -T40055- (17 mm).
– Loosen union nuts for high-pressure pipes at fuel rail using tool
insert, AF 17 -V.A.G 1331/6- .
– Unbolt covers for injectors -arrows-.

– Pull covers upwards and turn them 1/4 turn (90°).
Caution
When removing securing nuts on injector there is a risk that the

relevant nut will fall into the cylinder head. Proceed very care‐
fully to prevent unnecessary dismantling or further damage.
– Unbolt clamping pieces for injectors -arrows-.
8. Injectors 45
Audi TT 2007 ➤
– Apply puller -T10055- with adapter -T10055/1- as shown in

illustration and pull injector out upwards by tapping gently.
– After removal, lay injectors on a clean cloth.
Important instructions for installing injectors:
• When removing and installing, always renew the following
components and seals/O-rings: “copper seal”, “O-ring for in‐
jector bore”, “O-ring for injector return connection”.
connection”.
• Lubricate all O-rings with engine oil or assembly oil before in‐
stalling.
Note
♦ Note identification marks for cylinder allocation when re-in‐

stalling high-pressure pipes.
♦ The high-pressure pipes can be re-used after performing the
following checks:
♦ Check taper seats of high-pressure pipes for deformation and
cracks.
♦ The bore of the pipe must not be distorted, restricted or oth‐
erwise damaged.
♦ Corroded pipes must not be used again.
If a used injector is being re-installed:

– Spray tip of injector nozzle with rust-releasing spray. Wait ap‐
prox. 5 minutes and wipe off soot particles and oil with a cloth.
– If an injector
Protected byiscopyright.
very dirty,
Copyingthe tip oforthe
for private nozzle
commercial should
purposes, also
in part or in be
whole, is not
cleaned withunless
permitted a soft brassbywire
authorised brush
AUDI AG. AUDItoAGmake
does notitguarantee
easierortoaccept
re‐ any liability
move the withcopper
respect to seal. Do notofapply
the correctness thein wire
information brushCopyright
this document. to the bores
by AUDI AG.
in the nozzle.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
– Clean off deposits under the copper seal using a suitable scra‐
per.
Caution
To remove carbon deposits from the injector sealing surface,

clean the injector seat in the cylinder head with a cloth soaked
in engine oil or rust solvent. Take care not to damage the seal‐
ing surface.

Audi TT 2007 ➤
– Renew seal for injector bore using assembly sleeve -T10377- .
– To prevent damage to the new O-ring -2- for the fuel return
line connection, push it over assembly tool -1-.
– Install injectors.
– To tighten unions of high-pressure pipes at injectors, use tor‐

que wrench -V.A.G 1331- with ratchet -V.A.G 1331/1- and
socket -T40055- .
8. Injectors 47
Audi TT 2007 ➤
– To tighten unions of high-pressure pipes to fuel rail, use torque

wrench -V.A.G 1331- with tool insert, AF 17 -V.A.G 1331/6- .
♦ Observe tightening torque: Installing high-pressure pipes
⇒ page 52 .
♦ Tightening torques: refer to exploded view of fuel system
⇒ page 14
– Press return line connections carefully over the seals and onto
the injector units (check seal for damage before connecting
return line). The catch should engage audibly. Then press re‐
lease pin down carefully.
After replacement of one or more injectors, the “injector delivery
calibration values” and “injector voltage calibration values” for the
new injectors must be written into the engine control unit Vehicle
diagnostic, testing and information system -VAS 5051B- .
and “injector voltage calibration values” are correctly entered for
all the other injectors. Do NOT attempt to re-enter these calibra‐
tion values if the correct values are already stored in the engine
control unit.
Bleeding fuel system and checking for leaks
Note
The fuel system is self-bleeding; do not open the high-pressure

connections.
– Run engine at idling speed for several minutes and then switch
off.
– Switch off ignition.
– Check the complete fuel system including all 4 return line con‐
nections for leaks.
Renew affected component if leakage still occurs after tightening
to correct torque.
Note
The return lines can only be renewed together with the pressure
retention valvewithas onetounit.

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

Note

Audi TT 2007 ➤
9 Components of injection system
9.1 Removing and installing air mass meter

-G70-
Removing
– Unplug electrical connector -1- at air mass meter -G70- .
– Unscrew both bolts from air mass meter -G70- and carefully
pull air mass meter -G70- out of guide on air cleaner housing.
Installing
Note
♦ Use a silicone-free lubricant when installing the air hose.
– Check for dirt in air duct leading to air filter element. If neces‐
sary, clean salt residue, dirt and leaves out of air cleaner
housing (top and bottom sections); wash out or use a vacuum
cleaner as required. Removing and installing air cleaner
⇒ page 22 .
quence.

flap motor -V157-
Removing
– Remove engine cover panel -arrows-.
9. Components of injection system 49

Audi TT 2007 ➤

-arrow-.

Audi TT 2007 ➤

Note
Disregard item -4-.
– Unplug electrical connector -3- at intake manifold flap motor -

V157- .
Note
Disregard items marked -1, 2, 4- and -arrow-.
– Unscrew bolts -arrows- and detach intake manifold flap motor

-V157- .
Installing
• Tightening torque: refer to intake manifold with attached com‐
ponents - exploded view ⇒ page 24
Note
Renew O-ring.
– Install air pipe: Charge air cooler - exploded view ⇒ Rep. Gr.
21 .

Audi TT 2007 ➤
Note

and the seal.

lock -2-.
– Press air pipe/hose again and pull again to check
permitted that plug-in
connector is correctly engaged. with respect to the correctness of information in this document. Copyright by AUDI AG.
9.3 Installing high-pressure pipes


Audi TT 2007 ➤
♦ Socket -T40055-
Procedure
Note

following checks:
cracks.
erwise damaged.
– Use vacuum cleaner to remove dirt from taper seat at fuel rail.
– Clean fuel pipe and end of pipe using cleaning solution and
dry with compressed Protected
air. by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Lubricate threads of union nuts to
with respect with fuel. of information in this document. Copyright by AUDI AG.
the correctness
– Hand-tighten union nuts on high-pressure pipes (ensure that

pipes are not under tension).
• Tightening torque: 25 Nm

Audi TT 2007 ➤
– To secure high-pressure pipes, use torque wrench -V.A.G

1331- with ratchet -V.A.G 1331/1- and socket, AF 17 -
T40055- .
– To secure high-pressure pipes, use torque wrench -

V.A.G 1331- with tool insert, AF 17 -V.A.G 1331/6- .
9.4 Checking pressure retention valve in

fuel return line
The pressure retention valve maintains a residual pressure of ap‐
prox. 10 bar in the fuel return line.
This residual pressure is required for the control function of the
piezo injectors.
♦ Tester for fuel return system -6330-
WARNING


– Clean return line connection on cylinder 1 (with commercial
cleaning solution or similar) before removing.
– Dry return line connection on cylinder 1.
– Cover return line connection on cylinder 1 with a cloth.

Audi TT 2007 ➤
– Pull return line connection off cylinder 1; to do so, press both

tabs down and at the same time pull centre piece up to release
connection -arrow-.
Note
Take care to keep all components clean. No dirt must be allowed

to get into the disconnected return line or the open connection on
the injector.
– Connect tester fortofuel return system -VAS

in this6330- between re‐
with respect the correctness of information document. Copyright by AUDI AG.
turn line connection on injector and return line.
– Start engine.
– Check pressure indicated on tester.
♦ Specification: approx. 10 bar
If the value does not match the specification, fit a new pressure
retention valve.
9.5 Checking fuel system for leaks

– Run engine at idling speed for several minutes (do not press
accelerator) and then switch off. Fuel system will bleed itself
automatically.
– Check the entire fuel system for leaks.
to correct torque.
– After completing the repair, road-test the vehicle. Accelerate
with full throttle at least once. Then check the high-pressure
section of the fuel system again for leaks.
Note
9.6 Checking fuel pressure (low pressure)

system

Audi TT 2007 ➤
♦ K-Jetronic pressure tester -V.A.G 1318-
Test conditions:
• Battery voltage at least 12.5 V.
• Fuel filter OK.
• Ignition off.
Checking residual pressure
WARNING
♦ Always read rules for cleanliness andProtected

instructions for Copying for private or commercial purposes, in part or in whole, is not
by copyright.
working on fuel system ⇒ page 1 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
nection.
– Disconnect fuel supply line -arrow- at high-pressure pump.

Audi TT 2007 ➤
– Connect K-Jetronic pressure tester -V.A.G 1318- to fuel sup‐

ply line -1- with suitable adapter -2-. Connect the other adapter
-3- from K-Jetronic pressure tester -V.A.G 1318- to open con‐
nection at high-pressure pump.
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
In this way the K-Jetronic pressure tester -V.A.G 1318- is con‐
nected into the fuel supply line.

– Let fuel pumps run until maximum fuel pressure has built up.
• Specification: at least 3.5 bar
If specification is not obtained:
Check union between pressure gauge and fuel line for leaks.
Test pressure gauge for leaks.
Check fuel lines and their connections for leaks.
Fuel filter is blocked.
Check delivery rate of fuel pump ⇒ page 57 .
Note
Check fuel system for leaks.
9.7 Checking delivery rate of fuel pumps

♦ Measuring container (fuel-resistant)
Test conditions:
• Battery voltage at least 12.5 Volt.
• Fuel filter OK.
• Ignition switched off.

Audi TT 2007 ➤
Checking fuel delivery rate

WARNING

nection.
– Disconnect fuel supply line -arrow- at high-pressure pump.
– Hold fuel supply line -1- into a measuring container -2-.

– Then select “Basic setting”. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not


– Let fuel pumps run for 15 seconds and exit activation function.
• Specification in 15 seconds: at least 600 ml
If minimum delivery rate is not reached, check for the following
causes:
♦ Fuel pumps were not running for 15 seconds
♦ Fuel lines have been crushed
♦ Fuel filter is blocked
♦ Fuel pumps defective: Checking ⇒ Rep. Gr. 20
Note

Audi TT 2007 ➤
9.8 Checking fuel pressure regulating valve

-N276-
WARNING


– Remove noise insulation from injectors.
– Detach fuel return line -1-.
– Seal off the open return line connection with a plug -1-.
– Attach a suitable hose -3- to return line -2-.
– Hold thiswith
hose -1-
respect in correctness
to the a suitable container
of information -2-
in this to measure
document. the
Copyright by AUDI AG.
return flow rate.
– Start engine and let it idle.
• Specification: 100 ml (+/- 10 %) in 30 seconds
If specification is not obtained, fuel pressure regulating valve -
N276- is defective.
If it is not possible to start engine, perform test at starter cranking

speed.
N276- is defective.
9.9 Removing and installing fuel pressure

regulating valve -N276-

Audi TT 2007 ➤
♦ Torque wrench
♦ Open-end spanner insert, 30 mm
♦ Open-end spanner, 33 mm

Audi TT 2007 ➤
The fuel pressure regulating valve -N276- -2- is located in the fuel
rail. It maintains a constant pressure in the fuel rail and the injector
pipes (high-pressure fuel circuit).
If the pressure in the high-pressure fuel circuit is too high, the
regulating valve opens to allow some of the fuel to flow back from
the fuel rail to the fuel tank via a return line.
If the pressure in the high-pressure fuel circuit is too low, the fuel
pressure regulating valve -N276- closes and seals off the high-
pressure section of the system from the low-pressure section.
Note
The fuel pressure regulating valve -N276- cannot be re-used.
Removing
WARNING


– Remove fuel rail ⇒ page 28 .
– Before removal, clean area around thread for fuel pressure
regulating valve -N276- using commercial cleaning solution or
similar (no dirt must enter opening in fuel rail).
Note
Clean carefully; cleaning solution must not enter the electrical

connector.
– Dry off fuel pressure regulating valve -N276- .

– Slacken union nut (counterhold at hexagon flats on housing).
Then unscrew and remove by hand.
– Remove dirt from thread and sealing surface using vacuum
cleaner. Do not use metal tools, etc.
Note
Seal off hole immediately with a suitable plug to prevent dirt from
entering.

Audi TT 2007 ➤
Installing
Note
♦ The fuel pressure regulating valve -N276- has a deformable

sealing lip and no separate seal; it can therefore be used only
once.
♦ Check that sealing surfaces (deformable sealing lip) and
threads on new fuel pressure regulating valve -N276- are not
damaged.
♦ Check sealing surface at bore.
♦ The beginning of the thread and the deformable sealing lip of
the fuel pressure regulating valve -N276- must be coated with
diesel fuel.
– Screw on union nut by hand.

– Align new regulating valve so that connecting wire is free of
tension after connector is attached.
– Hold regulating valve in this position by holding
permitted unless authorisedhexagon
by AUDI AG.flats
on housing of regulating valve with open-end spanner or pliers

(water pump pliers or similar).

– Use suitable torque wrench with an open-end spanner insert
(30 mm) to tighten union nut.
– Install fuel rail ⇒ page 28 .
• Tightening torque: refer to fuel system - exploded view
⇒ page 14
– After installation, run engine at moderate speed for several
minutes and then switch off.
– Interrogate fault memory again.

Audi TT 2007 ➤

sender -G247-
The fuel pressure sender -G247- -1- is located in the fuel rail and
continuously measures the fuel pressure in the high-pressure
system. It transmits a corresponding voltage signal to the engine
control unit -J623- .
Should the sender fail, the engine control unit will control the fuel
pressure via a mapped open-loop backup function, allowing a
maximum of approx. 3000 rpm.
Removing
WARNING


sender using commercial cleaning solution etc. (no dirt must
enter opening in fuel rail).
Note

connector.
– Dry off fuel pressure sender -G247- .

– Unplug electrical connector at fuel pressure sender -G247- .
– Unscrew fuel pressure sender -G247- .
– Extract dirt from opening in fuel rail (thread and sealing sur‐
face)Protected
using a by vacuum cleaner.
copyright. Copying Doornot
for private use metal
commercial tools,
purposes, in part etc.
or in whole, is not
Note
Seal off opening in fuel rail immediately with a suitable plug to

prevent dirt from entering.
Installing
Note
♦ The fuel pressure sender -G247- does not have a seal; in‐
stead, it has a deformable sealing lip.
threads on fuel pressure sender -G247- are not damaged. If
inspection of fuel pressure sender -G247- shows that it is OK,
it can be used again.
♦ Check sealing surface at opening in fuel rail.
the fuel pressure sender -G247- must be lubricated with Mo‐
lykote grease.

Audi TT 2007 ➤
– Screw in fuel pressure sender -G247- by hand.

– Then tighten fuel pressure sender -G247- to specified torque.
• Tightening torque: refer to fuel system - exploded view
⇒ page 14
After installing fuel pressure sender -G247- , leave engine running
at moderate speed for a few minutes when bleeding fuel system
and then switch off again.
Note
The fuel system is “self-bleeding”; do NOT open the high-pres‐

sure connections.
– Interrogate fault memory and erase it if necessary.

– Carefully check the entire fuel system for leaks.
to correct torque.
Note
– After road test, interrogate fault memory again.

Audi TT 2007 ➤
10 Lambda probe and exhaust gas tem‐

perature sensors - exploded view
10.1 Lambda probe and exhaust gas temperature sensors - exploded view
1 - Bolt for exhaust gas pres‐

sure sensor 1 -G450-
❑ 4.5 Nm
⇒ page 67
❑ Pressure pipes to partic‐
ulate filter: 45 Nm
2 - Measuring line for exhaust
gas pressure sensor 1 -G450-
3 - Particulate filter
❑ Adaption must be per‐
formed after particulate
filter has been renewed;
use a vehicle diagnostic
tester
4 - Exhaust gas temperatureProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
sender 3 -G495- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

⇒ Rep. Gr. 26
❑ 45 Nm
Lambda probe heater -Z19-
❑ New Lambda probes
are coated with an as‐
sembly paste
❑ In the case of a used
Lambda probe, coat on‐
ly thread with high-tem‐
perature paste; refer to
⇒ Parts catalogue for
high-temperature paste
❑ The assembly paste /
must not make contact
with the slots on the
Lambda probe body
❑ 50 Nm
❑ 45 Nm
7 - Nut
10.2 Removing and installing Lambda probe

-G39- with Lambda probe heater -Z19-
10. Lambda probe and exhaust gas temperature sensors - exploded view 65
Audi TT 2007 ➤
♦ Lambda probe open ring spanner set -3337-
Removing
– Unplug electrical connector -4- for Lambda probe -G39- .
– Unscrew Lambda probe -G39- -3- using tool from Lambda

probe open ring spanner set -3337- .
Installing
When installing, note the following:
Note
♦ Threads of new Lambda probes are already coated with as‐

sembly paste; the paste must not get into the slots on the 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. For high-temperature paste
refer to ⇒ Parts catalogue .
♦ When installing, the Lambda probe wiring must always be re‐
attached at the same locations to prevent it from coming into
contact with the exhaust pipe.
• Tightening torques: refer to Lambda probe - overview permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 65

Audi TT 2007 ➤
10.3 Removing and installing exhaust gas

pressure sensor 1 -G450-
Exhaust gas pressure sensor 1 -G450- is connected via two pipes
to the take-off points upstream and downstream of the particulate
filter. Lambda probe - overview ⇒ page 65
Exhaust gas pressure sensor 1 -G450- detects the amount of de‐
posits in the particulate filter.
Removing
– Before disconnecting, spray hoses coming from exhaust gas
pressure sensor 1 -G450- with suitable release agent.
– Detach electrical connector -1- from exhaust gas pressure
sensor 1 -G450- .
– Carefully pull hoses off connections (take care to keep the ho‐
ses straight; the connections can easily break off exhaust gas
pressure sensor 1 -G450- ).
– Unscrew bolt and remove exhaust gas pressure sensor 1 -
G450- .
Installing
– When installing, note the following:
• Tightening torque for boltwithfor exhaust
respect gas pressure
to the correctness sensor
of information 1-
in this document. Copyright by AUDI AG.
G450- : refer to Lambda probe - overview ⇒ page 65 .
Note
♦ Before installing, blow out hoses leading from exhaust gas

pressure sensor 1 -G450- to particulate filter towards particu‐
late filter with compressed air (hoses can become obstructed
or may ice up due to condensation).
♦ Make sure that hoses are securely fitted and seal properly.
♦ If pressure connections are detached from particulate filter,
tighten to 45 Nm.
Adaption must be performed after renewing exhaust gas pressure

sensor 1 -G450- and/or particulate filter. (The procedure is de‐
scribed under Guided Functions.) Use vehicle diagnostic tester
to do so.
10. Lambda probe and exhaust gas temperature sensors - exploded view 67
Audi TT 2007 ➤
11 Engine control unit
11.1 Wiring and component check with test

box -V.A.G 1598/42-
♦ Adapter cable -V.A.G 1598/39-1-
♦ Test box -V.A.G 1598/42-

Audi TT 2007 ➤
Note
♦ The test box has 105 sockets. The connecting cable can be
disconnected from the test box. This means that only the cable
(and not the test box) has to be purchased for future engine
control units with different types of connectors.
♦ The smaller of the two connectors on the engine control unit
has the contacts 1 to 60. The larger of the two connectors has
the contacts 1 to 94.
♦ To carry out tests on the 60-pin wiring harness connector, the
adapter cable -V.A.G 1598/39-1- is connected to connector
“A” on the test box. For components connected to 60-pin wiring
harness connector ⇒ Current flow diagrams, Electrical fault
adapter cable -V.A.G 1598/39-2- must
Protected be connected
by copyright. to con‐
Copying for private or commercial purposes, in part or in whole, is not
nectors “A” and “B” on the testpermitted
box. unless
For components
authorised by AUDIconnec‐
ted to 94-pin wiring harness connector
with respect ⇒ Current
to the flow
correctness of information in this document. Copyright by AUDI AG.
diagrams, Electrical fault finding and Fitting locations.
♦ The test box -V.A.G 1598/42- is designed so it can be con‐
nected both to the wiring harness for the engine control unit
and to the engine control unit itself at the same time.
♦ The advantage of this is that the electronic engine control sys‐
tem remains fully functional when the test box is connected
(for example, for measuring signals when the engine is run‐
ning).
♦ The relevant test procedure will state whether it is necessary
to also connect the engine control unit to the test box.
WARNING
To prevent damage to the electronic components, select ap‐

propriate measuring range before connecting the measuring
cables and observe the test requirements.
– Remove engine control unit ⇒ page 70 .

– Connect the test box -V.A.G 1598/42- to wiring harness with
adapter cable -V.A.G 1598/39-1- or adapter cable -V.A.G
1598/39-2- . Connect earth clip of test box to negative terminal
of battery. The instructions for performing the individual tests
indicate whether or not the engine control unit itself also needs
to be connected to the test box.
– Carry out test as described in appropriate repair procedures.
Installing engine control unit
Installation is performed in the reverse sequence.
– After installation, the protective housing must be re-fitted on
the control unit.
– Clean threaded holes for shear bolts to remove any residue
from locking fluid. This can be done using a thread tap.
– Always use new shear bolts.
Perform the following after reconnecting engine control unit:
11. Engine control unit 69

Audi TT 2007 ➤
11.2 Renewing engine control unit -J623-

♦ Hot air blower -VAS 1978/14A- -item 1- with nozzle attachment
-2- from wiring harness repair set -VAS 1978 B-
♦ Small, commercially available vice grip pliers -3-
Removing
– Before removing the engine control unit -J623- , the adaption
values of the injectors and the ash deposit mass must be read
out. Use vehicle diagnostic tester to do so.
Note
If the adaption values of the injectors of the old (defective) engine

control unit cannot be read out, the adaption values must be en‐
tered into the new engine control unit manually and the adaption
procedure must be performed accordingly.
The engine control unit -1- is bolted to a protective casing

-2 and 5-. To make it more difficult to unscrew the shear bolts
-4- for locking plate -2-, their threads have been coated with lock‐
ing fluid.
The protective housing has to be removed before the connectors
can be unplugged from the engine control unit (e.g. to connect
the test box or renew the engine control unit).
– Switch off ignition and remove ignition key.
– Lever off caps on windscreen wiper arms with a screwdriver.
– Loosen hexagon nuts -arrows- several turns.

– Loosen wiper arms from wiper shaftswithbyrespect
tilting them slightly.
– Completely remove hexagon nuts and detach wiper arms from

wiper shafts.
Note
Use puller (commercially available) to remove wiper arms if nec‐

essary.

Audi TT 2007 ➤
– Pull off rubber seal -1- and remove plenum chamber cover
-2-.
– Release clip -arrow- and remove engine control unit -J623- .
Note
Cover painted surfaces with a cloth to prevent scratching.
To help prevent unauthorised access to the connectors on the

engine control unit, the engine control unit -1- is bolted on by
means of locking plates -2 and 5- and shear bolts -3 and 4-.
The threads of the two shear bolts -4- which are not screwed into
the engine control unit 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 neces‐
sary and would cause overheating of the control unit.

Audi TT 2007 ➤
Select settings on hot air blower as shown in illustration, i.e. set

temperature potentiometer -2- to maximum heat output and two-
stage air flow switch -3- to position 3.
WARNING
Heating the thread of the locking plate also heats up the shear
bolts and parts of the metal housing. Take care to avoid burns.
It is also important to ensure that only the thread is heated and
none of the surrounding components if at all possible. These
should be covered if necessary.
Apply heat to the threads of the shear bolts on the connector side
as shown in the illustration.
Switch on the hot air blower and heat the bolt for approximately
20 ... 30 seconds.
– Unscrew shear bolts using suitable vice-grip pliers (see arrow

in illustration).
– The two shear bolts screwed into the engine control unit do
not need to be heated. They can be removed without heating.
– Detach protective housing from control unit connectors.
– Release connectors on engine control unit -J623- and unplug
connectors.
– Take out old engine control unit -J623- and connect new en‐
gine control unit -J623- .
Installing
the engine control unit -J623- .
The procedure required after connecting the new engine control
unit is described in the Guided Fault Finding or Guided Functions.
Use vehicle diagnostic tester to do so.
– The injector delivery calibration and the injector voltage cali‐
bration must additionally be re-adapted in the engine control
unit -J623- after the control unit has been renewed (these
functions influence engine power and exhaust emissions).
– On vehicles with particulate filter the current mileage (km)
reading must be stored in the engine control unit via an adap‐
tion procedure.

Audi TT 2007 ➤
28 – Glow plug system

1 Checking glow plug system
Automatic glow period control unit -J179- is located in relay and
fuse holder in electronics box in plenum chamber.
A - Automatic glow period control unit -J179-
The glow plug system is activated via the automatic glow period
control unit -J179- . The automatic glow period control unit -J179-
is capable of self-diagnosis.
A fault is stored in the engine control unit if a fault occurs in the
glow plug system.
The procedure for checking the glow plug system is described in
the Guided Fault Finding.
For faster starting, the vehicle is equipped with electronically con‐
trolled glow plugs and a separate glow period control unit.
Each glow plug is activated and diagnosed separately.
1.1 Removing and installing glow plugs

♦ U/J extension and socket, 10 mm -3220-
♦ Pliers -3314-
Removing
1. 73
Audi TT 2007 ➤
Caution
Make sure that no wire connection is damaged when unplug‐

ging the connectors; otherwise the entire wiring harness must
be renewed. When unplugging the connectors, do not com‐
press the pliers -3314- with too much force so that the support
sleeve is not damaged.
– Apply groove -arrow A- of pliers -3314- to collar of support

sleeve -arrow B- and pull connectors off glow plugs.
– Clean glow plug openings in cylinder head; make sure no dirt
gets into cylinder.
Note
♦ Cleaning procedure:
♦ Use a vacuum cleaner to remove coarse dirt.
♦ Spray brake cleaner or suitable cleaning agent into glow plug
openings, let it work in briefly, and blow out with compressed
air.
♦ Then clean the glow plug openings using a cloth moistened
with oil.
– To slacken the glow plugs use special tool U/J extension and
socket, 10 mm -3220-
Installing
– To tighten the glow plugs use special tool U/J extension and
socket, 10 mm -3220- with a suitable torque wrench.
– Then tighten glow plugs to specified torque.
– Attach glow plug connectors correctly and make sure they are
securely fitted.
1.2 Removing and installing engine speed

sender -G28-
Removing
– Remove oil filter bracket ⇒ Rep. Gr. 17 .
– Unplug electrical connector at engine speed sender -G28-
-arrow- using assembly tool -T10118- .
Note
To release electrical connector without assembly tool -T10118- ,

press connector on engine speed sender in with a screwdriver
and at the same time lift release tab with a thin wire hook.
– Move wiring clear.
74 Rep. Gr.28 - Glow plug system

Audi TT 2007 ➤
– Unscrew securing bolt -2- for engine speed sender -G28-

-item 1-.
Installing
– Install oil filter bracket ⇒ Rep. Gr. 17 .
• Tightening torque: refer to overview of fitting locations
⇒ page 5 .
1.3 Removing and installing Hall sender -

G40-
– Remove front right wheel housing liner.
– Remove poly V-belt ⇒ Rep. Gr. 13 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove toothed belt ⇒ Rep. Gr. 15 . with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove vibration damper ⇒ Rep. Gr. 13 .

– Unplug electrical connector for Hall sender -G40- -arrow-.
– Release connector from its retainer.
– Unbolt Hall sender -G40- -arrow-.
– Using a screwdriver, remove projections and take out cover

for repair opening -arrows-.
– Take Hall sender -G40- off cylinder head and guide its con‐
nector through repair opening in toothed belt cover.
Installing
Install in reverse order. Note the following:
♦ Seal repair opening in toothed belt cover with rubber plug; for
rubber plug refer to ⇒ ETKA (Electronic parts catalogue) .
– Fit toothed belt and adjust valve timing ⇒ Rep. Gr. 15 .
1. 75
Service
Workshop Manual
Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-
valve common rail, generation II)
Engine ID
CFG
B
Edition 05.2010

Service
Repair Group
28 - Glow plug system

Copyright © 2010 Audi AG, Ingolstadt D3E8029B417

Audi TT 2007 ➤
TDI injection and glow plug system (4-cyl. 2.0 ltr. 4-valve common rail, generation II) - Edition 05.2010
Contents

1.4 To avoid any risk of injuries to persons and/or damage to the injection and glow plug system,
always observe the following safety precautions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 System layout ............................................................
12
4 Bleeding fuel withsystem
respect to the. correctness
. . . . . . .of.information
. . . . . . in. this
. . document.
. . . . . . Copyright
. . . . . by
. .AUDI
. . . AG.
.................... 14
5 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.4 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1 Intake manifold with attached components - exploded view . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.1 High-pressure pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.3 Performing first fuel filling operation after installing high-pressure pump . . . . . . . . . . . . . . 29
8 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.1 Injectors - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.2 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.3 Performing adaption of injector delivery calibration values . . . . . . . . . . . . . . . . . . . . . . . . 33
8.4 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.5 Checking return flow rate of injectors at starter cranking speed . . . . . . . . . . . . . . . . . . . . 36
8.6 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.7 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.1 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.2 Installing high-pressure pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.3 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.4 Checking fuel pressure (low pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.5 Checking delivery rate of fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.6 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 51
9.8 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10 Lambda probe and exhaust gas temperature senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.1 Lambda probe and exhaust gas temperature senders - exploded view . . . . . . . . . . . . . . . . 58
10.3 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 59
11.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Contents i
Audi TT 2007 ➤
1 ...................................................................... 67
1.1 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.2 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 69
1.3 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
ii Contents
Audi TT 2007 ➤

cleanliness
⇒ “1.1 Safety precautions”, page 1
⇒ “1.2 Safety precautions for vehicles with start/stop system”,
page 1
⇒ “1.3 Rules for cleanliness and instructions for working on fuel
system”, page 2
⇒ “1.4 To avoid any risk of injuries to persons and/or damage to
the injection and glow plug system, always observe the following
safety precautions:”, page 3
⇒ “1.5 Checking vacuum system”, page 3

WARNING

erly secured.
secured.
person.

start/stop system
WARNING

start/stop system.

Audi TT 2007 ➤

To prevent the high-pressure fuel pump from running while it is
empty and to ensure that the engine starts quickly after parts have
been renewed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank and
the high-pressure fuel pump are removed or renewed, the ba‐
be performed to bleed the fuel system.
♦ If the supplementary fuel pump, fuel line (between fuel tank
and high-pressure fuel pump) or fuel filter is removed or re‐
newed, the basic setting “Checking fuel system pressurisation
pump” must be performed before the engine is started for the
first time.
♦ If the high-pressure fuel pump is removed or renewed, the ba‐
be performed before the engine is started for the first time.
Procedure for first fuel filling ⇒ page 29
• Clean tools and workbench etc. before working on the injection
system.
• Thoroughly clean all unions and surrounding areas before dis‐
connecting.
• When removing components, plug all open connections im‐
mediately with suitable clean sealing caps.
• Do not remove sealing caps from components until immedi‐
ately prior to installation. After removal, components should
be kept in new, sealable plastic bags (use the original new part
packaging if possible).
• Before installation, check the injectors and their surroundings
visually; they must be undamaged and free of lint. Make sure
the injector bores in the cylinder head are clean. Wipe out if
necessary using a clean cloth, taking care not to cause dam‐
age. Do not use sharp objects of any kind.
• If the high-pressure fuel lines are to be re-used, you must mark
them before removal. High-pressure fuel lines must always be
re-installed in their original positions (i.e. on the same cylin‐
der).
per seal” and “O-ring for injector bore”.
• Always fit new copper seals for the injectors. Check all new O-
rings for damage before installing. Lubricate O-rings lightly
with assembly oil or clean engine oil before installing.
• Take care not to damage the injectors when removing the old
copper seals.
• Alignwith
the high-pressure
respect to the correctnessfuel lines so
of information they
in this are free
document. of tension.
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.

Audi TT 2007 ➤
• Do not dismantle individual common rail components.

• If there is a fault, the complete components must be renewed.
• Do not bleed the common rail system by unfastening high-
pressure components after the engine has been started.
• When the engine is running, do not perform any repairs to the
common rail system; in particular, do not open or detach the
high-pressure pipes.
• All cable ties which are released or cut open when removing
• When the fuel system is open: Do not work with compressed
air if this can be avoided. Do not move the vehicle unless ab‐
solutely necessary.
• Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must
Protected be cleaned
immediately. Damaged hoses must be renewed.
1.4 To avoid any risk of injuries to persons

and/or damage to the injection and glow
plug system, always observe the follow‐
ing safety precautions:
♦ Persons wearing a pacemaker should not lean over the engine
compartment while the engine is running, as the injectors use
high voltage pulses.
ning.
necting injection and glow plug system wiring or tester cables.
damaged.
unit and stored. The event memory should therefore be inter‐

Procedure
♦ Cracks

Audi TT 2007 ➤

– If a fault 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 a vacuum with the hand vacuum
pump -VAS 6213- or if the vacuum pressure drops again im‐
mediately, check the hand vacuum pump and connecting
hoses for leaks.

Audi TT 2007 ➤
2 Overview of fitting locations

Components “A” to “H” are not shown in the illustration.
1 - Supplementary fuel pump -

V393-
❑ Exploded view ⇒ Rep.
Gr. 20
2 - Pressure differential sender
-G505-
❑ Exploded view
⇒ page 58
❑Protected
Adaption must be per‐
formed
permitted after
unless renewing
this
with component
respect to the correctness of information in this document. Copyright by AUDI AG.
3 - Hall sender -G40- (cam‐

shaft position sensor)
⇒ page 10
❑ 10 Nm
4 - Injectors
❑ Exploded view
⇒ page 31
⇒ page 7
❑ Exploded view
⇒ page 58
❑ 50 Nm
7 - Position sender for charge
pressure positioner -G581-
⇒ page 10
8 - Exhaust gas recirculation
control motor -V338- with exhaust gas recirculation potentiometer -G212-
❑ Integrated into exhaust gas recirculation cooler
❑ Removing and installing ⇒ Engine, mechanics; Rep. Gr. 26
❑ Exploded view ⇒ page 43
❑ Checking ⇒ page 46
❑ For Lambda probe -G39-

Audi TT 2007 ➤

❑ 4.5 Nm
17 - Throttle valve module -J338- with throttle valve potentiometer -G69-
18 - Glow plugs
❑ 17 Nm
❑ In fuel supply line
20 - Charge pressure sender -G31- with intake air temperature sender -G42-
21 - High-pressure pump with fuel metering valve -N290-

❑ Do not open fuel metering valve -N290-
❑ After renewing, first fuel filling operation MUST be performed (it is important not to allow pump to run
while it is still empty) ⇒ page 29
24 - Fuel filter
❑ Exploded view ⇒ Rep. Gr. 20
❑ Renewing ⇒ Rep. Gr. 20
A - Low heat output relay -J359- and high heat output relay -J360-
❑ Fitting location ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
B - Brake light switch -F- and brake pedal switch -F47-
C - Clutch position sender -G476-

Audi TT 2007 ➤
E - Exhaust gas temperature sender 1 -G235-

F - Exhaust gas temperature sender 3 -G495-
G - Exhaust gas temperature sender 4 -G648-
H - Particulate filter
❑ Combined with catalytic converter
❑ Adaption must be performed after renewing this component

♦ In electronics box (plenum chamber)
Fitting location: accelerator position sender -G79- and accelerator

position sender 2 -G185-
♦ Combined with accelerator pedal module
Note
The illustration shows the set-up for left-hand drive vehicles.
Removing and installing accelerator pedal module ⇒ Rep. Gr.

20
Fitting location of brake light switch -F- and brake pedal switch -
F47-
1- Brake light switch -F- and brake pedal switch -F47-
♦ On brake master cylinder

Audi TT 2007 ➤
Fitting location of clutch position sender -G476-

♦ On clutch master cylinder-arrow-.
Integrated functions: clutch pedal switch for engine start -F194-
and clutch pedal switch -F36- (manual gearbox only)
Fitting location of fuel pump control unit -J538-

Removing andpermitted
installing ⇒ Rep. Gr. 20
Fitting location of charge pressure sender -G31- with intake air

temperature sender -G42-
1- Charge pressure sender -G31- with intake air temperature
sender -G42-
♦ At air pipe (right-side)

Audi TT 2007 ➤
Components at rear of engine

2 - Exhaust gas recirculation control motor -V338- with exhaust
gas recirculation potentiometer -G212-
4 - Vacuum unit for exhaust gas recirculation cooling system
Electrical connectors
1- For exhaust gas temperature sender 1 -G235-
3- For Lambda probe -G39-
Fitting location of pump for exhaust gas recirculation cooler -

V400-
♦ At front of engine
Fitting location of fuel temperature sender -G81-

♦ In fuel supply line at high-pressure pump

Audi TT 2007 ➤
Fitting location of Hall sender -G40-

♦ Next to camshaft sprocket -arrow-
Fitting location of coolant temperature sender -G62-

♦ On right side of engine under exhauster pump
Fitting location of radiator outlet coolant temperature sender -

G83-
♦ In coolant pipe (right-side) above alternator
Fitting location of position sender for charge pressure positioner

-G581- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ At rear of engine at turbocharger -arrow-.

Audi TT 2007 ➤
Fitting location of exhaust gas recirculation cooler change-over

valve -N345-
♦ On intake manifold -left arrow-.
Fitting location of engine speed sender -G28-

1- Engine speed sender -G28-
2- Sender wheel
♦ On flywheel side of engine.

Audi TT 2007 ➤
3 System layout
WARNING

Caution
The high-pressure fuel pump has very close tolerances and

must not be allowed to run without fuel. To prevent this and to
enable the engine to start quickly after parts have been re‐
newed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank
and the high-pressure pump are removed or renewed, the
first fuel filling operation must be performed. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ If a fuel pump, fuel line (between fuel tank and high-pres‐

sure pump) or fuel filter is removed or renewed, the fuel

system must be bled before the engine is started for the
first time.
♦ If the high-pressure pump is removed or renewed, the fuel
system must be bled before the engine is started for the
first time.
Procedure for first fuel filling ⇒ page 29
Note
The high-pressure pump will be damaged if the first fuel filling

procedure is not performed.

Audi TT 2007 ➤

❑ Do not unscrew
2 - High-pressure pump
❑ Exploded view
⇒ page 25
❑ After renewing, first fuel
filling operation MUST
be performed (it is im‐
portant not to allow
pump to run while it is
still empty) ⇒ page 29
❑ After renewing high-
pressure pump or fuel
pressure regulating
valve -N276- , learnt val‐
ues must be re-adapted;
see “Guided Functions”
in vehicle diagnostic
tester
3 - Fuel pressure sender -
G247-
❑ Exploded view
⇒ page 31
4 - Fuel rail
5 - Fuel pressure regulating
valve -N276-
❑ Exploded view
⇒ page 31
❑ After renewing high-
pressure
Protected pump Copying
by copyright. or fuelfor private or commercial purposes, in part or in whole, is not
pressure regulating
valve -N276-
with respect , learnt
to the val‐
ues must be re-adapted;
see “Guided Functions”
in vehicle diagnostic
tester
6 - Injector
8 - Not fitted
9 - Fuel tank
❑ With fuel system pressurisation pump -G6-
10 - Fuel filter
11 - Supplementary fuel pump -V393-
3. System layout 13
Audi TT 2007 ➤
4 Bleeding fuel system
Caution
If components of the fuel system between the fuel tank and the
high-pressure fuel pump are removed or renewed, the basic
setting “Checking fuel system pressurisation pump” must be
performed to bleed the fuel system.
If the supplementary fuel pump, fuel line (between fuel tank
and high-pressure fuel pump) or fuel filter is removed or re‐
newed, the basic setting “Checking fuel system pressurisation
pump” must be performed before the engine is started for the
first time.
Proceed as follows to fill fuel system with fuel:

– Select “Checking fuel system pressurisation pump” from the
list.
– Press “Start” button.
– The fuel pumps must run for approx. 1 minute to ensure that
the fuel system is filled sufficiently with fuel.
Note

switch off.
– Erase entry in event memory using diagnostic tester.
Note
test. Switch off the engine and erase the event memory. Then
continue the road test.
– Interrogate event memory.


Audi TT 2007 ➤
5 Air cleaner
⇒ “5.1 Air cleaner - exploded view”, page 15
⇒ “5.2 Removing and installing engine cover panel”, page 16
⇒ “5.3 Removing and installing air filter element”, page 17
⇒ “5.4 Removing and installing air cleaner housing”, page 18
⇒ “5.5 Removing and installing air mass meter G70 ”, page 20
1 - Hose connection
2 - Air hose
❑ To turbocharger
❑ Check for dirt and accu‐
mulated leaves, etc.
3 - Bolt
❑ 2x
❑ 1.5 Nm
4 - by
Protected Aircopyright.
massCopying
meterfor-G70-

⇒ page 20
5 - O-ring
❑ Renew
❑ Use silicone-free lubri‐
cant when installing
6 - Bolts
tion)
❑ 1.5 Nm
7 - Bolt
section)
❑ 8 Nm
8 - Sleeve
9 - Washer
❑ Clean out dirt, leaves
and salt deposits
11 - Air filter element
❑ Always use genuine part for air filter element
❑ Observe change intervals ⇒ Maintenance ; Booklet 810
❑ Clean out dirt, leaves and salt deposits
❑ On vehicles for cold climates, air cleaner (bottom section) with hot-air-intake hose is installed
❑ Country-specific version with snow screen
❑ Clean
5. Air cleaner 15
Audi TT 2007 ➤

❑ Clean
15 - Flutter valve
❑ To lock carrier
18 - Connecting hose
❑ To turbocharger

panel
Removing
– Carefully pull engine cover panel off retaining pins one after
the other -arrows-. Do not jerk the cover panel away, and do
not try to pull on one side only.
Installing
your fist or with any kind of tool.
– Position engine cover panel on engine (note locations of oil
filler neck and oil dipstick).
– Press engine cover panel with both hands into the rubber
grommets at the rear and then into the grommets at the front.

Audi TT 2007 ➤

ment
Removing
– Remove bolts -arrows-.
Note
Disregard -items 1, 2, 3-.
Installing
• Tightening torque
To ensure that the air mass meter functions properly, it is impor‐
tant to observe the following notes and instructions.
Note
reach the air mass meter and affect the air mass value. This
would lead to loss of power, since a smaller injection quantity
is calculated.
♦ The air cleaner housing MUST be clean.
♦ To prevent malfunctions, cover critical parts of the engine air
intake (air mass meter, air pipes, etc.) with a clean cloth when
blowing out the air cleaner housing with compressed air.
♦ Observe environmental requirements for disposal.
Note
5. Air cleaner 17
Audi TT 2007 ➤

(top and bottom sections) using a vacuum cleaner.
– When installing air filter element, check that it is properly cen‐
tred in retainer in air cleaner (bottom section).
– Ensure secure fit of intake hose at air mass meter.
quence.
5.4 Removing and installing air cleaner

housing
Removing
– Pull cover off air duct (release clips on sides) -arrows-.
– Release clips on left and right -arrow A- and unclip air duct at
bottom -2-.
– Swivel air duct (bottom) slightly to the rear and detach air duct
(bottom) from retainers -3-.
– Detach air pipe -1- from air duct (bottom) -arrow B-.

Audi TT 2007 ➤
– Unplug electrical connector -2- from air mass meter -G70- .

– Detach hose -1-.
– Release hose clip -3- and detach air hose.
– Unscrew bolt -4- and remove air cleaner housing.
Installing
Note
♦ Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
♦ Use silicone-free lubricant when installing air hose.


hose.
5. Air cleaner 19
Audi TT 2007 ➤

-G70-
Removing
– Remove air cleaner housing ⇒ page 18 .
– Carefully pull air mass meter -G70- out of guide on air cleaner
housing.
Installing
important to observe the following instructions.
Note
is calculated.
♦ Always renew seal if damaged (air leaks in intake system).
♦ Use a silicone-free lubricant when installing the air hose and
seal.
cleaner as required.
– Install air cleaner housing ⇒ page 18 .

Audi TT 2007 ➤
6 Intake manifold
⇒ “6.1 Intake manifold with attached components - exploded
view”, page 21
⇒ “6.2 Removing and installing intake manifold”, page 22
6.1 Intake manifold with attached components - exploded view
1 - Guide tube
❑ For oil dipstick
2 - Seal
❑ Renew
3 - Gasket
❑ Renew
4 - Bolt
❑ 8 Nm
6 - Bolt
❑ 9 Nm
7 - Intake manifold
❑ With intake manifold
flap motor -V157- and
intake manifold flap po‐
tentiometer -G336-
❑ Must not be dismantled
⇒ page 22
8 - Bracket
❑ For exhaust gas recircu‐
lation cooler change-
over valve -N345-
9 - Bolt
❑ 9 Nm
cooler change-over valve -
N345-
11 - Gasket
❑ Renew
12 - Bolt
❑ 20 Nm
13 - Connecting pipe Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ To exhaust gas recirculation cooler

14 - Clamp
❑ Renew
❑ 5 Nm
15 - Connection
❑ For exhaust gas recirculation
16 - Bolt
❑ 8 Nm
Audi TT 2007 ➤
17 - Seal
❑ Renew
18 - Throttle valve module -J338-
❑ With throttle valve potentiometer -G69-
19 - Bolt
❑ 8 Nm
20 - Bolt
❑ 9 Nm
21 - Clip
♦ Socket T30 -T10405-
Removing
WARNING


– Loosen hose clip -arrow-.
– Detach electrical connectors at glow plugs ⇒ page 67 .

Audi TT 2007 ➤
– Take exhaust gas recirculation cooler change-over valve -

N345- -left arrow- out of bracket and move clear to one side.
Note
Disregard -arrow- on right-side of illustration.
– Remove bolts -2- and place coolant return line to one side.
– Remove bolts -arrows- and place fuel return line to one side.
– Remove bolt -2- and union nuts -1 and 3- and detach high-
pressure pipe.
Audi TT 2007 ➤
– Unplug electrical connector -2- at throttle valve module -

J338- .
– Remove bolt -1- for dipstick guide tube.
Note
Disregard -arrows-.
– Open clamp -1- and detach.
Note
Disregard -item 2-.
– Unscrew intake manifold bolts -arrows- in diagonal sequence

starting from outside and working inwards using socket T30 -
T10405- .
– Carefully take out intake manifold.
Installing
Installation is carried
Protected by copyright. outforinprivate
Copying the orreverse order;
commercial note
purposes, the
in part or infollowing:
whole, is not
• Tightening
with respect to torque
the correctness of information in this document. Copyright by AUDI AG.
view”, page 21
Note
Renew seals and/or gaskets.
– Tighten intake manifold bolts in diagonal sequence, working

from inside to outside.
– Install air pipe ⇒ Rep. Gr. 21 .

Audi TT 2007 ➤
⇒ “7.1 High-pressure pump - exploded view”, page 25
⇒ “7.2 Removing and installing high-pressure pump”, page 26
⇒ “7.3 Performing first fuel filling operation after installing high-
pressure pump”, page 29
⇒ “7.4 Checking fuel system for leaks”, page 30
7.1 High-pressure pump - exploded view
1 - Bracket for ancillaries

⇒ Rep. Gr. 13
2 - Bolt
❑ 2x
❑ Renew
❑ 20 Nm + 180° further
3 - Hub
❑ Use counterhold tool -
T10051- when loosen‐
ing and tightening
❑ To remove, use puller -
T40064-
sprocket
❑ 3x with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Renew
6 - Nut
❑ 95 Nm
7 - Bolt
❑ Renew
❑ With fuel metering valve
-N290- (do not open)
❑ After renewing, first fuel
filling operation MUST
be performed (it is im‐
portant not to allow
pump to run while it is still empty) ⇒ page 29
❑ After renewing high-pressure pump or fuel pressure regulating valve -N276- , learnt values must be re-
adapted; see “Guided Functions” in vehicle diagnostic tester
11 - High-pressure pipes
❑ Between high-pressure pump and fuel rail
Audi TT 2007 ➤
Note

❑ Tightening torque ⇒ Item 9 (page 32)

pump
♦ Puller -T40064- with T40064/1
Removing
Caution

sure pump.
⇒ page 29

Audi TT 2007 ➤
– Remove toothed belt from camshaft and high-pressure pump

⇒ Rep. Gr. 15 .
– Remove bolts -2- and detach toothed belt sprocket from high-
pressure pump.
Note
Disregard -item 1-.
– Counterhold using counterhold tool -T10051- and remove nut

-1- at hub of high-pressure pump.
– Apply puller -T40064- with thrust piece -T40064/1- and pin -

T40064/2- as shown in illustration and pull hub off high-pres‐
sure pump. If necessary, counterhold using an open-end
spanner (24 mm).
Audi TT 2007 ➤
Note
Disregard -items 1, 3-.
pressure pipe.
– Unplug electrical connectors -1- and -3-.

– Detach fuel supply hose -2- and fuel return hose -4-.

Audi TT 2007 ➤
– Remove bolts -arrows- for high-pressure pump.

– Carefully take out high-pressure pump.
Installing
• Tightening torques
⇒ “7.1 High-pressure pump - exploded view”, page 25
– Install toothed belt ⇒ Rep. Gr. 15 .
– Install high-pressure pipe ⇒ page 45 .
Caution

sure pump.
⇒ page 29
7.3 Performing first fuel filling operation af‐

ter installing high-pressure pump
Caution

sure pump.
be allowed to run while still empty.
Note

♦ Only remove sealing plugs immediately prior to installation of
fuel pipes.
♦ There must be sufficient fuel in the tank.
– Connect vehicle diagnostic tester.

list.
– The fuel pumps start
Protected by running.
– The fuel pumps must
with respect run
to the for approx.
correctness 1 minute
of information to ensure
in this document. thatby AUDI AG.
Copyright
the high-pressure pump is filled with sufficient fuel.
switch off.
Audi TT 2007 ➤

– Erase entry in event memory using vehicle diagnostic tester.
Note

– Run engine at idling speed for several minutes (do not press
accelerator) and then switch off. Fuel system will bleed itself
automatically.
– Check the entire fuel system for leaks.
to correct torque.
Note

Audi TT 2007 ➤
8 Injectors
⇒ “8.1 Injectors - exploded view”, page 31
⇒ “8.2 Checking injectors”, page 33
⇒ “8.3 Performing adaption of injector delivery calibration values”,
page 33
⇒ “8.4 Checking return flow rate of injectors with engine running”,
page 33
⇒ “8.5 Checking return flow rate of injectors at starter cranking
speed”, page 36
⇒ “8.6 Checking for injectors sticking open”, page 38
⇒ “8.7 Removing and installing injectors”, page 39
8.1 Injectors - exploded view
1 - Seal
❑ In cylinder head cover
⇒ Rep. Gr. 15
2 - Copper seal
❑ Renew
3 - O-ring
❑ Renew
4 - Injector
❑ The following compo‐
nents and seals/O-rings
must always be re‐
newed when the injec‐
tors are removed and
installed: “copper seal”
and “O-ring for injector
bore”.
❑ The following compo‐
nents and seals/O-rings
must always be re‐
newed when an injector
is renewed: “clamping
piece”, “copper seal”
and “O-ring for injector
bore”.
❑ When re-installing
“high-pressure injector
pipe” check taper seats
visually for damage,
scores
Protected andCopying
by copyright. corrosion
for private or commercial purposes, in part or in whole, is not
(always renew if dam‐
aged)
❑ If they are to be re-in‐

stalled, the injectors,
high-pressure fuel pipes
and clamping pieces
must always be re-fitted on the same cylinder
5 - O-ring
❑ Renew
8. Injectors 31
Audi TT 2007 ➤

❑ To fuel tank
❑ Must not be kinked, damaged or clogged
❑ Do not dismantle
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system. Then
check fuel return lines for leaks
7 - Bolt
❑ Renew
8 - Clamping piece
❑ If they are to be re-installed, the injectors and clamping pieces must always be re-fitted on the same
cylinder
❑ If an injector is renewed, the corresponding clamping piece must also be renewed
❑ Between fuel rail and injectors
❑ Lubricate threads of union nuts with clean engine oil
❑ 25 Nm
10 - Bolt
❑ 22 Nm
11 - Fuel rail
❑ Always renew after removing
❑ 80 Nm
❑ After renewing high-pressure pump or fuel pressure regulating valve -N276- , learnt values must be re-
adapted; see “Guided Functions” in vehicle diagnostic tester
14 - O-ring
❑ Renew
❑ Between high-pressure pump and fuel rail
Note
❑ Lubricate threads of union nuts with clean engine oil

❑ 25 Nm
16 - Bolt
❑ 8 Nm
❑ 100 Nm
18 - Grommet
❑ In cylinder head cover

Audi TT 2007 ➤
Installation position of clamping piece

• One clamping piece is always used to secure two injectors.
• The bulge -arrow- of the clamping piece should point down‐
wards.
8.2 Checking injectors

There are three different tests for checking the operation of the
injectors.
• Checking adaption of “Injector delivery calibration values”
⇒ page 33
• Checking return flow rate of injectors with engine running
⇒ page 33
• Checking return flow rate of injectors at starter cranking speed
⇒ page 36
8.3 Performing adaption of injector delivery

calibration values
The “Injector delivery calibration values” function serves to correct
the injection rates for each cylinder of a common rail system in‐
dividually across the entire operating range.
The 7-digit adaption values -1- (details in illustration are only an
example) are marked separately
Protected on each
by copyright. Copying injector.
for private The values
or commercial purposes, in part or in whole, is not
may consist of letters and/or
permitted numbers.
Injector (view from above)
1 - Check sum
2 - Data matrix code
3 - Part number
When a new injector is installed, the adaption value must be writ‐
ten into the engine control unit.
When a new engine control unit is installed, the “Adaption values
for injectors” must be written into the new control unit.
are correctly entered for all the other injectors. Do NOT attempt
to re-enter these values if the correct values are already stored in
the engine control unit.
The adaption procedure is described in the “Guided Fault Find‐
ing”. (The procedure is also described under “Guided Functions”.)

with engine running
A - Checking return flow rate of all injectors
♦ Fuel-resistant measuring container
8. Injectors 33
Audi TT 2007 ➤
WARNING


– Disconnect hose connection at fuel line.
– Seal off the open return connection with a plug -1-.
– Hold end of fuel return hose -2- (lengthen if necessary) in a
measuring container to measure the total return flow rate.
– Start engine and let it idle for 2 minutes.
• Specification for 2 minutes: 0 ml to 50 ml
– If specification is attained, increase engine speed to 2000 ...
2500 rpm for approx. 2 minutes and then check return flow rate
again.
• Specification for 2 minutes: less than 250 ml
Note
1000 ml = 1 litre
If specification is exceeded, this indicates that one or more injec‐

tors are defective. Check return flow rate from each injector
individually.
B - Checking return flow rate of individual injectors

♦ Hose clamps for hoses up to 25 mm -3094-

Audi TT 2007 ➤

– Clean all return line connections (e.g. with commercial clean‐
ing solution etc.) before removing.
– Clamp off fuel return hose -arrow- using a hose clamp -3094- .
8. Injectors 35
Audi TT 2007 ➤
– Pull return line connections off injectors; to do so, press tabs

-1- and -2- down and at the same time pull release pin upwards
-arrow-.
Note

– Connect hoses onto return line connections of all 4 injectors.

1348/2 B- .
– Start engine and let it idle for several minutes.
Caution
Risk of damage to injectors when return lines are disconnec‐

ted.
♦ Do NOT press the accelerator during this test; the engine
must only run at idling speed.
– When the engine is warm and running
permitted at idlingbyspeed,
unless authorised AUDI AG. theAUDI re‐
AG does not guarantee or accept any liability
turn flow rates at each of thewith
4 return
respect tolines must not
the correctness differ by
more than a small amount.
– If one injector has a significantly higher return flow rate than
the others it must be renewed ⇒ page 39 .
– Push return line connections carefully onto injectors. The
catch should engage audibly. Then press release pin down
carefully.
8.5 Checking return flow rate of injectors at

starter cranking speed
If it is not possible to start engine, check return flow rate of injec‐
tors at starter cranking speed.


Audi TT 2007 ➤
WARNING

-arrow-.
Note

– Unplug electrical connector -arrow- at fuel pressure regulating

valve -N276- .
Note
This prevents fuel from being injected when starter is operated.
– Connect the 4 hoses onto return line connections of all 4 in‐

jectors.
1348/2 B- .
– Operate starter three times. (Wait approx. 20 seconds each
time after operating starter to prevent it from overheating.)
– If fuel comes out of one injector, that injector must be renewed.
– Re-attach electrical connector on fuel pressure regulating
valve -N276- .
– Push return line connections carefully onto injectors. The
catch should engage audibly. Then press release pin down
carefully.
8. Injectors 37
Audi TT 2007 ➤
8.6 Checking for injectors sticking open

♦ Screw plug -T40204-
WARNING


– Clean all connections (with commercial cleaning solution or
similar) before removing.
♦ Make sure all parts are clean; no dirt must be allowed to enter
the fuel system.

♦ Check all cylinders in turn.

Start with cylinder No. 1.
– Unscrew union nut for cylinder 1 on fuel rail. Also loosen union
nut on injector slightly. Seal off open connection on injector
pipe.
– Plug open connection using plug -T40204- .
• The electrical connector of the relevant injector must remain
connected.
– Erase all entries in the event memory.
– Perform test drive.

Audi TT 2007 ➤
Note
♦ The fault “positive fuel pressure control” should no longer be

indicated when the defective injector has been located.
♦ Other fault messages may possibly be stored in the memory.
These result from previous steps and can be disregarded.
– Interrogate event memory after road-testing vehicle. If a fault

relating to “positive fuel pressure control” is still indicated, re‐
peat the above steps for all connections until the fault is no
longer indicated after the road test.
Observe all instructions for connecting injector pipes.
8.7 Removing and installing injectors

♦ Puller -T10055-
♦ Assembly sleeve -T10377-
♦ Puller -T10415-
8. Injectors 39
Audi TT 2007 ➤
Removing
WARNING

Caution
♦ Mark cylinder numbers on injector units. They must al‐

ways be re-installed on the same cylinders.
tion system.
diately.

-arrow-.
– Unplug electrical connectors -arrows- at injectors.

– Unscrew union nuts on corresponding high-pressure pipe
(-1 to 4-) and detach corresponding high-pressure pipe.
– Unscrew bolt -1- for clamping piece.

Audi TT 2007 ➤
– Apply puller -T10055- with puller -T10415- as shown in illus‐

tration, and pull out injector upwards.
Note
To avoid damaging the sealing lip, rotate the injector while pulling
it out.
– After removal, lay injectors on a clean cloth.

Important instructions for installing injectors:
• Lubricate all O-rings with engine oil or assembly oil before in‐
stalling.
Note

following checks:
cracks.
erwise damaged.
If a used injector is being re-installed:

– Spray tip of injector nozzle with rust-releasing spray. Wait ap‐
prox. 5 minutes and wipe off soot particles and oil with a cloth.
– If an injector is very dirty, the tip of the nozzle should also be
cleaned with a soft brass wire brush to make it easier to re‐
move the copper seal. Do not apply the wire brush to the bores
in the nozzle.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
– Clean off deposits under the copper seal using a suitable scra‐
per.
Caution permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
To remove carbon deposits from the injector sealing surface,

clean the injector seat in the cylinder head with a cloth soaked
in engine oil or rust solvent. Take care not to damage the seal‐
ing surface.
8. Injectors 41
Audi TT 2007 ➤
– Renew seal for injector bore using assembly sleeve -T10377- .

– Install injectors.
– Press return line connections carefully over the seals and onto
the injector units (check seal for damage before connecting
return line). The catch should engage audibly. Then press re‐
lease pin down carefully.
When one or more injectors have been renewed, the “Injector
delivery calibration values” for the new injectors must be pro‐
grammed in the engine control unit.
are correctly entered for all the other injectors. Do NOT attempt
to re-enter these values if the correct values are already stored in
the engine control unit.
Bleeding fuel system and checking for leaks
Note
The fuel system is self-bleeding; do not open the high-pressure

connections.
– Run engine at idling speed for several minutes and then switch
off.
– Check the complete fuel system including all 4 return line con‐
nections for leaks.
to correct torque.
Note
The return lines can only be renewed together with the pressure
retention valve as one unit.

once. Then inspect the high-pressure section
Protected by copyright. of the
Copying fuel orsys‐
for private commercial purposes, in part or in whole, is not
tem again for leaks. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note

Audi TT 2007 ➤

⇒ “9.1 Removing and installing throttle valve module J338 ”, page
43
⇒ “9.2 Installing high-pressure pipes”, page 45
⇒ “9.3 Checking fuel pressure regulating valve N276 ”,
page 46
⇒ “9.4 Checking fuel pressure (low pressure)”, page 47
⇒ “9.5 Checking delivery rate of fuel pumps”, page 49
⇒ “9.6 Removing and installing fuel pressure regulating valve
N276 ”, page 51
⇒ “9.7 Removing and installing fuel pressure sender G247 ”, page
52
⇒ “9.8 Removing and installing fuel rail”, page 55
9.1 Removing and installing throttle valve

module -J338-
Removing

Audi TT 2007 ➤

-arrow-.

– Loosen hose clip -5- at throttle valve module -J338- , detach
air pipe -2-, but leave in position.
Note
Disregard item -4-.
– Loosen hose clip -arrow-.

Audi TT 2007 ➤
– Unplug electrical connector -2-.

– Remove bolts -arrows- and detach throttle valve module -
J338- .
Installing
view”, page 21
Note
Fit new O-ring.
9.2 Installing high-pressure pipes

♦ Socket -T40055-

Audi TT 2007 ➤
Procedure
Note

following checks:
cracks.
erwise damaged.
Caution
The fuel rail and the clamping pieces can be slackened so that
the injector pipes are not installed under tension. If necessary,
move the fuel rail slightly and turn the corresponding injector
slightly. Never bend the pipes or subject them to tension.
Bending the pipes would ultimately cause them to fracture.
– Use vacuum cleaner to remove dirt from taper seat at fuel rail.
– Clean fuel pipe and end of pipe using cleaning solution and
dry with compressed air.
– Hand-tighten union nuts on high-pressure pipes (ensure that
pipes are not under tension).
• Tightening torque ⇒ “8.1 Injectors - exploded view”, page 31
– To tighten unions of high-pressure pipes to fuel rail and injec‐
tors, use torque wrench -V.A.G 1331- with socket -T40055- .
9.3 Checking fuel pressure regulating valve

-N276-

Audi TT 2007 ➤
WARNING


– Release hose clip -arrow- and detach fuel return hose from
fuel rail.
– Seal off open return line connection with a plug.
– Connect test hose -2- to return line connection of fuel rail -3-.
– Hold end of test hose into measuring container -4- to measure
return flow rate.
– Start engine and let it idle for 30 seconds.
• Specification: 90 … 110 ml in 30 seconds
N276- is defective.


Audi TT 2007 ➤
Test conditions:
• Fuel filter OK.
• Ignition off.
WARNING

nection.
– Release hose clip and detach fuel supply line -arrow- from
high-pressure pump.
– Connect K-Jetronic pressure tester -V.A.G 1318- to fuel sup‐
ply line -1- with suitable adapter -2-.
– Connect second hose -3- (from K-Jetronic pressure tester -
V.A.G 1318- ) to open connection on high-pressure pump, as
shown in illustration below.

Audi TT 2007 ➤
Note
In this way the K-Jetronic pressure tester -V.A.G 1318- is con‐

nected into the fuel supply line.
– Connect vehicle diagnostic tester (e.g. vehicle diagnostic, test‐

ing and information system -VAS 5051B- ).
list.
– Press “Start” button.
– Press “Start” key: The fuel pump will start running.
– Let fuel pump run until maximum fuel pressure has built up.
• Specification: at least 3.5 bar
♦ Leak in union between pressure gauge and fuel line
♦ Leak in pressure tester
♦ Leak in fuel lines and their connections
♦ Fuel filter is blocked. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Check delivery rate of fuel pump ⇒ page 49 .
Note
9.5 Checking delivery rate of fuel pumps

♦ Measuring container (fuel-resistant)
Test conditions:
• Battery voltage at least 12.5 Volt.
• Fuel filter OK.
• Ignition switched off
Checking fuel delivery rate

Audi TT 2007 ➤
WARNING

nection.
– Release hose clip and detach fuel supply line -arrow- from
high-pressure pump.
– Hold fuel supply line -1- into a measuring container -2-.

– Connect vehicle diagnostic tester.
list.
– Press “Start” key: The fuel pump will start running.
– Let fuel pump run for 15 seconds andbyexit
Protected activation
copyright. function.
• Specification in 15 seconds: at least 600 tomlthe correctness of information in this document. Copyright by AUDI AG.
with respect
If minimum delivery rate is not reached, check for the following

causes:
♦ Fuel pump was not running for 15 seconds
♦ Fuel lines have been crushed
♦ Fuel filter is blocked
♦ Fuel pumps defective: Checking ⇒ Rep. Gr. 20
Note

Audi TT 2007 ➤

regulating valve -N276-
The fuel pressure regulating valve -N276- -2- is located in the fuel
rail. It maintains a constant pressure in the fuel rail and the injector
pipes (high-pressure fuel circuit).
If the pressure in the high-pressure fuel circuit is too high, the
regulating valve opens to allow some of the fuel to flow back from
the fuel rail to the fuel tank via a return line.
If the pressure in the high-pressure fuel circuit is too low, the fuel
pressure regulating valve -N276- closes and seals off the high-
pressure section of the system from the low-pressure section.
Note
Fuel pressure regulating valve -N276- must always be renewed

after it has been removed.
Removing
WARNING


regulating valve -N276- using commercial cleaning solution or
similar (no dirt must enter opening in fuel rail).
Note

connector.
– Dry off fuel pressure regulating valve -N276- .

– Slacken union nut (counterhold at hexagon flats on housing).
Then unscrew and remove by hand.
face) using a vacuum cleaner. Do not use metal tools, etc.
– Seal off open fuel rail connections with clean plugs.
Installing
• Tightening torque ⇒ “8.1 Injectors - exploded view”, page 31

Audi TT 2007 ➤
Note
♦ The fuel pressure regulating valve -N276- has a deformable

sealing lip and no separate seal; it can therefore be used only
once.
threads on new fuel pressure regulating valve -N276- are not
damaged.
♦ Check sealing surface at opening in fuel rail.
the fuel pressure regulating
Protected valve for
by copyright. Copying -N276- must
private or be coated
commercial purposes, with
in part or in whole, is not
diesel fuel. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Screw on union nut by hand.

– Align new regulating valve so that connecting wire is free of
tension after connector is attached.
– Hold regulating valve in this position by holding hexagon flats
on housing of regulating valve with open-end spanner or pliers
(water pump pliers or similar).
– Use suitable torque wrench with an open-end spanner insert
(30 mm) to tighten union nut.
– After installation, run engine at moderate speed for several
minutes and then switch off.
After renewing high-pressure pump and/or fuel pressure regulat‐
ing valve -N276- , adaption must be performed. (The procedure
is described under Guided Functions.)
– Interrogate event memory again.

sender -G247-
The fuel pressure sender -G247- is located in the fuel rail and
continuously measures the fuel pressure in the high-pressure
system. It transmits a corresponding voltage signal to the engine
Removing
WARNING


Audi TT 2007 ➤

sender using commercial cleaning solution etc. (no dirt must
enter opening).
Note

connector.
– Dry off fuel pressure sender -G247- .

– Unplug electrical connector -B- at fuel pressure sender -
G247- .

Audi TT 2007 ➤

face) using a vacuum cleaner. Do not use metal tools, etc.
– Seal off opening in fuel rail with a plug.
Installing
Note
♦ The fuel pressure sender -G247- does not have a seal; in‐
stead, it has a deformable sealing lip.
threads on fuel pressure sender -G247- are not damaged. If
inspection of fuel pressure sender -G247- shows that it is OK,
it can be used again.
♦ Also check sealing surface at opening in fuel rail.
the fuel pressure regulating valve -N276- must be coated with
diesel fuel.
– Screw in fuel pressure sender -G247- by hand.

– Then tighten fuel pressure sender -G247- to specified torque.
– After installing fuel pressure sender -G247- , leave engine
running at moderate speed for a few minutes when bleeding
fuel system and then switch off again.
Note
The fuel system is “self-bleeding”; do NOT open the high-pres‐

sure connections.
– Interrogate event memory and erase it if necessary.

– Carefully check the entire fuel system for leaks.
– Renew affected component if leakage still occurs after tight‐
ening to correct torque.
section of the fuel
Protected system
by copyright. again
Copying for leaks.
Note
– After road test, interrogate event memory again.

Audi TT 2007 ➤
9.8 Removing and installing fuel rail

Removing
WARNING


– Unplug electrical connector -arrow- at fuel pressure regulating
valve -N276- .
– Unplug electrical connector -B- at fuel pressure sender -

G247- .
– Disconnect vacuum hose -A- from cylinder head cover.
– Release hose clip -arrow- and detach fuel return hose from
fuel rail.

Audi TT 2007 ➤
– Release retaining clips -arrows- at wiring harness and detach

electrical connectors from glow plugs.
pressure pipe.
– Disconnect wiring guide from fuel rail and move clear to one
side.

Audi TT 2007 ➤
– Loosen union nuts on the 4 high-pressure pipes -1-.

– After removal, lay high-pressure pipes on a clean cloth.
– Unscrew both bolts -arrows- and remove fuel rail.

Installing
– Install high-pressure pipes so they are free of tension
⇒ page 45 .
Note

following checks:
cracks.
erwise damaged.

Audi TT 2007 ➤
10 Lambda probe and exhaust gas tem‐

perature senders
⇒ “10.1 Lambda probe and exhaust gas temperature senders -
exploded view”, page 58
⇒ “10.2 Removing and installing Lambda probe G39 with Lambda
probe heater Z19 ”, page 58
⇒ “10.3 Removing and installing pressure differential sender
G505 ”, page 59
10.1 Lambda probe and exhaust gas temperature senders - exploded view
1 - Turbocharger
3 - Hose
-G505-
⇒ page 59
5 - Bolt
❑ 8 Nm
6 - Bracket
❑ For pressure differential
sender -G505-
7 - Nut
❑ 9 Nm
8 - Exhaust gas temperature
sender 3 -G495-
❑ 45 Nm
⇒ Rep. Gr. 26
❑ 50 Nm
⇒ page 58
sender 4 -G648-
❑ 45 Nm
⇒ Rep. Gr. 26
sender 1 Protected
-G235-by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 45 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.


Audi TT 2007 ➤
Removing
– Unplug electrical connector -2- for Lambda probe -G39- and
move electrical wiring clear.
Installing
⇒ “10.1 Lambda probe and exhaust gas temperature senders
- exploded view”, page 58
Note

body.
slots on the Lambda probe body. For high-temperature paste
refer to ⇒ Electronic parts catalogue
♦ When installing, the Lambda probe wiring must always
permitted beauthorised
unless re‐ by AUDI AG. AUDI AG does not guarantee or accept any liability
attached at the same locations to prevent it from coming
with respect to into
10.3 Removing and installing pressure differ‐

ential sender -G505-
The pressure differential sender -G505- detects the amount of
deposits in the particulate filter.
Removing
– Detach heat shield sleeve.
10. Lambda probe and exhaust gas temperature senders 59

Audi TT 2007 ➤

– Remove bolt -2- and detach pressure differential sender -
G505- from bracket.
– Detach retaining clips from both hoses.
– Before disconnecting, spray the hoses for the pressure differ‐
ential sender -G505- with suitable release agent.
– Carefully disconnect the hoses from their connections (take
care to keep the hoses straight: the connections on pressure
sensor can break off easily).
Installing
⇒ “10.1 Lambda probe and exhaust gas temperature senders
Note
♦ Before installing, blow out control pipes from pressure differ‐

ential sender -G505- to particulate filter towards particulate
filter with compressed air (pipes can become obstructed or
may ice up due to condensation).
♦ Make sure that hoses are securely fitted and seal properly.
♦ If pressure pipes are detached from particulate filter, tighten
pressure pipe connections ⇒ Rep. Gr. 26 .
♦ Secure the heat insulation sleeve in the original position when
installing.
Adaption must be performed after renewing pressure differential

sender -G505- and/or particulate filter. (The procedure is descri‐
bed under Guided Functions.)

Audi TT 2007 ➤

⇒ “11.1 Wiring and component check with test box V.A.G 1598/42
”, page 61
⇒ “11.2 Removing and installing engine control unit J623 ”, page
62

box -V.A.G 1598/42-
♦ Adapter cable -V.A.G 1598/39-
♦ Test box -V.A.G 1598/42-

Audi TT 2007 ➤
Note
-A- on the test box. For components connected to 60-pin wiring
adapter cable -V.A.G 1598/39-2- must be connected to con‐
nectors -A- and -B- on the test box. For components connec‐
ted to 94-pin wiring harness connector ⇒ Current flow
ning).
The engine control unit has to be removed before connectors can

be unplugged from engine control unit ⇒ page 62 .
WARNING


to be connected
Protected to the testCopying
by copyright. box.for private or commercial purposes, in part or in whole, is not
– Carry out test
withas described
respect in appropriate
to the correctness repair
of information in procedures.

– Interrogate event memory and erase if necessary.
11.2 Removing and installing engine control

unit -J623-

Audi TT 2007 ➤

♦ Small vice-grip pliers -3- (commercially available)
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 housing
-5-. To make it more difficult to unscrew the shear bolts -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
Protected unplugged
by copyright. Copyingfrom theorengine
for private commercialcontrol
purposes,unit
in part(e.g. to is not
or in whole,
connect
permittedthe test
unless box or
authorised renew
by AUDI the engine
AG. AUDI control
AG does not guaranteeunit).
or accept any liability
Removing
– Before removing the engine control unit -J623- , the adaption
values of the injectors and the ash deposit mass must be read
out. Use vehicle diagnostic tester to do so.
– Store adaption values as electronic file.
– Switch off ignition and remove ignition key after storing elec‐
tronic file containing adaption values.
Note
If the adaption values of the injectors of the old (defective) engine

control unit cannot be read out, the adaption values must be en‐
tered into the new engine control unit manually and the adaption
procedure must be performed accordingly.

– Loosen wiper arms from wiper shafts by tilting slightly.
wiper shafts.

Audi TT 2007 ➤
Note
If necessary, use puller -T10369- or a commercially available

puller to remove wiper arms.
– Remove seal -1-.
Caution
Risk of damage to plenum chamber cover.

♦ Apply a small amount of soap solution to transition be‐
tween windscreen and plenum chamber cover.
– Starting at edge of windscreen, carefully pull plenum chamber

cover -2- vertically upwards off retainer at windscreen
-arrows-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
– Move clear engine wiring harness at rear of plenum chamber

partition panel.
– Release clip -arrow- and remove engine control unit -J623- .
air blower.

Audi TT 2007 ➤

WARNING
20 ... 30 seconds.

in illustration).
– Detach protective housing from control unit connectors.
– Unscrew both securing bolts from engine control unit -J623- .

Audi TT 2007 ➤
– Release multi-pin connectors -1- -arrow- and disconnect.

Installing
the engine control unit -J623- .
The procedure required after connecting the new engine control
unit is described in the Guided Fault Finding or Guided Functions.
Use vehicle diagnostic tester to do so.
– The injector delivery calibration and the injector voltage cali‐
bration must additionally be re-adapted in the engine control
unit -J623- after the control unit has been renewed (these
functions influence engine power and exhaust emissions).
– On vehicles with particulate filter the current mileage (km)
reading must be stored in the engine control unit via an adap‐
tion procedure.
– Install wiper arms ⇒ Electrical system; Rep. Gr. 92 .

Audi TT 2007 ➤
28 – Glow plug system

1 Checking glow plug system
Automatic glow period control unit -J179- is located in relay and
fuse holder in electronics box in plenum chamber.
1 - Automatic glow period control unit -J179-
The glow plug system is activated via the automatic glow period
control unit -J179- . The automatic glow period control unit -J179-
is capable of self-diagnosis.
A fault is stored in the engine control unit if a fault occurs in the
glow plug system.
The procedure for checking the glow plug system is described in
the “Guided Fault Finding”.
For faster starting, the vehicle is equipped with electronically con‐
trolled glow plugs and a separate glow period control unit.
Each glow plug is activated and diagnosed separately.
1.1 Removing and installing glow plugs

♦ Pliers -3314-
Removing
– Remove engine cover panel ⇒ page
permitted 16 .
1. 67
Audi TT 2007 ➤
Caution
♦ Make sure that no wire connection is damaged when un‐

plugging the glow plug connectors; otherwise the entire
wiring harness must be renewed.
♦ When unplugging the glow plug connectors, do not com‐
press the pliers -3314- with too much force so that the
support sleeve is not damaged.
– Release retaining clips -arrows- at wiring harness and detach

electrical connectors from glow plugs.
– Apply groove -arrow A- of pliers -3314- to collar of support

sleeve -arrow B- and pull glow plug connectors off glow plugs.
– Clean glow plug openings in cylinder head; make sure no dirt
gets into cylinder.
Note
♦ Cleaning procedure:
♦ Use a vacuum cleaner to remove coarse dirt.
♦ Spray brake cleaner or suitable cleaning agent into glow plug
openings, let it work in briefly, and blow out with compressed
air.
♦ Then clean the glow plug openings using a cloth moistened
with oil.
– To slacken the glow plugs use special tool U/J extension and
socket, 10 mm -3220-
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;

to thenote the following:
with respect correctness of information in this document. Copyright by AUDI AG.
• Tightening torque ⇒ “2 Overview of fitting locations”, page 5

Audi TT 2007 ➤
– Fit glow plug connectors -1- back onto glow plugs -arrow-.
Note
Check that glow plug connectors are securely seated.
1.2 Removing and installing automatic glow

period control unit -J179-
Removing
– Slide the two clips in the direction of the -arrows- and remove
cover from electronics box in engine compartment.
– Pull automatic glow period control unit -J179- -arrow- out of

relay carrier below electronics box in engine compartment.
Installing
1.3 Removing and installing Hall sender -

G40-
Removing
– Remove toothed belt ⇒ Rep. Gr. 15 .
1. 69
Audi TT 2007 ➤
– Unplug electrical connector -arrow- from Hall sender -G40-

and detach connector from retainer.
– Unbolt Hall sender -G40- -arrow-.
– Using a screwdriver, remove projections and take out cover

for repair opening -arrows-.
– Take Hall sender -G40- off cylinder head and guide its con‐
nector through repair opening in toothed belt cover.
Installing
– Seal repair
Protected opening
by copyright. in toothed
Copying for private orbelt coverpurposes,
commercial with rubber
in part or plug;
in whole,for
is not
rubber plug
permitted unlessrefer to ⇒by AUDI
authorised Electronic
AG. AUDI parts
AG doescatalogue . accept any liability
not guarantee or
– Fit toothed belt and adjust valve timing ⇒ Rep. Gr. 15 .

sender -G28-
♦ Socket, 4 mm -T10370-

Audi TT 2007 ➤
Removing
– Remove noise insulation ⇒ Rep. Gr. 66 .
– Unplug electrical connector -1- at engine speed sender -G28-

using assembly tool -T10118- .
ProtectedNote
To release electrical connector without assembly tool -T10118- ,

press connector on engine speed sender in with a screwdriver

and at the same time lift release tab with a thin wire hook.
– Unscrew bolt -arrow- for engine speed sender -G28- using

socket (4 mm) -T10370- .
Installing
1. 71
Service
Workshop Manual
Audi TT 2007 ➤
Injection and ignition system (6-cyl. 3.2 ltr. 4-valve
injection engine)
Engine ID BUB CBR
A
Edition 07.2007

Service
Repair Group
28 - Ignition system


Audi TT 2007 ➤
Injection and ignition system (6-cyl. 3.2 ltr. 4-valve injection engine) - Edition 07.2007
Contents

2 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.7 Intake manifold - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.8 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.10 Checking vacuum unit for intake manifold flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.11 Removing and installing vacuum unit for intake manifold flaps . . . . . . . . . . . . . . . . . . . . . . 22
2.12 Checking fuel pressure regulator and residual pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.13 Fuel rail with injectors - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.15 Checking injection quantity and spray pattern of injectors; checking for leaks . . . . . . . . . . 29
2.16 Removing and installing Lambda probes (before catalytic converter) . . . . . . . . . . . . . . . . 32
2.17 Removing and installing Lambda probes (after catalytic converter) . . . . . . . . . . . . . . . . . . 33
3 Engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1 Wiring and component check with test box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1 General notes and safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.1 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2 Ignition system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.3 Removing and installing ignition coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Contents i
Audi TT 2007 ➤
ii Contents
Audi TT 2007 ➤

cleanliness

Observe the following to prevent injuries to persons and damage
to the injection and ignition system:

necting electrical wiring for the injection or ignition system or

tester cables.
♦ Faults are stored in engine control unit if electrical connectors
have been unplugged:
– With ignition switched off, connect vehicle diagnostic, testing
and information system -VAS 5051B- .
– Start “Guided Functions” mode.
– Generate readiness code in engine control unit.
Caution

battery.
– Disconnect battery ⇒ Rep. Gr. 27 .

WARNING

♦ Wrap a cloth around the connection before opening the
fuel system. Then release pressure by carefully loosening
the connection.

Audi TT 2007 ➤

WARNING

erly secured.
Injuries can also be caused if the passenger's airbag is trig‐
gered in a collision.
secured.
TT Coupé:
Test equipment must always be secured on the rear seat with
a strap and operated from the rear seat by a second person.
TT Roadster:
♦ Move the passenger's seat back as far as it will go.
♦ Use only vehicle diagnosis and service information sys‐
tem -VAS 5052- or diagnosis system -VAS 5053- .
♦ The test equipment -1- must rest flat on the passenger's
thighs (as shown in illustration) and must be operated by
the passenger.

opening.
♦ Seal off open lines and connections with clean plugs or sealing
caps immediately.
that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).
♦ When the system is open: Do not work with compressed
permitted unless authorised byair.
AUDI AG. AUDI AG does not guarantee or accept any liability
Do not move the vehicle unless absolutely necessary.


Audi TT 2007 ➤
2 Injection system
2.1 Test data

Engine data 3.2 ltr. / 4V / 184 kW engine
Idling speed 600 ... 700 rpm1)
Cannot be adjusted; regulated by idling speed stabili‐
sation
Maximum rpm governed by approx. 6,500 rpm
deactivation of fuel injectors
Fuel pressure at idling speed approx. 4.0 bar
Residual pressure after 10 minutes at least 3.0 bar
Injectors Spray pattern Two-hole nozzle / same for all injectors
Injection quantity 128 … 140 ml
(30orsec.)
Protected by copyright. Copying for private commercial purposes, in part or in whole, is not
• 1)Current
values
with respect ⇒ Data of
to the correctness sheets forinexhaust
information emission
this document. Copyright bytest.
AUDI AG.
2.2 Overview of fitting locations
1 - 3-pin connector
❑ For knock sensor 1 -
G61-
⇒ page 9
2 - Knock sensor 1 -G61-
⇒ page 9
3 - Activated charcoal filter sol‐
enoid valve 1 -N80-
4 - Lambda probe before cata‐
lytic converter -G39- with
⇒ page 7
⇒ page 32
5 - Electrical connectors
❑ For Lambda probe after
catalytic converter -
G130- with Lambda
probe 1 heater after cat‐
alytic converter -Z29-
❑ For Lambda probe 2 af‐
ter catalytic converter -
G131- with Lambda
probe 2 heater after cat‐
alytic converter -Z30-
⇒ page 7
6 - Lambda probe after catalyt‐
ic converter -G130- with Lamb‐
da probe 1 heater after catalyt‐
2. Injection system 3
Audi TT 2007 ➤
ic converter -Z29-
8 - Lambda probe 2 after catalytic converter -G131- with Lambda probe 2 heater after catalytic converter -Z30-
9 - Lambda probe 2 before catalytic converter -G108- with Lambda probe 2 heater -Z28-
10 - Heating element for crankcase breather -N79-
11 - Ignition coils with output stages
❑ Cylinder 1 ignition coil 1 with output stage -N70-
❑ 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 electric throttle -G188-
❑ For Lambda probe, before catalytic converter -G39- with Lambda probe heater -Z19-
❑ For Lambda probe 2, before catalytic converter -G108- with Lambda probe 2 heater -Z28-
15 - Clutch position sender -G476-
❑ For vehicles with manual gearbox
❑ Fitting location ⇒ page 6 .
16 - Accelerator position sender -G79- and accelerator position sender 2 -G185-
Fitting location ⇒ page 6
17 - Instrument cluster
❑ With exhaust emissions warning
with respect to lamp
the correctness -K83- in this document. Copyright by AUDI AG.
of information
18 - Electronics box in engine compartment

❑ With fuel pump relay -J17-
❑ With Motronic current supply relay -J271-
❑ With secondary air pump relay -J299-
❑ Fitting locations ⇒ page 8
19 - Sender 1 for secondary air pressure -G609-
❑ Only for engine code CBRA
20 - Hall sender 2 -G163-

Audi TT 2007 ➤
21 - Exhaust camshaft control valve 1 -N318-

❑ Brown connector
22 - Inlet camshaft control valve 1 -N205-
❑ Black connector
23 - Hall sender -G40-
25 - Vacuum unit for intake manifold flaps
27 - Variable intake manifold change-over valve -N156-
28 - Secondary air pump motor -V101-
29 - Checking secondary air inlet valve -N112- and secondary air inlet valve 2 -N320-
❑ Only for engine code CBRA
31 - 3-pin connector
❑ For engine speed sender -G28-
32 - Injectors
❑ Cylinder 1 injector for cylinder 1 -N30-
❑ Checking injection quantity and spray pattern; checking for leaks ⇒ page 29
Audi TT 2007 ➤
Fitting location of accelerator position sender -G79- with acceler‐

ator position sender 2 -G185-
♦ To unplug the electrical connector -2- press the release tab
and pull off the cable guide -1-.
♦ Removing and installing ⇒ Rep. Gr. 20
Note
Diagram shows set-up on left-hand drive vehicles.

Fitting location of connectors for Lambda probes before catalytic

converter
1- Lambda probe 2 before catalytic converter -G108- with
Lambda probe 2 heater -Z28-
2- Lambda probe before catalytic converter -G39- with Lamb‐
da probe heater -Z19-
Note
Disregard -item 3-.

Audi TT 2007 ➤
Fitting location and tightening torque of Lambda probes before

catalytic converter
♦ In front exhaust pipe
– Tighten Lambda probes to 55 Nm.
Fitting location of connectors for Lambda probes after catalytic

converter Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ On underside of vehicle (right-side)

– Remove nuts -1- and -2- on retainer for electrical connectors.
Note
Disregard -item 3-.
– Detach cover.
1- Lambda probe after catalytic converter -G130- with Lambda
probe 1 heater after catalytic converter -Z29-
2- Lambda probe 2 after catalytic converter -G131- with Lamb‐
da probe 2 heater after catalytic converter -Z30-
Fitting location and tightening torque of Lambda probes after cat‐

alytic converter
♦ In catalytic converters.
– Tighten Lambda probes to 55 Nm.
Audi TT 2007 ➤
Fitting locations in electronics box in engine compartment

2.1 - Electric fuel pump 2 relay -J49-
2.2 - Continued coolant circulation relay -J151-
3 - Secondary air pump relay -J299-
4 - Motronic current supply relay -J271-
5 - Fuel pump relay -J17-
Fitting location: engine speed sender -G28- with 3-pin connector

♦ At front of engine.
1- 3-pin connector
2- Engine speed sender -G28-
Fitting location of intake manifold change-over valve -N156-

♦ On vacuum reservoir (at front of engine) -arrow-.
Fitting location of coolant temperature sender -G62-

♦ At front left of cylinder head -arrow-.

Audi TT 2007 ➤
Fitting location of knock sensor 1 -G61-

♦ At rear right on cylinder block.
1- Knock sensor 1 -G61-
2- 3-pin connector

♦ At front of cylinder block -arrow-.
Fitting location of Hall sender and camshaft control valves

♦ On left side of cylinder head.
1- Hall sender -G40-
2- Hall sender 2 -G163-
3- Inlet camshaft control valve 1 -N205-
4- Exhaust camshaft control valve 1 -N318-
Fitting location of secondary air inlet valves (engine code CBRA)

♦ At vacuum reservoir (at front of engine)
1- Secondary air inlet valve -N112-
2- Secondary air inlet valve 2 -N320-
Audi TT 2007 ➤
Fitting location of sender 1 for secondary air pressure -G609-

(engine code CBRA)
♦ Near throttle valve module -J338-
1- Sender 1 for secondary air pressure -G609-
Note
Disregard -arrows-.
1 - Gasket
❑ Clipped into air cleaner
housing (bottom sec‐
tion)
2 - Front air duct
and salt deposits
3 - Bolt
❑ 2 Nm
4 - Lower part of air duct
and salt deposits
5 - Air duct cover
6 - Bolt
❑ 5 Nm
7 - Bolt
❑ 3 Nm
8 - Air hose
⇒ page 14
10 - Seal
❑ Renew if damaged
11 - Air cleaner housing (top
section)
⇒ “2.4 Removing and in‐
stalling air filter ele‐
ment”, page 12
❑ Always use genuine part for air
Protected filter element
13 - Air cleaner housing (bottom section)

Audi TT 2007 ➤
14 - Bolt
❑ 10 Nm
15 - Rubber grommet
❑ Captive
16 - Bolt
❑ 10 Nm
17 - Bracket for air cleaner housing
18 - Retaining peg
❑ 10 Nm
19 - Rubber grommet
Audi TT 2007 ➤

ment
Removing
– Detach resonance pipe -2- from air intake hose.
– Disconnect air intake hose -1- from throttle valve module -
J338- .
– Detach electrical connector -3- for air mass meter -G70- .
– Detach air cleaner housing (top section) -arrow- and take out
air filter element.
Installing
• Tightening torque ⇒ page 10 .
To ensure the proper function of the air mass meter it is important
to observe the following notes and instructions.
Note
is calculated.
pressed air.
– Blow out water drain (small hole in bottom section of air clean‐
er housing) with compressed air.
air intake hose (engine intake side). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
centred in the retainer in the air cleaner housing (bottom sec‐
tion).
– Fit the top section of the air cleaner housing carefully on the
bottom section, without using force. Make sure the top section
of the air cleaner housing is fitted straight on the air filter ele‐
ment (note position of sealing lip on air filter element).

Audi TT 2007 ➤

housing
Removing
– Remove air filter element ⇒ page 12 .
– Unscrew bolts -arrows- and remove air duct.
– Unscrew air cleaner housing (lower section) -arrows-.

Installing
• Tightening torques ⇒ page 10 .
Installation is carried out in the reverse order; note the following.
pressed air.
Audi TT 2007 ➤

-G70-
Removing
– Detach air intake hose -arrows-.

– Then carefully pull air mass meter -G70- out of guide on air
cleaner housing (top section).
Installing
Note
♦ Renew O-ring.
is calculated.
♦ Use silicone-free lubricant when fitting air intake hose.

Audi TT 2007 ➤
2.7 Intake manifold - exploded view
1 - Change-over barrel
2 - Bearing bush
3 - O-ring
❑ Renew
4 - Bolt
5 - Bearing cap
6 - Intake manifold
7 - Bolt
❑ 20 Nm
8 - Bolt
❑ 20 Nm
9 - Seal
10 - Connection for crankcase
breather
❑ With heater element for
crankcase breather -
N79-
11 - O-ring
12 - Throttle valve module -
J338-
⇒ page 19
13 - Bolt
❑ 10 Nm
14 - Bolt
❑ 20 Nm
15 - Heat shield for exhaust
manifold
❑ With support for intake manifold
16 - Gasket
❑ Renew
❑ Insert into intake manifold
17 - Bolt
❑ 13 Nm
18 - Bolt
❑ 10 Nm
19 - Vacuum unit
❑ For intake manifold flaps
20 - Vacuum connection
❑ To intake manifold change-over valve -N156-
21 - O-ring
❑ Renew
Audi TT 2007 ➤
22 - Bearing bush
Engine lifting eye to cylinder head: tightening torque

Tighten bolts -arrows- to 20 Nm.
Oil dipstick and vacuum reservoir: tightening torques

Tighten bolts -3- and -4- to 5 Nm.

Removing
Note
All cable ties which are released

Protected by or cut open
copyright. Copyingwhen removing
for private must
be refitted in the same position when installing.
Caution
Observe notes on procedure for disconnecting the battery ⇒

Rep. Gr. 27 .
– Disconnect earth wire at battery with ignition switched off.


Audi TT 2007 ➤
– Unplug electrical connectors -1, 2, 3- and move wiring clear.

– Remove crankcase breather hose -4-.
– Remove ignition coils ⇒ page 43 .
– Remove throttle valve module -J338- ⇒ page 19 .
– Disconnect vacuum hoses -1, 3, 4- at rear of intake manifold.

Vehicles with engine code letters CBRA:
– Disconnect vacuum hose -2- leading to fuel system diagnostic
pump -V144- .
All vehicles (continued): Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unbolt hose bracket fromwith
intake
respectmanifold -arrows-
to the correctness and inmove
clear to rear, with hoses attached.
– Remove rear securing bolts -arrows- for intake manifold.
– Unhook connector -arrow- for engine speed sender -G28-

from bracket on guide tube for oil dipstick.
Audi TT 2007 ➤
– Pull out oil dipstick.

– Remove bolt -3-, pull out guide tube for oil dipstick -2- and
move clear to one side.
– Unscrew bolt -4- and detach vacuum reservoir -1- from intake
manifold.
– Move vacuum reservoir to side (hoses remain attached).
– Release relay lever -arrow- and detach.

– Detach vacuum unit for intake manifold change-over and
move to side with vacuum hose -3- connected.
– Unscrew bolts -arrows- and remove engine lifting eye (left-

side).
– Unscrew bolts -arrows- at front of intake manifold.

Audi TT 2007 ➤
– To avoid damaging the surface of the intake manifold, place a

clean cloth -1- over the lock carrier.
– Swing the intake manifold forwards -arrow A- and take it out
to the left -arrow B-.
Note
Cover or plug the intake ports in the cylinder head with a clean
cloth or foam plastic to prevent small items from dropping in.
Installing
Note
Renew seals and gaskets.
– Install ignition coils ⇒ page 43 .

– Install throttle valve module -J338- ⇒ page 19 .
– Install air filter element ⇒ page 12 .
– Connect earth strap to battery ⇒ Rep. Gr. 27 .
2.9 Removing and

Protected by copyright. installing
Copying throttle
for private or commercial valve
purposes, in part or in whole, is not
module
with respect-J338-
Removing
– Detach air intake hose -arrows-.
Note
Disregard -item 1-.

– Remove crankcase breather hose -1-.
– Move Lambda probe wiring at throttle valve module -J338-
clear
Note
Disregard -item 2-.
Audi TT 2007 ➤

– Detach throttle valve module -J338- from intake manifold.
Installing
2.10 Checking vacuum unit for intake mani‐

fold flaps
Only perform this test if there is a loss of engine torque, poor flex‐
ibility or lack of pulling power.
♦ Hand-operated vacuum pump -VAS 6213-
Procedure
– Start engine. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Abruptly floor accelerator pedal and observe linkage at vac‐
uum unit.
• The linkage should move -arrow-.
Proceed as follows if the linkage on the vacuum unit does not
move:
♦ Check vacuum system for leaks.
♦ Check that linkage of change-over mechanism moves freely.
♦ Check proper connection of vacuum lines.
♦ Check vacuum hoses.

Audi TT 2007 ➤
If no fault is found:
– Detach vacuum hose -3- from vacuum unit.
Note
Disregard items marked -1-, -2- and -arrows-.
– Connect hand-operated vacuum pump -VAS 6213- to vacuum

unit as shown in illustration.
– Use hand-operated vacuum pump to generate vacuum.

– At the same time observe linkage at vacuum unit:
• The linkage should move -arrow-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Vent vacuum hand pump. with respect to the correctness of information in this document. Copyright by AUDI AG.
• The linkage should return to its original position.
Note
Observe the movement of the linkage over the complete range of

travel. It should move steadily and smoothly.
If the linkage on the vacuum unit does not move, or only moves
jerkily:
– Renew vacuum unit ⇒ page 22 .
Audi TT 2007 ➤
2.11 Removing and installing vacuum unit for

intake manifold flaps
Removing
– Release relay lever -arrow- and detach.
– Pull vacuum unit off intake manifold.
– Detach vacuum hose -3- from vacuum unit.
Installing
Note
Renew O-ring.
2.12 Checking fuel pressure regulator

with respect and re‐ of information in this document. Copyright by AUDI AG.
to the correctness
sidual pressure
Note
The fuel pressure regulator is integrated in the fuel filter and can‐
not be renewed on its own.

♦ K-Jetronic tester -V.A.G 1318- with adapters -V.A.G 1318/11- ,

-V.A.G 1318/17- and -V.A.G 1318/23-

Audi TT 2007 ➤
Procedure
• Fuel pump relay OK.
• Fuel pump OK; checking ⇒ Rep. Gr. 20 .
• Fuel filter OK
Measuring fuel pressure:
– Press the two clips in direction of the -arrows- and remove
– Disconnect electric fuel pump 2 relay -J49- -item 2.1-.
Note
Disconnecting the electric fuel pump 2 relay -J49- will prevent the
fuel pump from being activated when the driver's door is opened.
WARNING
The fuel system is pressurised. Before opening the system

place a clean cloth around the connection. Then release pres‐
sure by carefully loosening the connection.
– Disconnect fuel supply pipe -arrow- by pulling release ring.
– Disconnect fuel supply pipe -arrow- at fuel rail.
Audi TT 2007 ➤
– Connect the K-Jetronic tester -V.A.G 1318- with adapters -

V.A.G 1318/11- , -V.A.G 1318/17- and -V.A.G 1318/23- .
– Connect pressure tester to fuel supply hose.
– Connect a fuel-resistant auxiliary hose between fuel rail and
tester.
Note
Use hose clips -arrows- to secure the auxiliary hose.
– Open cut-off valve on pressure tester.

• Lever points in direction of flow.
– Start the engine and run at idling speed.
– Measure the fuel pressure.
• Specification: approx. 4.0 bar
– Check fuel pump delivery rate ⇒ Rep. Gr. 20 .
Checking leakage and residual pressure:
– Check leak-tightness and residual pressure by watching the
drop in pressure on the pressure gauge.
• After 10 minutes pressure should still be at least 3.0 bar.
If the residual pressure drops below 3.0 bar:
– Allow pressure to build up, then switch off ignition. At the same
time close cut-off valve of K-Jetronic tester -V.A.G 1318- .
• Lever is at right angle to direction of flow -arrow-.
– Observe pressure drop on pressure gauge.
If the pressure drops again:
– Check pipe connections, injectors and O-rings on fuel rail for
leaks.
– Check pressure gauge for leaks.
If the pressure now does not drop:
– Open cut-off valve on pressure gauge (lever points in direction
of flow).

Audi TT 2007 ➤
side).
– Disconnect fuel return pipe -arrow- by pressing release tab.
Audi TT 2007 ➤
– Connect adapter hose -1318/17-1- to fuel return pipe.

– Clamp off adapter hose using hose clamp -3094- .
Note
Do not attach hose clamp -3094- directly to fuel pipe - Danger of

damage.
– Cover the return pipe connection with a cloth.

– Start the engine and briefly run at idling speed.
– Allow pressure to build up, then switch off ignition.
– Observe pressure drop on pressure gauge.
If pressure does not drop, non-return valve of fuel pump is de‐
fective.
– Renew fuel pump ⇒ Rep. Gr. 20 .
If the pressure drops again:
– Renew fuel filter with integral fuel pressure regulator ⇒ Rep.
Gr. 20 .
Note
Before removing the pressure tester, release the fuel pressure by

opening the cut-off valve. Hold a container under the connection.
– Installation is carried out in the reverse order; note the follow‐

ing:
Note
– Fit electric fuel pump 2 relay -J49- -item 2.1- back into relay
and fuse holder. with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi TT 2007 ➤
2.13 Fuel rail with injectors - exploded view
1 - Fuel rail
2 - Fuel hose
WARNING
Unplug electric fuel
pump 2 relay -J49- be‐
fore detaching fuel hose
⇒ page 28 .
3 - Bolt
❑ 10 Nm
4 - O-ring
⇒ page 27
❑ Lubricate lightly with
clean engine oil
5 - Retaining clip
❑ After installing injector,
make sure the retaining
clip is seated correctly.
6 - Injector
7 - O-ring
⇒ page 27
❑ Renew
clean engine oil

Removing
WARNING
The fuel system is pressurised. Wrap a cloth around the con‐

nection before opening the system. Then release pressure by
carefully loosening the connection.
Audi TT 2007 ➤

– Detach electric fuel pump 2 relay -J49- -item 2.1-.
Note
Disconnecting the electric fuel pump 2 relay -J49- will prevent the
fuel pump from being activated when the driver's door is opened.
– Remove intake manifold ⇒ page 16 .
– Move wiring harness -1- at fuel rail clear.

– Detach fuel rail -2- with injectors from cylinder head and lay it
aside with fuel hose connected.
– Pull off retaining clip and detach appropriate injector.
Installing
• Renew the O-rings at all opened connections. (When renew‐
ing the front O-ring, ensure that the plastic cap is not removed
from the injector head. The O-ring must be pulled off over the
plastic cap).
• Lubricate the O-rings with clean engine oil.
• Make sure injectors are installed in correct position.
• Make sure retaining clips are properly connected.
• Position fuel rail together with injectors (properly secured)
against intake manifold and press into place evenly.
– Install intake manifold ⇒ page 16 .

Audi TT 2007 ➤
– Fit electric fuel pump 2 relay -J49- -item 2.1- back into relay
and fuse holder.
2.15 Checking injection quantity and spray pattern of injectors; checking for leaks

equipment required
♦ Remote control -V.A.G
1348/3A- for V.A.G 1348
with adapter cable -
V.A.G 1348/3-2-
V.A.G 1594C-
♦ Adapter cable, 121-pin -
V.A.G 1598/31- (test box)
♦ Injection rate tester -
V.A.G 1602-
Procedure
• Fuel pressure OK; testing ⇒ page 22 .
– Remove intake manifold ⇒ page 16 .
– Remove fuel rail together with injectors ⇒ page 27 . Fuel hose
remains connected.
Audi TT 2007 ➤
Checking for leaks

– Detach fuse at “position 1” -arrow- from “fuse holder 2” (brown)

-item 2-.
– Connect remote control -V.A.G 1348/3A- for V.A.G 1348 with

adapter cable -V.A.G 1348/3-2- as follows:
♦ To contact for fuse for fuel pump (fuse is detached);
♦ To “+” wire at front of electronics box in engine compartment.
– Connect battery earth cable.
– Press remote control button -V.A.G 1348/3 A- .
• The fuel pump should run.
– Visually check the fuel injectors for leaks.
• When the fuel pump is running, no more than 1 to 2 drops a
minute should escape from any one of the injectors.
If the fuel loss is greater:
– Renew defective fuel injector ⇒ page 27 .
Checking injection quantity
– Unplug electrical connectors for injectors.
– Place one injector in a measuring glass for injection rate tester
-V.A.G 1602- .

Audi TT 2007 ➤
– Using a test lead and crocodile clamp from auxiliary measuring

set -V.A.G 1594C- , connect one contact of injector to earth
“–”.
– Connect second contact of injector to remote control -
V.A.G 1348/3 A- using adapter cable -V.A.G 1348/3-2- .
– Connect crocodile clamp to battery “+” (positive terminal in
engine compartment).
– Connect test lead from auxiliary measuring set -V.A.G 1594C-

with in-line fuse -arrow- to contact for fuse for fuel pump (fuse
is detached).
– Connect test lead to “+” wire on front side of electronics box in
engine compartment.
• The fuel pump should run.
– Press remote control button -V.A.G 1348/3 A- for 30 seconds.

– Carry out test for all fuel injectors using a new test glass each
time.
Note with respect to the correctness of information in this document. Copyright by AUDI AG.
Also check the spray pattern when testing the injection rate. The
spray pattern should be the same for all injectors.
– After all six injectors have been activated:

– Disconnect test lead (to switch off fuel pump).
– Place measuring glasses on a level surface.
• Specification: 128 ... 140 ml for each injector.
If the measured values for one or more of the fuel injectors do not
meet the specification:
– Renew defective injector ⇒ page 27 .
If the measured values for all the injectors are outside the speci‐
fication:
– Check fuel pressure ⇒ page 22 .
– Install injectors together with fuel rail ⇒ page 28 .
Audi TT 2007 ➤
– Fit fuse on “position 1” -arrow- back in “fuse holder 2” (brown)

-item 2-.
2.16 Removing and installing Lambda

probes (before catalytic converter)
Removing
– Unplug corresponding electrical connector.
– Move electrical wiring to corresponding Lambda probe clear.
Note
Disregard -item 3-.

Audi TT 2007 ➤
– Unscrew corresponding Lambda probe using ring spanner

-3337/1- .
Installing
Note
♦ New Lambda probes are coated with an assembly paste.

♦ If reinstalling the old Lambda probes, coat the threads with
high-temperature paste ⇒ Electronic parts catalogue .
♦ The assembly paste/high-temperature paste must not get into
the slots on the probe body.
♦ When installing, the Lambda probe wire must always be reat‐
tached at the same locations to prevent it from coming into

– Install air filter element ⇒ page 12 .
2.17 Removing and installing Lambda

probes (after catalytic converter)

Removing
– Remove nuts -1- and -2- on retainer for electrical connectors
on underside of vehicle (right-side).
Note
Disregard -item 3-.
Audi TT 2007 ➤
– Remove cover and unplug corresponding electrical connector.

– Remove plug connector from retainer and move wiring to cor‐
responding Lambda probe clear.
– Unscrew corresponding Lambda probe using ring spanner

-3337/1- .
Installing
Note
♦ New Lambda probes are coated with an assembly paste.

♦ If reinstalling the old Lambda probes, coat the threads with
high-temperature paste ⇒ Electronic parts catalogue .
♦ The assembly paste/high-temperature paste must not get into
the slots on the probe body.
♦ Fit all cable ties in the original positions when installing.

Audi TT 2007 ➤
3 Engine control unit -J623-

box
♦ Adapter cable, 121-pin -V.A.G 1598/31- (test box)
Note
♦ The adapter cable, 121-pin -V.A.G 1598/31- (test box) is de‐

signed for simultaneous connection to the wiring harness
leading to the engine control unit and to the engine control unit
itself.
ning).
♦ The instructions for performing the individual tests indicate
whether or not the engine control unit itself also needs to be
connected to the test box.
♦ Always use auxiliary measuring set -V.A.G 1594C- to connect
test equipment (e.g. voltage tester -V.A.G 1527B- , hand-held
multimeter -V.A.G 1526C- etc.).
Procedure
– Remove engine control unit -J623- ⇒ page 35 .
– Connect adapter cable, 121-pin -V.A.G 1598/31- (test box) to
multi-pin connectors of wiring harness.
– Connect earth clip of test box to earth.
– The instructions for performing the individual tests indicate
connected to the test adapter.
– Carry out test as described in relevant repair procedures.
– After completing test, re-install engine control unit
⇒ page 35 .

unit -J623-
The multi-pin connectors of the engine control unit are enclosed
in a protective housing, which is secured by a locking device and
shear bolts -arrows-. To make it more difficult to unscrew the
shear unless
bolts,authorised
the threads have additionally been orcoated with lock‐
permitted by AUDI AG. AUDI AG does not guarantee accept any liability
ing
withfluid.
The protective housing has to be removed before multi-pin con‐

nectors can be unplugged from engine control unit (e.g. to con‐
nect test box or renew engine control unit).
3. Engine control unit J623 35

Audi TT 2007 ➤
♦ Hot air blower, 220 V/ 50 HZ -VAS 1978/14- -item 1-
♦ Shrink element for hot air blower -VAS 1978/15- -item 2-

♦ Vice-grip pliers -3- (commercially available)
Removing
– Pry off caps on windscreen wiper arms with a screwdriver.
– Loosen nuts -arrows- several turns.
– Tilt windscreen wiper arms one by one and loosen from wiper
shafts.
– Remove nuts completely and take off wiper arms.
Note
Use puller (commercially available) to remove wiper arm if nec‐

essary.
-2- (carefully pull plenum chamber cover off retainer at wind‐
screen).
– Detach engine wiring harness at rear plenum chamber panel.
– Remove bolt -arrow- and detach engine control unit from re‐
tainer.

Audi TT 2007 ➤
– Unplug electrical connector -arrow- for body wiring harness

-1-.
Caution
The following procedure must be followed exactly to prevent

any damage (burning) to wiring, connectors, insulation and
control units. Observe operating instructions for hot air blower.
– Select settings on hot-air blower as shown in illustration, i.e.

set temperature potentiometer -2- toProtected
maximum heatCopying
by copyright. outputfor private or commercial purposes, in part or in whole, is not
and two-stage air flow switch -3- 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
Parts of the protective housing will become very hot as a result

of heating the shear bolts. Take care to avoid burns. Try to
ensure that only the thread is heated and none of the nearby
components. These should be covered if necessary.
– Carry out the following operations on the two shear bolts

-arrows-, one after the other.
3. Engine control unit J623 37

Audi TT 2007 ➤
– Fit shrink element for hot air blower -VAS 1978/15- to hot air
blower 220 V/ 50 HZ -VAS 1978/14- .
– Place the shrink element for hot air blower close to the shear
bolt on the protective housing.
– Switch on the hot air blower and heat the bolt for 20 ... 25
seconds.
– Grasp the bolt head with the vice-grip pliers and unscrew the
shear bolt.
– Slide back protective housing -arrow 1-.

– Unplug electrical multi-pin connector -arrow 2-.
Note
When the connectors are disconnected from the engine control

unit, the learnt values are erased but the contents of the fault
memory remain intact.
Installing
– Reinstall the engine control unit into the protective housing.
– Use new shear bolts.
After installing a new engine control unit, the following operations
must be performed:
– Activate engine control unit in “Guided Functions” under the
test procedure / function “Renew engine control unit” ⇒ Vehicle
diagnosis, testing and information system VAS 5051.

Audi TT 2007 ➤
28 – Ignition system
1 General notes and safety precau‐
tions
1.1 General notes on ignition system

♦ A voltage of at least 12.5 V is required for proper operation of
electrical components.
♦ If the engine starts, runs for a short period and then cuts out
after completing fault finding, repairs or component tests, this
may be due to the immobiliser disabling the engine control
unit. The fault memory must then be interrogated and, if nec‐
essary, the control unit must be adapted.

tester cables.
– Start “Guided Functions” mode.permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Caution

battery.
1. General notes and safety precautions 39

Audi TT 2007 ➤

WARNING

erly secured.
secured.
TT Coupé:
TT Roadster:
tem -VAS 5052-Protected
or diagnosis system -VAS 5053- .

the passenger.
40 Rep. Gr.28 - Ignition system

Audi TT 2007 ➤
2 Servicing ignition system
2.1 Test data

Test data 3.2 ltr. / 4V / 184 kW engine
Idling speed 600 ... 700 rpm1)
Cannot be adjusted; regulated by idling speed stabili‐
sation
Maximum rpm governed by approx. 6,500 rpm
deactivation of fuel injectors
Ignition timing
Not adjustable (determined by control unit)
Ignition system Multi-coil system with 6 ignition coils (output stages in‐
tegrated) connected directly to spark plugs via spark
plug connectors
Designation of spark plugs ⇒ Data sheets for exhaust emission test
• 1)Current values ⇒ Data sheets for exhaust emission test.
2. Servicing ignition system 41

Audi TT 2007 ➤
2.2 Ignition system - exploded view
1 - Ignition coils with output

stages
❑ Cylinder 1 ignition coil 1
with output stage -N70-
with output stage -
N127-
with output stage -
N291-
with output stage -
N292-
with output stage -
N323-
with output stage -
N324-
⇒ page 43
2 - 4-pin connector
❑ For ignition coils with
output stage
3 - Bracket
❑ For connector for knock
sensor 1 -G61-
4 - Bolt
❑ 10 Nm
5 - 3-pin connector
❑ Black Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ With gold-plated con‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
tacts with respect to the correctness of information in this document. Copyright by AUDI AG.

7 - Bolt
❑ 20 Nm
❑ To ensure correct operation of the knock sensor, it is important to adhere to the specified tightening
torque.
8 - Camshaft adjuster
❑ Exhaust side
❑ With sender wheel for Hall sender 2 -G163-
❑ Adjusting valve timing after re-installation ⇒ Rep. Gr. 13
9 - Upper cover for camshaft timing chain
10 - Seal
❑ Renew
❑ For exhaust camshaft
12 - Bolt
❑ 10 Nm

Audi TT 2007 ➤
❑ Black
❑ With gold-plated contacts
❑ For inlet camshaft
❑ Black
❑ With gold-plated contacts
❑ Inlet side
❑ With sender wheel for Hall sender -G40-
❑ Adjusting valve timing after re-installation ⇒ Rep. Gr. 13
18 - Spark plug
❑ Current values ⇒ Data sheets for exhaust emission test
❑ Removing and installing ⇒ Maintenance ; Booklet 810
19 - Valve timing housing
❑ For variable valve timing
2.3 Removing and installing ignition coils

♦ Puller -T10095 A-
♦ Assembly tool -T10118-

Audi TT 2007 ➤
Removing
– Detach electrical connectors at ignition coils by releasing tab
-arrow- with assembly tool -T10118- and carefully pulling con‐
nector.
– Attach puller -T10095 A- to ignition coils as shown in illustra‐

tion -arrow- and remove ignition coils one at a time.
Installing
– Insert the ignition coils into the holes so that the flat edges align
with one another -arrows-.

Service
Maintenance
Audi TT 2007 ➤ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Edition 04.2010 with respect to the correctness of information in this document. Copyright by AUDI AG.

Service
Maintenance
Heading
1. Overview of engines
2. Delivery Service
3. Description of work
4. Type plate, vehicle identification number
5. Lifting the vehicle
6. Tow-starting/towing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7. Vehicle tests carried out as part of inspection services and maintenance

Copyright © 2010 Audi AG, Ingolstadt A00IGTT0220

Audi TT 2007 ➤
Maintenance - Edition 04.2010
Contents
1 Overview of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Delivery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Description of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Cap for suspension strut protective tube: greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Reading out: measured value block 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Battery: checking "no load" voltage before engine is started for first time . . . . . . . . . . . . . . 6
3.4 Battery: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Battery: checking that battery cables are securely fitted . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 Battery: performing battery test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.7 Tyres: checking condition, wear pattern, tread depth and correcting tyre pressures . . . . . . 14
3.8 Brake system: visual check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.9 Lights: checking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.10 Brake pads: checking thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.11 Brake fluid level (depends on brake pad wear): checking . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.12 Brake fluid: changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.13 S tronic gearbox: changing oil and renewing Protected byoil filter Copying
copyright. . . . .for. private
. . . . or. .commercial
. . . . . .purposes,
. . . . . in. .part
. .or. in. .whole,
. 21 is not
3.14 Electric windows: checking positions with . . .respect

. . . . to. the
. . correctness
. . . . . . .of.information
. . . . . . in. this
. . document.
. . . . . .by. AUDI. . AG. 21
3.15 G17 additive: adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.16 Ignition keys: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.17 Diesel particulate filter: reading out ash deposit mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.18 Data memory: interrogating with vehicle diagnostic, testing and information system
VAS 5051/ 5052 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.19 Noise insulation: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.20 Haldex coupling: changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.21 Poly V-belt: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.22 Fuel filter: renewing (2.0 ltr. TDI CR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.23 Cooling system: checking coolant additive level and topping up with coolant if necessary
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.24 Instrument cluster: setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.25 Air cleaner: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.26 Bonnet arrester hook: lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.27 Engine cover panel: removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.28 Engine and engine compartment (from below): visual check for leaks and damage . . . . . . 38
3.29 Engine oil: draining or extracting, changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.30 Bonnet hinges: lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.31 Engine oil: filling up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.32 Engine: checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.33 Navigation system: releasing eject button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.34 Radio: activating anti-theft coding by entering fixed code number . . . . . . . . . . . . . . . . . . . . 44
3.35 Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.36 Wheel bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.37 Tyre pressure monitoring system: updating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.38 Manual gearbox/final drive: checking oil level, topping up with oil if necessary . . . . . . . . . . 47
3.39 Windscreen wiper/washer system: checking jet settings, adjusting jets if necessary . . . . 47
3.40 Headlight washer system: checking jet settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.41 Wiper blades: checking park position and checking for damage . . . . . . . . . . . . . . . . . . . . 50
3.42 Service interval display: resetting or adapting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.43 Fuse for headlight washer system: fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.44 Dust and pollen filter: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.45 Track rods, track control links, swivel joints, guide links and drive shafts on front and rear
axle: checking boots, play, and secure fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.46 Transport mode: deactivating (using vehicle diagnostic, testing and information system VAS
5051/5052 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.47 Door arresters, door hinges and lock cylinders: lubricating . . . . . . . . . . . . . . . . . . . . . . . . 57
Contents i
Audi TT 2007 ➤
3.48 Transport locks: removing locking elements for front and rear suspension struts . . . . . . . . 57
3.49 Underseal: visual check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.50 Plenum chamber: checking and cleaning water drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.51 Winter tyres (factory-fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.52 Toothed belt for camshaft drive: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.53 Clock: setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.54 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4 Type plate, vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5 Lifting the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6 Tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7 Vehicle tests carried out as part of inspection services and maintenance . . . . . . . . . . . . . . 71
ii Contents
Audi TT 2007 ➤
1 Overview of engines
Petrol engines
Engines ⇒ Petrol engines
Engine code BWA CDLA CDLB BUB
Capacity 2.0 ltr. 2.0 ltr. 2.0 ltr. 3.2 ltr.
No. of cylinders / 4/4 4/4 4/4 6/4
valves per cylinder
Exhaust emissions EU IV EU IV EU IV EU IV
standard
Power output (kW at 147 / 5100 - 6000 195 / 6000 199 / 6000 184 / 6333
rpm)
Torque (Nm at rpm) 280 / 1800 - 5000 350 / 2500 … 5250 350 / 2500 … 5250 320 / 2500
Bore (∅ mm) 82.5 82.5 82.5 84.0
Stroke (mm) 92.8 92.8 92.8 95.5
Compression ratio 10.5:1 9.8:1 9.8:1 10.85:1
Fuel injection / ignition TFSI TFSI TFSI MPI
RON at least 98 unleaded 1) 98 unleaded 1) 98 unleaded 1) 98 unleaded 1)
1)Unleaded RON 95 can also be used, but will result in a slight
loss of power.
Engines ⇒ Petrol engines

Engine code CCZA CESA CDAA CDMA CEPA
Capacity 2.0 ltr. 2.0 ltr. 1.8 ltr. 2.0 ltr. 2.5 ltr.
No. of cylinders / 4/4 4/4 4/4 4/4 5/4
valves per cylinder
Exhaust EU V EU V EU V EU IV EU V
emissions
standard
Power output (kW 147 / 5100 - 155 / 4300 - 118 / 4500 - 195 / 6000 250 / 5400 -
at rpm) 6000 6000 6200 6500
Torque (Nm at 280 / 1800 - 350 / 1600 - 250 / 1500 - 350 / 450 / 1600 -
rpm) 5000 4200 4500 2500 … 5250 5300
Bore (∅ mm) 82.5 82.5 82.5 82.5 82.5
Stroke (mm) 92.8 92.8 84.1 92.8 92.8
Compression
permitted ratioby AUDI AG.9.8:1
unless authorised 9.8:1
AUDI AG does not guarantee or accept any liability9.8:1 9.8:1 10:1
Fuel injection / ig‐ TFSI TFSI TFSI TFSI TFSI
nition
RON at least 98 unleaded 1) 98 unleaded 1) 95 unleaded 98 unleaded 1) 98 unleaded 1)
loss of power.
Diesel engines
Engines ⇒ Diesel engines
Engine code CBBB CFGB
Capacity 2.0 ltr. 2.0 ltr.
No. of cylinders / valves per cylinder 4/4 4/4
1. Overview of engines 1
Audi TT 2007 ➤
Engines ⇒ Diesel engines

Engine code CBBB CFGB
Exhaust emissions stand‐ EU V EU V
ard
Power output (kW at rpm) 125 / 4200 125 / 4200
Torque (Nm at rpm) 350 / 1750 - 2500 350 / 1750 - 2500
Bore (∅ mm) 81 81
Stroke (mm) 95.5 95.5
Compression ratio 16.5 :1 16.5 :1
Fuel injection / ignition TDI TDI
CR II CR II
CN at least 51 51
Diesel particulate filter X X
loss of power.
2 1. Overview of engines
Audi TT 2007 ➤
2 Delivery Service
Work to be completed Page
In the case of stock vehicles: performing steps ELSA mainte‐

specified in maintenance table “stock vehicles” nance table
Battery: checking that battery cables are se‐ ⇒ page 9
curely fitted
Battery: checking no load voltage ⇒ page 6
Data memory: reading out ⇒ page 23
Service interval display: resetting ⇒ page 50
Instrument cluster: setting the language ⇒ page 28
Daytime running lights: activating (see MMI Op‐
erating Manual)
Fuse for headlight washer system: fitting ⇒ page 53
Transport mode: deactivating ⇒ page 56
Transport locks: removing locking elements for ⇒ page 57
suspension struts
Cap for suspension strut protective tube: greas‐ ⇒ page 5
ing
G17 additive: adding into tank ⇒ page 21
Clock: setting ⇒ page 58
Front passenger's airbag: checking key switch
on / off, must be set to “on” (see Owner's Man‐
ual)
Ignition keys: checking operation. Enter the ⇒ page 22
number of ignition keys which have been
checked and handed over to the customer: ____
Service Schedule: removing vehicle data sticker
from supplied pack on front passenger's side
and sticking into Service Schedule under “War‐
ranty entitlement record”
Entering record of Delivery Service
Owner's literature: checking that it is complete
and preparing for handover to customer
Cooling system: coolant must be filled to max. ⇒ page 26
level
Engine: checking oil level and topping up if nec‐ ⇒ page 44
essary
Headlight washer system: fitting fuse ⇒ page 53
Navigation system: releasing eject button ⇒ page 44
Brake system: brake fluid must be filled to max. ⇒ page 18
level
Wheel bolts: tightening to specified torque
Protected ⇒ page
by copyright. Copying 46or commercial purposes, in part or in whole, is not
for private
Radio or radio/navigation system: disposing of
label with serial number and fixed code number

(supplied pack on front passenger's side) after

entering fixed code number
Radio and radio/navigation system: activating ⇒ page 44
anti-theft coding by entering fixed code number
Tyre pressure on all 4 wheels and spare wheel: ⇒ page 14
checking (note: 3.5 bar when car leaves factory) ⇒ page 46
Saving pressures in tyre pressure monitoring
system
2. Delivery Service 3
Audi TT 2007 ➤
Work to be completed Page

Accessories: installing (components stored in
luggage compartment, glove box, supplied
pack); keep puller or plastic clip in vehicle tool
kit.
Vehicle (from below): checking for damage
(without removing noise insulation)
Protective seat covers, plastic sheeting for car‐
pet: removing
Floor mats: fitting
Cleanliness of vehicle interior: checking front
and rear seats, interior trim, carpeting/mats,
windows
Cleanliness of vehicle exterior: checking paint‐
work, trims, windows, wiper blades
Transport protection: removing protective edge
strips on doors
Interior mirror with compass: calibrating (if “C” is ⇒ Rep. Gr. 68
displayed on mirror)
Road test and reset DIS ⇒ page 45
4 2. Delivery Service
Audi TT 2007 ➤
3 Description of work
The following chapters describe the work steps necessary for
performing the services listed in the maintenance tables.
Please refer to the relevant maintenance table for information on
when a service is due.
3.1 Cap for suspension strut protective

tube: greasing
♦ Lubricant G 000 405 A2
♦ Brush
Coat contact surface -arrow- of plastic cap at suspension strut

protective tube with G 000 405 A2.
Note
After removing the spring inserts/spacers and greasing the cap

for the suspension strut protective tube, make sure that the boot
is correctly seated in the suspension strut mounting and at the
shock absorber tube.
3.2 Reading out: measured value block 32
Note
Only applies in certain countries. For the countries affected, refer

to maintenance table.
3. Description of work 5
Audi TT 2007 ➤
– Carry out the following steps, one after the other.

♦ Connect -VAS 5051/5052-
♦ Self-diagnosis
♦ Engine electronics
♦ Measured value blocks
♦ Select measured value block 32
♦ Display zone 2 (4-cyl. engines)
♦ Display zones 2 and 4 (V6 and V8 engines)
Note
Add four times as much G17 additive ⇒ page 21 if there is a

deviation of > 15% in the values.
3.3 Battery: checking "no load" voltage be‐

fore engine is started for first time
3.3.1 Special tools and workshop equipment
required
– Ensure that the following rules are observed, otherwise correct
measurements cannot be guaranteed.
6 3. Description of work
Audi TT 2007 ➤
♦ The battery must not be placed under load from connected

electrical equipment for at least 12 hours before the test.
♦ The battery must not be charged for at least 12 hours before
test.
Remove rear moulded insert -3- for tools below luggage com‐
partment floor covering.
– Detach cover -arrow- for battery compartment.
– Detach moulded insert above battery.
– With ignition switched off, measure voltage between battery

clamps -2- and -3-.
1- If the tester indicates 12.5 V or more, then the battery is OK.
2- If the tester indicates 12.2 to 12.5 V the battery must be
charged ⇒ Rep. Gr. 27 .
3- If the tester indicates between 11.6 and 12.2 V proceed as
follows: Charge battery ⇒ Rep. Gr. 27 . After charging bat‐
tery allow to stand with no load for 24 hours. Then carry out
battery test / battery load test ⇒ page 9 .
4- If tester indicates 11.6 V or less the battery must be renewed
⇒ Rep. Gr. 27 .
Always adhere to correct procedure, otherwise measurements
will be falsified.
Audi TT 2007 ➤
3.4 Battery: checking
3.4.1 Batteries with “magic eye”

The battery is located in the luggage compartment (rear right).
– Switch off the ignition and remove the ignition key from the
lock.
– Remove rear moulded insert -3- for tools below luggage com‐
partment floor covering.
Note
-Item 1- and -item 2- can be disregarded.
– Detach cover -arrow- for battery compartment.

– Detach moulded insert above battery.
♦ The magic eye -arrow- indicates the electrolyte level and the
charge level of the battery to be checked.
♦ Three different colours are used as indicators:
– Green → the battery is sufficiently charged.
– Black → no charge or charge too low
– Colourless or yellow → critical electrolyte level has been
reached. Battery must be renewed.
3.4.2 Battery with sealing plugs

♦ A visual check of the battery is sufficient for batteries with
clearly visible external min. and max. marks.
♦ The electrolyte level must be aboveProtected
the minimum
by copyright.marking, but or commercial purposes, in part or in whole, is not
Copying for private
must not exceed the maximum marking.

♦ If the external min. and max. marks on the battery are not
clearly visible or if the electrolyte level cannot be checked
properly due to an opaque battery housing, the sealing plugs
must be unscrewed. It is then possible to visually check the
electrolyte level from the inside.
♦ The electrolyte level must align with the marking inside the
battery (plastic moulding). This corresponds to the max. mark‐
ing on the outside.
Audi TT 2007 ➤
Note
If electrolyte level is too low, the cell plates dry out, resulting in a
loss of battery capacity (loss of power). The cell plates must be
fully covered by electrolyte (sulphuric acid) in order to prevent
corrosion of plates, plate bridges and cell connectors. Corrosion
of these parts will impair battery function and make it unreliable.
It will be rendered unusable.
WARNING
If the electrolyte level is below the min. marking the battery

must be renewed! ⇒ Rep. Gr. 27
3.5 Battery: checking that battery cables are

securely fitted
– Check that battery clamps are securely fitted. If necessary,
tighten nuts -1- and -4-.
WARNING
If the battery clamp on the positive terminal is not fitted se‐
curely, disconnect the battery earth strap from the battery
negative terminal first to avoid possible accidents.
– Check that battery is securely installed. If necessary tighten

securing bolt -2- on retainer plate -3-.
Tightening torque Nm
Battery clamps to battery terminals 5
Bolt on retainer plate 22
3.6 Battery: performing battery test

Audi TT 2007 ➤
♦ Battery tester -VAS 6161- (with printer)
♦ Battery tester -VAS 5097 A-
Note
♦ During battery test with battery tester -VAS 6161- (with print‐
er), battery earth wire does not have to be disconnected.
♦ It is not necessary to remove the battery when using battery
tester -VAS 5097A- . The battery does not have to be discon‐
nected.
3.6.1 Performing battery test using battery

tester -VAS 6161- (with printer)
♦ The battery tester with printer -VAS 6161- no longer puts the
battery under load, but works by measuring the dynamic con‐
ductivity. For this reason it is possible to perform several
measurements without re-charging the battery.
♦ "No-load" voltage measurement can be performed without de‐
lay.
♦ All battery types are stored in the tester. These data can be
updated.
♦ The battery bar code can be directly read off with the optionally
available 2D scanner.
♦ The integrated temperature sensor improves the quality of
measurements.
♦ The data can be stored on an SD card.
Note
For more information on the battery tester -VAS 6161- (with print‐
er), refer to the tester's ⇒ operating instructions .
Audi TT 2007 ➤

♦ Battery tester (with printer) -VAS 6161-
Note
For instructions on how to use the battery tester -VAS 6161- refer
to its ⇒ operating instructions .
Procedure:
• The battery temperature must be at least +10 °C.
WARNING permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Risk of injury due to electrolyte.

♦ The accident prevention procedures must be observed
when handling electrolyte.
♦ Wear eye protection and protective clothing.
♦ Sealing plugs of batteries which are not maintenance-free
must be firmly screwed in when measuring voltage under
load.
Risk of explosion due to a discharged battery with “magic eye”.
♦ If the “magic eye” is colourless or light yellow, do not test
or charge the battery. Do not attempt to jump-start the ve‐
hicle! There is a danger of explosion if you test or charge
the battery or jump-start the vehicle! The battery must be
renewed.
– Switch off ignition and all electrical equipment.

– On vehicles with “magic eye” check colour of “magic eye”.
– Switch on battery tester -VAS 6161- (with printer).
– Connect red test clamp “+” of battery tester to positive battery
terminal or jump start terminal in engine compartment.
– Connect black test clamp “–” of battery tester to negative bat‐
tery terminal or jump start terminal in engine compartment.
Note
Make sure the test clamps make proper contact.
– Select one of the following functions:

♦ Maintenance test
Audi TT 2007 ➤
♦ Service test
♦ Warranty test
Maintenance test
– Select “Maintenance test” from the menu.
– Connect scanner and scan in vehicle identification number.
– Select connection point: “at battery post” or “at jump start
post”.
– Select vehicle model.
– Scan in battery's bar code.
– Determine temperature by holding temperature sensor at a
distance of approx. 5 cm over battery or jump start post until
a constant temperature is displayed.
– Start test.
– If required, print out test log.
Service test
– Select “Service test” from the menu.
– Determine temperature by holding temperature sensor at a
distance of approx. 5 cm over battery until a constant temper‐
ature is displayed.
– Select battery type: “Regular”, “AGM”, “2*6V” or “Gel”.
– Select rating units: “CCA”, “JIS”, “DIN”, “SAE”, “IEC” or “EN”.
– Start test.
Warranty test
– Select “Warranty test” from the menu.
– Select fitting location: “in vehicle” or “out of vehicle”.
– Determine temperature by holding
Protected temperature
by copyright. Copying for sensor at a
distance of approx. 5 cm permitted
over battery until a constant temper‐
ature is displayed.
– Select battery type: “Regular”, “AGM”, “2*6V” or “Gel”.

– Select corresponding rating using arrow buttons.
– Start test.
Note
The test log is required for warranty processing.
– Switch off battery tester.

– Detach test clamps.
Audi TT 2007 ➤
Test result on printout:

1- Test mode
2- Test result
3- Measured voltage
4- Measured nominal value of battery
5- Nominal value of battery set on tester
6- Temperature measured above battery
7- Fitting location of battery
8- Position of battery clamp set on tester
9- Selected battery type
Result of maintenance test Measures
Battery good Battery OK
Charge battery Charge battery
Charge battery instantly Charge battery completely and
repeat test. Faults can occur if
battery is not completely charg‐
ed when test is repeated
Mark as defect Mark as “defect” and remove
from vehicle
Check tester connection Remove battery and repeat test
Battery frozen Thaw battery and repeat test
Check connection Connect cable directly to bat‐
tery and not to jump-start termi‐
nal
Result of service test and war‐ Measures

ranty test
Battery good Battery OK
Battery good
with respect - recharge
to the correctness of informationCharge battery
in this document. completely
Replace battery Remove battery and repeat

test. Result "Replace battery"
can arise if cables do not make
proper contact
Bad cell - replace Renew battery
Battery frozen Thaw battery and repeat test
Check connection Connect cable directly to bat‐
tery and not to jump-start termi‐
nal
– Renew battery ⇒ Rep. Gr. 27 .
Note
If the battery has to be renewed, observe disposal regulations.
3.6.2 Performing battery load test using VAS

5097 A
– Read operating instructions for battery tester.
Audi TT 2007 ➤
– Connect the clamps of the test leads to battery terminals as

described in operating instructions for the tester.
The clamps must make good contact with the battery terminals.
– As the load current differs depending on the battery, the cur‐
rent must be set on the tester according to battery capacity ⇒
Operating instructions for battery test equipment.
– Perform a battery load test as described in the operating in‐
structions.
Please note the test results shown on the display of the tester.
Display on bat‐ Delivery Inspection Inspection Service
tery tester LongLife Service
Battery Very Battery OK Battery OK
Good
Battery Good Battery OK Battery OK
Battery Sufficient Renew battery Charge battery1)
Battery Not Good Renew battery Charge battery1)
Battery Faulty Renew battery Renew battery2)
Cannot be tested Renew battery Renew battery2)
1) - Perform battery load test again after recharging the battery.
If tester shows “Battery Good” after charging, battery is OK. How‐
ever, if tester still shows “Battery Not Good”, battery must be
renewed.
2) - Agree battery replacement with customer.
– Renew battery ⇒ Rep. Gr. 27 .
Notes on battery load test:
The battery voltage will decrease during the test due to the high
load (high current flow).
If a battery is in working order battery voltage will only drop to
minimum voltage.
If the battery is defective or only insufficiently charged, battery
voltage will very quickly drop below minimum voltage.
After carrying out the load test the voltage will remain at this low
level for quite a while; voltage will only rise again slowly.
3.7 Tyres: checking condition, wear pattern,

tread depth and correcting tyre pres‐
sures
Note
All tyres and wheels (front and rear) must be of same type and
size. On four-wheel drive vehicles you must also ensure that all
tyres are made by the same manufacturer and have the same
tread pattern.
Delivery Inspection
– Check tyre tread surfaces and sidewalls for damage and re‐
move any foreign bodies.
Inspection Service
– Check tyres for scuffing, one-sided wear, porous sidewalls,
cuts and fractures.
Audi TT 2007 ➤
WARNING
Any defects must be reported to the customer.
Checking tyre wear pattern

– The wear pattern of the front tyres indicates, for example,
whether the toe and camber have to be checked.
♦ Feathering on tread indicates incorrect toe setting.
♦ One-sided tread wear is usually due to incorrect camber.
Note
If the above types of wear are found, check wheel alignment to

determine the cause (repair measure).
Checking tyre tread depth

♦ Minimum depth: 1.6 mm
Note
♦ This figure may vary for individual countries due to different

legislation.
♦ If the tread depth is approaching the minimum permissible
tread depth, the customer must be informed.
3.7.1 Inflating to correct pressures

The correct inflation pressures are listed on the sticker inside the
B-pillar.
Note
Please note that the tyre pressures listed on the sticker apply to
cold tyres. When the tyres are warm, the actual pressures will be
higher, but must not be reduced.
3.7.2 Spare wheel

• Collapsible spare wheel
The correct tyre pressure
permitted unless is indicated
authorised by AUDI ondoes
AG. AUDI AG thenotsidewall.
guarantee or accept any liability
3.8 Brake system: visual check for leaks

and damage
– Check following components for leaks and damage:
♦ Brake master cylinder
♦ Brake servo
♦ ABS hydraulic unit
♦ Brake calipers
Audi TT 2007 ➤
– Ensure that brake hoses are not twisted.

– Make sure that brake hoses do not touch any components
when steering is on full lock.
– Check brake hoses for porosity, blistering and brittleness.
– Check brake hoses and pipes for chafing.
– Check brake pipe connections and mountings for correct seat‐
ing, leaks and corrosion.
WARNING with respect to the correctness of information in this document. Copyright by AUDI AG.
Any faults found must be rectified (repair measure).
3.9 Lights: checking function

– The following components must be checked:
♦ Front lights: side lights, dipped beam, main beam, front fog
lights, turn signals, hazard warning lights
♦ Tail light cluster: brake lights (incl. 3rd brake light), rear lights,
reversing lights, rear fog light, number plate light, turn signals,
hazard warning lights
♦ Horn, glove box light and luggage compartment light
3.10 Brake pads: checking thickness

♦ Test pin T40139
Test pin
Before using the test gauge to check the pad thickness, push the
sliding ring towards the tip of the gauge as far as it will go.
Then insert the test gauge through the wheel rim and bring the tip
of the gauge into contact with the brake disc. Then slide the body
of the gauge uniformly towards the brake pad until the gauge
makes contact with the backplate of the brake pad.
Then take out the test pin and read off the value on the scale
marked with the brake symbol.
Note
♦ When removing the test pin, take care not to move the sliding
ring. This would give an incorrect measurement.
♦ The second scale on the test pin (with the tyre symbol) can be
used for checking tread depth.
Audi TT 2007 ➤
Front disc brake pads:

a - Pad thickness including backplate
- Wear limit: 7
Rear disc brake pads:

a - Pad thickness including backplate
- Wear limit: 7
WARNING
When brake pad thickness (including backplate) is down to 7,

the brake pads have reached their wear limit and must be re‐
newed (repair measure). The customer must be informed.
Note
♦ On some vehicles (fitted with aftermarket rims) it may not be

possible to insert the test pin through the wheel rim and bring
it into contact with the brake disc or the brake pad, due to the
shape of the rim. In this case proceed as follows:
♦ Determine thickness of outer pads by checking visually (using
electric torch through cut-out in rim).
♦ Determine thickness of inner pads by checking visually (with
help of electric torch and mirror).
3.11 Brake fluid level (depends on brake pad

wear): checking
Note
Only use new genuine VW/Audi brake fluid, refer to ETKA.
WARNING
♦ Brake fluid is poisonous. It also has caustic properties and

must therefore not be allowed to come into contact with
paintwork.
♦ Brake fluid is hygroscopic, i.e. it absorbs moisture from the
surrounding air. It must therefore always be stored in air-
tight containers.
– Note the following:
Audi TT 2007 ➤
3.11.1 Delivery Inspection

♦ The fluid level must be at the MAX mark.
Note
The fluid level must not exceed the MAX marking, otherwise the
fluid will overflow.
3.12 Brake fluid: changing
Note
Only use new genuine VW/Audi brake fluid, refer to ETKA.
Changing brake fluid with brake filling and bleeding equipment -

VASpermitted
5234-unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
WARNING
♦ Brake fluid must on no account come into contact with liq‐

uids containing mineral oils (oil, petrol, cleaning agents).
Mineral oils damage the plugs and sleeves in the brake
system.
♦ Brake fluid is poisonous and must under no circumstances
be sucked through a tube using the mouth. Because of its
caustic properties it must also not come into contact with
paintwork.
♦ Brake fluid is hygroscopic, i.e. it absorbs moisture from the
surrounding air. It must therefore always be stored in air-
tight containers.
♦ Always observe the relevant environmental regulations for
disposal.
3.12.1 Changing brake fluid with brake filling

and bleeding equipment -VAS 5234-
♦ Brake filling and bleeding equipment -VAS 5234-
Audi TT 2007 ➤
♦ Container for collecting used fluid
Note
♦ The brake fluid reservoir must always be adequately filled to

ensure that no air can enter the brake system from the reser‐
voir.
♦ The strainer in the brake fluid reservoir must not be removed.
♦ Observe the instructions given in the operating manual for the
brake filling and bleeding equipment -VAS 5234- .
– Unscrew cap -1- from brake fluid reservoir.
Audi TT 2007 ➤
– Use extraction hose included in brake filling and bleeding

equipment -VAS 5234- to extract as much brake fluid as pos‐
sible.
WARNING
Do not reuse the old brake fluid that has been extracted.
– Connect adapter -1- to brake fluid reservoir.

– Connect filling hose -2- included with brake filling and bleeding
equipment -VAS 5234- to adapter.
Vehicles with manual gearbox:
– Remove cap from bleeder screw on clutch slave cylinder.
– Connect bleeder hose -1- attached to collector bottle to bleed‐

er screw on clutch slave cylinder, open bleeder screw and let
approx. 100 ml flow out. Close bleeder screw and fit cap
permitted unlessback
on. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Repeatedly depress the clutch pedal.

Continuation for all vehicles:
– Remove caps from bleeder screws.
er screw (front left), open bleeder screw and allow approx. 200
ml of brake fluid to flow out. Close bleeder screw.
Audi TT 2007 ➤
– Repeat the procedure on the other front side of the vehicle.

er screw (rear left), open bleeder screw and allow approx. 200
ml of brake fluid to flow out. Close bleeder screw.
– Repeat the procedure on the other rear side of the vehicle.
– Fit caps back on bleeder screws on brake calipers.
– Move filling lever on brake filling and bleeding equipment -
VAS 5234- to position -B- (see operating instructions).
– Detach filling hose from adapter.
– Unscrew adapter from brake fluid reservoir.
– Screw cap onto brake fluid reservoir.
– Check brake fluid level and correct as necessary.
– Check pedal pressure and free play of brake pedal. Free play:
no more than 1/3 of pedal travel
3.12.2 Table - sequence for changing brake flu‐

id / quantities
Front left 200 ml
Front right 200 ml
Rear left 200 ml
Rear right 200 mlby AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless authorised
Clutch slave cylinder 200 ml
Total quantity 1000 ml
3.13 S tronic gearbox: changing oil and re‐

newing oil filter
– Change gear oil ⇒ Rep. Gr. 00 ; Direct shift gearbox .
3.14 Electric windows: checking positions

The electric window regulators “forget” their current positions and
the automatic open/close function when the battery is disconnec‐
ted.
– Activate the automatic open/close function as follows:
– Close the windows all the way to their top positions using the
window switches.
– Then operate all window switches again for at least one sec‐
ond in the “close” direction to activate the automatic one-touch
function.
– Press switch to open window. The side window should move
all the way down automatically.
3.15 G17 additive: adding
Note
Only applies in certain countries. For the countries affected, refer

to maintenance table.
Audi TT 2007 ➤
♦ When adding G17 additive into the tank, the ratio must be
10 ml of additive per 10 litres of fuel.
♦ The following table lists the quantities to be added depending
on the fuel level indicated on the fuel gauge.
Mixture ratio:
Indicated on fuel gauge G17 fuel additive
approx. 1/4 approx. 15 ml
Note
♦ The quantities listed in the table refer to a fuel tank with a ca‐
pacity of 60 litres. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ If the fuel level in the fuel tank is other than quoted in the table,
add additive in steps of 10 ml additive per 10 litres of fuel.
3.16 Ignition keys: checking operation

– Open key ring to check each key individually.
– Insert one ignition key after the other into ignition lock and start
engine with each key.
– If the engine switches off automatically after approx. 3 sec‐
onds and the odometer display shows “safe” the ignition key
has not been matched to the immobiliser.
– Repair measure: Guided Fault Finding (matching ignition
keys).
– Make a note in the delivery record of the number of ignition
keys which have been checked and handed over.
3.17 Diesel particulate filter: reading out ash

deposit mass
Note
Engines affected: see Maintenance table.
Audi TT 2007 ➤
♦ Connect VAS 5051 or 5052.

♦ Guided Functions
♦ Read measured values
♦ Oil ash deposits
♦ Maximum value for ash deposit mass (4-cyl. engines): 60 g
Note
If ash deposit mass is <= 60 g the vehicle can be driven for a

further 30,000 km (19,000 miles).
WARNING
If ash deposit mass value is 60 g or greater for 4-cyl. engines,

the diesel particulate filter must be renewed.
3.18 Data memory: interrogating with vehicle

diagnostic, testing and information sys‐
temby-VAS
Protected 5051/
copyright. Copying 5052-
– Carry outwith
therespect
following steps, ofone
to the correctness after inthe
information this other.
document. Copyright by AUDI AG.

♦ Vehicle Self-Diagnosis
♦ Gateway - Fitting list
♦ Read out control units for which entries have been made in
fault memory.
♦ Eliminate relevant faults (when approved by customer).
3.19 Noise insulation: removing and installing

– Remove noise insulation -fasteners 1 ... 4-.
Audi TT 2007 ➤
3.20 Haldex coupling: changing oil

– Change oil: ⇒ Rep. Gr. 39 .
3.21 Poly V-belt: renewing

Vehicles with 4-cyl. petrol engine 2.0 ltr. TFSI:
– Removing and installing poly V-belt ⇒ Rep. Gr. 13
Vehicles with 6-cyl. petrol engine 3.2 ltr. MPI:
Vehicles with 4-cyl. diesel engine 2.0 ltr. TDI CR:
3.22 Fuel filter: renewing (2.0 ltr. TDI CR)

♦ Diesel extractor -VAS 5226-
Note
♦ Please ensure that no diesel fuel makes contact with the cool‐
ant hoses.
♦ If necessary, clean hoses immediately.
♦ Observe disposal regulations.
♦ Follow the procedure shown below:

– Unscrew bolt from drain pipe -1-.

– Attach diesel extractor -VAS 5226- to connection.
– Use diesel extractor -VAS 5226- to draw off about 100 ml of
diesel fuel.
– Renew seal and screw bolt into drain pipe.
– Loosen all bolts on cover -arrows- in diagonal sequence (ap‐
prox. 1.5 to 2 turns).
Audi TT 2007 ➤
– Unscrew bolts completely and remove cover from filter.
– Remove filter element -1- and seals -2 and 3- from filter hous‐
ing -4-.
– Renew seals -3-.

– Install new filter element.
– Install new seal -2- on cover of filter.
– Fit cover with seal onto filter housing.
Audi TT 2007 ➤
– Pre-tighten bolts in diagonal sequence (2 turns).
Note
The bolts have to be tightened diagonally in correct sequence.

Otherwise, the cover will tilt on the centre pipe and the cover and
seal could get damaged.
– Tighten bolts in sequence shown.

– Start engine and check fuel system for leaks (visual check).
Tightening torques Nm
Bolts on filter housing 5
Note
Observe disposal regulations.
3.23 Cooling system: checking coolant addi‐

tive level and topping up with coolant if
necessary
Note
♦ The coolant additive ratio must be at least 40 % (gives anti‐

freeze protection down to –25 °C), but should not exceed 60 %
(frost protection down to –40 °C); beyond this concentration
both the frost protection and the cooling efficiency are reduced
again.
♦ Frost protection should be ensured down to temperatures of
about –25 °C.
♦ For approved coolant additive, refer to ⇒ ETKA .

♦ Refractometer -T10007-
Audi TT 2007 ➤
Note
For exact readings for the following tests refer to the light-dark
border. Before carrying out the tests, you can first determine the
light-dark border for water. To do so, use a pipette to place a drop
of water on the glass. The light-dark border will now show up
clearly at the “WATERLINE” marking.
– Check the coolant additive concentration using the refractom‐

eter -T10007- . Observe the instructions in the operating man‐
ual.
Scale -1- on the refractometer applies to coolant additives G 12,
G 12 Plus, G 12 Plus Plus and G 11.
Scale -2- refers only to coolant additive -G 13- (previously called
L80).
Note
♦ Frost protection should be ensured down to temperatures of

about –25 °C.
♦ If greater frost protection is required in very cold climates, the
proportion of coolant additive can be increased, but only up to
60 % (this gives frost protection at temperatures down to ap‐
prox. -40 °C). Beyond this concentration the frost protection
and also the cooling efficiency are reduced again.
Checking coolant level and topping up with coolant if necessary

– Check coolant level in coolant expansion tank while the engine
is cold.
Audi TT 2007 ➤
♦ Delivery Inspection: Coolant level should be above “Min.”

marking -arrow-
♦ Inspection Service: Coolant level should be above “Min.”
marking -arrow-
– If coolant level is too low, add required amount (using correct
mixture ratio).
Note
If fluid losses are greater than can be reasonably expected, de‐

termine the cause and rectify faults (repair measure).
Mixture ratio:
Frost protection Coolant additive Water
to
–25 °C approx. 40 % approx. 60 %
Note
♦ Coolant additives prevent frost and corrosion damage, scaling

and also raise the boiling point of the coolant. It is therefore
essential to use the correct coolant additive in the cooling sys‐
tem all year round.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
antifreeze ratio must be at least 40 %.
3.24 Instrument cluster: setting the language

– Carry out the following
Protected steps,
by copyright. one
Copying after orthe
for private other.purposes, in part or in whole, is not
commercial
♦ Connect VASwith5051
respector
to 5052.
♦ Guided Fault Finding/Guided Functions

♦ Go to - Function / component selection
♦ Servicing
♦ Adapting the language
♦ Follow the instructions shown on the screen.
Audi TT 2007 ➤
3.25 Air cleaner: cleaning housing and re‐

newing filter element
3.25.1 6-cyl. petrol engine 3.2 MPI

– Open hose clip -2- with hose clip pliers -V.A.G 1921- and re‐
move intake hose -1-.
– Release and detach connector -3- from air mass meter.
– Remove securing bolts -arrows-.
– Lift out air cleaner housing (top section).
– Take out old filter element -arrow-.

– Clean filter housing and install new filter element.
– Install air cleaner housing (top section) and tighten bolts -ar‐
rows-.
– Fit connector -3- onto air mass meter and make sure it en‐
gages.
– Fit intake hose -1- onto air cleaner housing and secure with
hose clip -2-.
Important: observe general notes at the end of the section
⇒ page 36
3.25.2 4-cyl. petrol engine 2.0 ltr. TFSI

Audi TT 2007 ➤
♦ Spring-type clip pliers -VAS 5024-

– Open clamps -1 and 2- and disconnect air hose from air mass
meter.
– Unclip intake hose -arrows-.
– Release spring-type clips -4- and detach air intake hose from
engine cover panel.
– Carefully pull engine
permitted unless cover
authorisedpanel
by AUDIoff
AG.at positions
-1 - 2 - 3 - 4-withone after
respect another.
Caution
Always observe this sequence (risk of breaking engine cover

panel).
– Cover open intake hose with a clean cloth.

Removing air filter element
– Unscrew all bolts -arrows-.
Audi TT 2007 ➤
– Detach engine cover panel (note retainers -arrows-).
– Pull air filter element out of engine cover panel.

Note
♦ Self-tapping screws are used in production to secure the top

section of the air cleaner to the bottom section. If these screws
are tightened or loosened with a power screwdriver the thread
in the top section of the air cleaner housing can be damaged.
♦ For this reason, a power screwdriver must ONLY be used if
the following requirements are met:
♦ Power screwdriver: max. 200 rpm.
♦ It must be possible to set the max. tightening torque to 3 Nm.
♦ To install the engine cover panel, first align it at the four mount‐
ing points. Then use the flat surface of your hands to fit the
cover onto the engine evenly, pressing downwards onto the
four mounting points simultaneously.
♦ When installing the engine cover panel, make sure the rubber
sleeve is properly seated between the air cleaner housing and
the engine intake.
– Assembly is conducted in reverse sequence.

⇒ page 36
Audi TT 2007 ➤

Removing
– Disconnect air hose -1- from air mass meter -G70- .
– Detach air cleaner (top section) -arrows- and remove air filter
element.
Installing
Installation is performed in reverse sequence; note the following:
To ensure the correct function of the air mass meter it is important
to observe the following notes and adhere to the procedures de‐
scribed below.
Note
♦ If the air filter element is very dirty or wet, dirt particles or water
can reach the air mass meter and falsify the detected air mass
values. This will cause a loss of power, as the calculated in‐
jection quantities will be too low.
♦ Always use genuine air filter elements (same as original equip‐
ment).
♦ The air cleaner housing must always be clean.
♦ Secure all hose connections with genuine hose clips (same as
original equipment) ⇒ Electronic parts catalogue .
♦ When cleaning the air cleaner housing with compressed air,
cover the critical components of the engine intake system such
as the air mass meter and intake pipes etc. with a clean cloth
to avoid malfunctioning.
Audi TT 2007 ➤
er) with compressed air.
– Clean the air cleaner housing (top and bottom sections) to re‐
move any salt residue, dirt and leaves (if necessary vacuum-
clean).
– Check air mass meter and air hose (engine intake side) for salt
residue, dirt and leaves.
– Check air duct leading from lock carrier to air cleaner housing
for dirt and leaves. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– When installing the air filter element make
with respect sure
to the it is positioned
centrally on the mounting in the bottom section of the air
cleaner.
– Carefully fit the top section of the air cleaner on the bottom
section of the air cleaner, without applying any force. When
fitting the top section of the air cleaner, make sure it is NOT
positioned on the air filter element at an angle (observe sealing
lip of air filter element).
– Make sure that the air hose is correctly seated at the air mass
meter.
Air cleaner (top section) 5
⇒ page 36

Removing
– Pull engine cover panel -1- off upwards -arrows-.
Audi TT 2007 ➤
– Loosen hose clips -1- and -2-.

– Remove bolts -arrows- and detach air cleaner (top section).
– Take out air filter element.
Installing
Installation is performed in reverse sequence; note the following:
To ensure the correct function of the air mass meter it is important
to observe the following notes and adhere to the procedures de‐
scribed below.
Note
♦ If the air filter element is very dirty or wet, dirt particles or water
can reach the air mass meter and falsify the detected air mass
values. This will cause a loss of power, as the calculated in‐
jection quantities will be too low.
ment).
♦ The air cleaner housing must always be clean.
original equipment) ⇒ Electronic parts catalogue .
♦ When cleaning the air cleaner housing with compressed air,
cover the critical components of the engine intake system such
as the air mass meter and intake pipes etc. with a clean cloth
to avoid malfunctioning.
er) with compressed air.
– Clean the air cleaner housing (top and bottom sections) to re‐
clean).
– Check air mass meter and air hose (engine intake side) for salt
residue, dirt and leaves.
– Check air duct leading from lock carrier to air cleaner housing
for dirt and leaves.
– When installing the air filter element make sure it is positioned
cleaner.
– Carefully fit the top section of the air cleaner on the bottom
positioned on the air filter element at an angle (observe sealing
lip of air filter element).
– Make sure that the air hose is correctly seated at the air mass
meter.
Air cleaner (top section) 5
⇒ page 36
Audi TT 2007 ➤
3.25.5 4-cyl. petrol engine 1.8 ltr. TFSI, 2.0 ltr.

TFSI
– Loosen the bolts -arrows- and pull the cover up.
– Remove old filter element.
⇒ page 36
3.25.6 4-cyl. diesel engine 2.0 ltr. CR TDI en‐

gine
– Loosen the bolts -arrows- and pull the cover up.
⇒ page 36
Audi TT 2007 ➤
3.25.7 General notes
Note
♦ If the air filter element is very dirty or soaked with water, dirt
particles or moisture can reach the air mass meter -G70- and
falsify the detected air mass values. This will cause a loss of
power, as the calculated injection quantities will be too low.
ment).
♦ Use a lubricant (silicon-free) when installing intake hose.
original equipment): refer to ETKA.
♦ Check whether the water drain hose in the bottom section of
the air cleaner is dirty or blocked (clean if necessary).
♦ Clean the air cleaner housing (top and bottom sections) to re‐
clean).
♦ Check air mass meter and intake hose (engine intake side) for
salt residue, dirt and leaves.
♦ Check intake duct as far as air filter element for dirt.
♦ When installing the air filter element make sure it is positioned
cleaner.
♦ Carefully fit the top section of the air cleaner on the bottom
positioned on the air filter element at an angle. Note position
of sealing lip on air filter element (to prevent air leaks).
♦ Then secure top section of air cleaner to bottom section.
3.26 Bonnet arrester hook: lubricating

– Only grease the bonnet arrester hook at the points shown in
the illustration -arrows-.
♦ Lubricant: “G 052 778 A2”
3.27 Engine cover panel: removing

Audi TT 2007 ➤
♦ Hose clip pliers -VAS 6340-
4-cyl. petrol engine 2.0 ltr. (TFSI)

– Release clips at air mass meter -A- and at air intake hose
-B- using hose clip pliers -VAS 6340- and push them back.
– Unplug air mass meter -2- and move connector to one side.
– Detach engine cover panel first at front -arrows 3-, then at rear
-arrows 4-.
– To do so, reach under the sides of the cover.
Note
♦ To install the engine cover panel, first align it at the four mount‐
ing points. Then use the flat surface of your hands to fit the
cover onto the engine evenly, pressing downwards onto the
four mounting points simultaneously.
♦ When installing the engine cover panel, make sure the rubber
sleeve is properly seated between the air cleaner housing and
the engine permitted
intake.unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4-cyl. petrol engine 2.0 ltr. TFSI

Removing
– Carefully pull off engine cover panel -arrows-. Do not jerk the
cover panel away, and do not try to pull on one side only.
Installing
– Carefully press engine cover panel back into mountings.
– To avoid causing damage, do not bang the engine cover panel
down with your fist or a tool.
Audi TT 2007 ➤
4-cyl. petrol engine 1.8 ltr. TFSI, 2.0 ltr. TFSI:

– Pull off engine cover panel -arrows-.
5-cyl. petrol engine 2.5 ltr. TFSI:

– Pull engine cover panel -1- off upwards -arrows-.
4-cyl. CR TDI engine:

– Pull off engine cover panel -arrows-.
3.28 Engine and engine compartment (from

below): visual check for leaks and dam‐
age
– Carry out visual check as follows:
– Check engine and gearbox for leaks and damage.
– Check final drive, drive shaft boots and steering system for
leaks and damage.
WARNING

Audi TT 2007 ➤
3.29 Engine oil: draining or extracting, chang‐

ing oil filter
WARNING
On some engine versions it is NOT permissible to draw off the

engine oil with an oil extractor. Refer to maintenance table.
Note
Oil should always be changed when engine is warm.

♦ Oil extractor -V.A.G 1782-
♦ Hazet strap wrench -2171-1-

♦ Oil filter tool -3417-
♦ Oil drain adapter -T 40057-
Audi TT 2007 ➤
Note

TFSI
– Remove noise insulation ⇒ page 23 .
– Use Hazet strap wrench -2171-1- or oil filter tool -3417- to
slacken oil filter and then remove it.
Note
– Open oil drain plug / draw off engine oil.

– Clean sealing surface for oil filter at engine.
– Lightly lubricate rubber seal.
– Screw in new filter and tighten.
– Screw in oil drain plug with new seal.
– Fill up with engine oil, specifications ⇒ page 43 .
Oil filter 22
Oil drain plug 30

TFSI
– Remove noise insulation ⇒ page 23 .
Note
Before removing the oil filter you must drain engine oil from the
filter so that it does not spill onto the engine or other components.
Audi TT 2007 ➤
– Unscrew protective cap on base valve -1-.

– Detach hose with ball head from oil drain adapter -T 40057-
and screw stud into base valve on oil filter housing -2- until you
feel a slight resistance.
– Now fit hose with ball head onto stud and screw oil drain
adapter -T 40057- on further as far as it will go; you should
hear the drain valve click.
– Let oil filter drain.
WARNING
Hot engine oil
– Unscrew the oil drain adapter -T 40057- .

– Now check that base valve -1- is flush and level as shown in
illustration (A02-0423).
– Now screw on the protective cap.
– Unscrew oil filter housing -2- using oil filter tool -3417- or
36 mm socket, e.g. socket, 36 mm -T10125- , and remove oil
filter.
– Renew filter element -4- and seal -3-.
Note
♦ Note position of service tab on seal -arrow-.

– Clean sealing surfacepermitted
on oil unless
filterauthorised
housing. by AUDI AG. AUDI AG does not guarantee or accept any liability
– Lightly lubricate rubber seal.
– Flat side of seal must face outwards.
– Screw in filter housing and tighten.
Oil filter 25+5
Oil drain plug 30
Audi TT 2007 ➤
3.29.3 4-cyl. CR TDI engines:

– Remove noise insulation before draining oil via the oil drain
plug ⇒ page 23 .
– Unclip vacuum control valve -1- from bracket and move clear
to one side.
– Loosen sealing cap -2- using socket (32 mm) .
Note
Loosen sealing cap before draining/extracting oil, so that engine

oil can flow out of oil filter housing.

– Renew O-rings and oil filter element.
Note
Observe disposal regulations. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Tighten sealing cap using socket (32 mm) .

– Clip vacuum control valve -1- into bracket.

Oil drain plug 30
Sealing cap 25
3.29.4 6-cyl. petrol engine 3.2 ltr. MPI

– Remove noise insulation before draining oil via oil drain plug
⇒ page 23 .
Audi TT 2007 ➤
– Drain oil via drain plug -1-.
Note
– Loosen lower part of filter -3- on hexagon -2- or on circumfer‐

ence -4- and remove.
– Wipe filter housing with a cloth.
– Remove old O-ring.
– Use new O-ringProtected
and moisten with
by copyright. oil.for private or commercial purposes, in part or in whole, is not
Copying
– Install new filter element
with respectand
to the new O-ring.
– Tighten lower part of filter -3- on hexagon -2- to 30 Nm.

– Fit new seal to drain plug -1- and tighten to 10 Nm.
Oil drain plug 30
3.30 Bonnet hinges: lubricating

– Spray bonnet hinge joints with lubricating spray G 052 778 A2.
3.31 Engine oil: filling up
Note
♦ Please observe the engine oil capacities and oil grades listed
in the maintenance table.
♦ Use only engine oil with the specification VW 507 00 on vehi‐
cles equipped with diesel particulate filter.
Engines with turbocharger:

– When the engine oil and oil filter have been changed, it is im‐
portant to note the following after starting the engine for the
first time:
♦ The engine must only run at idling speed as long as the oil
pressure warning lamp in the dash panel is on. Do not rev up!
If the engine is revved up the turbocharger can be damaged
or fail completely.
♦ The full oil pressure is not attained until the warning lamp has
gone out, only then can the engine be revved up.
All models:
– Finally, check oil level ⇒ page 44 .
Audi TT 2007 ➤
3.32 Engine: checking oil level
Note
♦ Engine oil temperature at least 60 °C.

♦ Vehicle must be level (horizontal).
♦ Wait a few minutes after switching off the engine to allow the
oil to flow back into the sump.
– Pull out the dipstick, wipe with a clean cloth and insert again
as far as it will go.
– Pull out the dipstick again and read off the oil level.
Markings on oil dipstick:
a - Oil must not be topped up.
b - Oil can be topped up. The oil level may rise as far as area
-a- after topping up.
c - Oil must be topped up. The oil level is sufficient if it is some‐
where in area -b- (grooved area) after topping up.
Note
The oil level must not be above marking -a- on the dipstick.
3.33 Navigation system: releasing eject but‐

ton
♦ Servicing
♦ J401 - Navigation system, lock / release eject button
3.34 Radio: activating anti-theft coding by en‐

tering fixed code number
The radio units are supplied with a fixed code. This means that
each radio unit with anti-theft coding is programmed with its own
code number. The fixed code is not activated by the factory. To
enhance anti-theft protection, a radio card is no longer provided
in the operating manuals for the radios and navigation systems.
Audi TT 2007 ➤
The procedure for entering the radio code is no longer described

in the operating manuals.
The anti-theft coding of the ready-to-use unit is only activated by
entering the fixed code.
For radios chorus II+, concert II+, and symphony II+, enter the
radio code as follows:
– Switch on the radio. The display will show "Code 1000".
– Repeatedly press the top left control button "X___" (arrow) until
the first digit of the radio code appears in the display.
– Then enter the remaining three digits of the radio code using
the other three control buttons.
– Press the control button for "ENTER". The radio coding is now
completed.
– Dispose of the sticker with the radio code.
If the radio code is entered incorrectly at two consecutive attempts
and the display shows "Code Safe 2", proceed as follows:
Leave the radio switched on for approx. 60 minutes. After 60 mi‐
nutes the display will show "Code Safe / Code 1000" and the radio
will switch off.
Enter the radio code again.
For the navigation system BNS 5.0 enter the radio code as fol‐
lows:
– Switch on navigation system.
– Enter PIN via speller.
– Confirm entry with "OK".
– Dispose of the sticker with the radio code.
Note
♦ Please inform the customer that the anti-theft coding can only
be obtained from the dealership or workshop.
♦ Without the code, the radio is of no interest to potential thieves.
3.35 Road test

To what extent the following can be checked depends on vehicle
equipment and local conditions (urban/country).
– The following points must be checked during the road test:
♦ Engine: performance, misfiring, idling speed, acceleration
♦ Clutch: permitted
pullingunless
away, pedalbypressure,
authorised odours
♦ Gear selection: ease of operation, gear lever position
♦ Automatic gearbox: selector lever position, shift lock / ignition
key lock, shift behaviour, instrument cluster display
♦ Brake pedal and handbrake: operation, travel and effective‐
ness, pulling to one side, juddering, squeal
♦ ABS function: pulsing must be felt at the brake pedal when
performing ABS-controlled braking.
♦ Steering: operation, steering free play, steering wheel central‐
ised when wheels are in straight-ahead position
Audi TT 2007 ➤
♦ Sliding/tilting sunroof: operation

♦ Cruise control system: operation
♦ Radio: quality of reception, interference
♦ Driver Information System (DIS): functions
♦ Air conditioner: operation
♦ Vehicle: moving off line when travelling straight ahead (level
road)
♦ Imbalance: wheels, drive shafts
♦ Wheel bearings: noises
♦ Engine: hot starting behaviour
♦ Horn: checking
3.36 Wheel bolts: tightening to specified tor‐

que
3.36.1 Wheel bolts

The adapter for loosening and tightening anti-theft wheel bolts is
included in vehicle tool kit.
Note
Ensure that wheel bolts are tightened in diagonal sequence to the

following tightening torque:
Wheel bolts 120
– Place puller and adapter back in vehicle tool kit after complet‐
ing work.
3.37 Tyre pressure monitoring system: up‐

dating
The system must be updated to store the new pressures following
any change to the wheels, e.g. tyre pressures or changing or re‐
placement of tyres.
– With ignition switched on and vehicle stationary, press and

hold button for tyre pressure monitoring system -arrow- until
tyre pressure warning lamp in instrument cluster flashes sev‐
eral times and an acoustic signal is heard.
– The tone indicates that the tyre pressure monitoring system
has been updated.
Audi TT 2007 ➤
3.38 Manual gearbox/final drive: checking oil

level, topping up with oil if necessary
– Remove oil filler plug -arrow-.
♦ Specification: oil level up to lower edge of filler hole
3.38.1 6-speed dual clutch gearbox

For notes on checking the oil level and changing the oil please
refer to ⇒ Rep. Gr. 34 ; Checking gear oil level and topping up .
3.38.2 6-speed manual gearbox

Oil filler plug (hexagon socket) 30
Oil filler plug (multi-point socket) 45
If the oil level is below the range specified, the gearbox must
be checked for leaks (repair measure). It is then not sufficient

to merely top up the oil.
– Refer to the current parts catalogue (ETKA) for correct gear

oil specification.
3.39 Windscreen wiper/washer system:

checking jet settings, adjusting jets if
necessary
♦ Washer jet adjusting tool -T10127- fitted with needle
-3125/5A-
♦ or
Audi TT 2007 ➤
♦ Washer jet adjusting tool -T40187- fitted with needle

-3125/5A-
WARNING
Risk of injury.
♦ When you are not using the adjusting tool -T40187- , make
sure that both sides of the tool are covered with the covers
-3- and -4- and locked at all times.
♦ If one of the sides is not locked with the cover, the needle
-3125/5A- -1- or the adjusting pin -2- can cause injury.
♦ When opening one of the sides, always make sure the
opposite side of the tool does not point to your hand.
– Release long cover -1- on adjusting tool -T40187- -arrow - and

slide it back -arrow B-.
– Fit adjusting pin -2- onto each jet -arrow- in washer jet unit
-1- and aim at the marks made on the windscreen; adjust as
necessary.
– If the spray pattern cannot be set as specified, clean the ob‐
structed washer jet.
WARNING
Risk of injury.
♦ Always cover and lock the adjusting pin with the cover af‐
ter using it. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
Never use pins or other sharp objects as these will damage the
water channels in the jet.
Audi TT 2007 ➤
Setting
Note
The specified settings allow for the motion of the vehicle when
driving. When the vehicle is stationary the jets will spray at a
slightly different angle.
– Mark the six points on the glass using a water-soluble marker

pen.
Dimensions in Driver's side Passenger's side
mm
-a- = 300 300
-b- = 600 600
-c- = 320 320
-d- = 335 335
-e-
Protected by = Copying for private
copyright. 495 or commercial purposes, in part
495or in whole, is not
-f- to=the correctness of information
with respect 175 175by AUDI AG.
in this document. Copyright
– Use adjusting tool -T10127- to aim the individual jets at the

points marked.
– If the spray pattern cannot be set as specified, clean the ob‐
structed washer jet.
Cleaning washer jet:
– Remove washer jet ⇒ Rep. Gr. 92 .
– Rinse washer jet with clean water in opposite direction to nor‐
mal flow.
– To remove any remaining obstructions, blow out with com‐
pressed air only (in opposite direction to normal flow).
– If the spray pattern still cannot be set as specified, renew the
affected washer jet.
3.40 Headlight washer system: checking jet

settings
The headlight washer jets are set by the manufacturer and there‐
fore do not need to be adjusted.
Audi TT 2007 ➤
3.41 Wiper blades: checking park position

and checking for damage
3.41.1 Park position for windscreen wiper

blades
Note
♦ Every 2nd time the windscreen wiper motor is switched off, it

will return the wiper arms slightly past the end position, which
ensures that the lip of the wiper blade is tipped the other way.
♦ To do so, the wiper motor will first move the wiper arms down
and then up again just a little to their final position. You must
not adjust or check the wiper crank while the wiper arms are
in this raised position.
♦ Instead, carry out adjustment or checks only after the wiper
motor has moved the wiper arms directly to their normal final
position (not raised); if necessary let wipers carry out a brief
wipe.
– Switch windscreen wipers on and
permitted offauthorised
unless and letbythem
AUDI AG. return
AUDI AG todoes not guarantee or accept any liability
their park position. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Check for the following distances between tips of wiper blades
and cowl panel trim of plenum chamber at bottom edge of
windscreen:
♦ Distance a = 5 mm + 10
♦ Distance b = 24 mm + 10
– If necessary adjust wiper arm ⇒ Rep. Gr. 92 .
Note
These figures specify the distance between the tip of the wiper
blades and the black cowl panel trim at the bottom edge of the
windscreen. The layout is symmetrically opposite for right-hand
drive vehicles.
3.42 Service interval display: resetting or

adapting
3.42.1 Service interval display: resetting (vehi‐

cles up to model year 2007)
Audi TT 2007 ➤

♦ Servicing
♦ Combi processor, Resetting ESI
Note
♦ Please note function description of Guided Fault Finding/ Gui‐

ded Functions.
♦ ESI = Extended Servicing Intervals
3.42.2 Service interval display: resetting (vehi‐

cles from model year 2008 onwards)
Note
From model year 2008 onwards, all vehicles are equipped with
the same advanced maintenance concept as the Audi A5.

♦ Servicing
3.42.3 Oil grade: adapting

Audi TT 2007 ➤

♦ Also use K-lead adapter VAS 6017B.
♦ Servicing
♦ Combi processor, Adapting oil grade
Note
♦ The oil grade must be adapted when changing the setting from
Inspection Service to LongLife Service or vice versa.
♦ Inspection Service = oil grade 1
♦ LongLife Service = oil grade 2
ded Functions.
3.42.4 Maximum values: adapting
Note
Only applies up to model year 2007.
Audi TT 2007 ➤

♦ Servicing
♦ Combi processor, Adapting max values ESI
Maximum values for LongLife service
Minimum mileage in km 15000
Maximum mileage in km 30000
Maximum time interval in days 730
Maximum values for Inspection Service
Minimum mileage in km 15000
Maximum mileage in km 15000
Maximum time interval in days 365
Note

ded Functions.
3.42.5 Service interval display: resetting (after

completing a Service) without the use of
VAS 5051/5052
Note
If the service interval display is reset manually via the dash panel
insert it will automatically be set to a fixed interval.
– When button 1 is pulled out the message “SERVICE” will be
displayed.
– Within the next 5 seconds pull the button out again until the
message “SERVICE IN .... KM... DAYS” appears.
– The service interval display has been reset.
3.43 Fuse for headlight washer system: fitting

– Fuse for headlight washer system: 30 amp fuse is provided in
fuse carrier 1, socket 1, in electronics box in engine compart‐
ment.
Audi TT 2007 ➤
– Fit fuse in fuse carrier 1, socket 6, in electronics box in engine

compartment.
3.44 Dust and pollen filter: removing and in‐
stalling
Note
♦ The dust and pollen filter is available in different versions with

and without active charcoal filter insert ⇒ Parts catalogue .
The Audi TT with air conditioner is currently fitted with a dust
and pollen filter with active charcoal filter insert.
♦ Clean the area around the dust and pollen filter in the air con‐
ditioner unit before fitting a new filter.
♦ On vehicles with special equipment for driving schools you
may have to remove the pedal cluster (some driving school
pedals have detachable connections ⇒ Fitting instructions ;
Equipment for driving schools .)
– Remove screws -A- and take out insulating mat -B-.

– Cover floor carpeting beneath dust and pollen filter with paper.
Audi TT 2007 ➤
– Push cover -B- in direction of arrow -C- and then remove cov‐
er.
Note
If the tabs -D- no longer hold properly, the cover -C- can be se‐
cured with bolts -A-.
– Take dust and pollen filter -A- out of aperture in air conditioner
unit -B-.
– Clean aperture in air conditioner unit -B- (e.g. with a vacuum
cleaner) after removing the dust and pollen filter.
3.45 Track rods, track control links, swivel

joints, guide links and drive shafts on
front and rear axle: checking
Protected by copyright.boots,
Copying for play,
and secure fit permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
The test must be carried out with vehicle raised on a lifting plat‐
form (wheels free to move).
– Check play by moving the track rods and wheels.

♦ There should be no play.
Audi TT 2007 ➤
– Check that boots -arrow- are not damaged and are seated
correctly.
– Check boots -arrow- are not damaged and are seated cor‐
rectly.
– Also check the rear side of the protective boots using a mirror.
– Check play at supporting joints -arrow-.
– Check boots of drive shafts.

Check boots of steering box -arrow 1- for damage.
Note
Disregard arrows -2- and -3-.
3.46 Transport mode: deactivating (using ve‐

hicle diagnostic, testing and information
system -VAS 5051/5052- )
The transport mode serves to maintain the vehicle's ability to start
(battery power level). The transport mode limits the extent to
which the battery discharges. When the vehicle is in transport
mode, many functions are restricted or no longer available at all,
e.g. CD changer and radio are deactivated.
Deactivate transport mode via Guided Fault Finding or Guided
Functions.
♦ Vehicle Self-Diagnosis
♦ Collective services
♦ Energy manager, deactivate transport mode
Audi TT 2007 ➤
3.47 Door arresters, door hinges and lock cyl‐

inders: lubricating
– Only grease the door arresters at the points shown in the il‐
lustration -arrow-.
– Lubricate the lock cylinders.
3.48 Transport locks: removing locking ele‐

ments for front and rear suspension
struts
Two different types of transport locks are used. (Spring inserts at
the front; arrester blocks at the rear.)
– Relieve the load on the coil springs (e.g. by raising vehicle on
a lifting platform).
Note
♦ It is not necessary to remove the wheels.

♦ Ensure that surface of springs is not damaged.
– Pull the locking elements out of the springs.
Note
After removing the spring inserts/spacers and greasing the cap

for the suspension strut protective tube, make sure that the boot
is correctly seated in the suspension strut mounting and at the
shock absorber tube.
3.49 Underseal: visual check for damage

– When performing visual check, check underbody, wheel hous‐
ings and side members.
WARNING
3.50 Plenum chamber: checking and clean‐

ing water drain
– Remove plenum chamber cover.
Audi TT 2007 ➤
Note
♦ Visually inspect plenum chamber for dirt (leaves, etc.).

♦ Clean plenum chamber and water drain if there is any dirt.
Removing plenum chamber cover ⇒ Rep. Gr. 50 ; Removing and

installing plenum chamber cover
3.51 Winter tyres (factory-fitted)
Note
♦ On vehicles supplied from the factory with winter tyres, check

the tyre pressures as part of the Delivery Inspection.
♦ The warning sticker indicating the maximum permissible
speed for the tyres must be affixed in a position where it is
immediately visible to the driver.
3.52 Toothed belt for camshaft drive: renew‐

ing
– Removing and installing toothed belt: ⇒ Rep. Gr. 13
Vehicles with 4-cyl. diesel engine 2.0 ltr. TDI:
– Removing and installing toothed belt: ⇒ Rep. Gr. 13
3.53 Clock: setting

Radio-controlled clock
Note
The clock can function as a radio-controlled quartz clock or as a

normal quartz clock.
If the radio-controlled clock receives a valid radio signal it will au‐

tomatically switch to the operating mode “radio-controlled quartz
clock”. The signal reception symbol (radio tower with radio waves)
will then be shown in the display. If the clock does not receive a
valid signal it will automatically switch to the “quartz clock” mode
after three days; the signal reception symbol will then disappear.
3.54 Spark plugs: renewing
Note
Always observe the relevant environmental regulations for dis‐

posal.

Audi TT 2007 ➤
♦ Spark plug socket and extension -3122B-
♦ Puller for pencil-type ignition coils -T40039-
♦ Puller -T10095/a-
Audi TT 2007 ➤
♦ Puller -T10094 A-
3.54.1 6-cyl. petrol engine 3.2 ltr. MPI

– Detach connectors for ignition coils with output stage
-arrows-.
– Release retaining tabs on connectors using assembly tool -

T10118- .
– Place assembly tool -T10118- on retainer tab -arrow- and then
carefully pull off the connector.
Audi TT 2007 ➤
– On straight (not rounded) side of connector, push puller -

T10095/a- onto ignition coil with output stage in direction of
arrow.
– Pull ignition coil with output stage off upwards in a straight line.
– Note installation position of ignition coils with output stage rel‐

ative to connectors before you remove the coils -arrows-.
Straight side of connector must fit onto straight side of ignition coil
with output stage.
– Unscrew spark plugs using spark plug socket and extension

-3122B- .
– Install new spark plugs using spark plug socket and extension
-3122B- . 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 Nm
Spark plugs in cylinder head 20

– Assembly is conducted in reverse sequence.

TFSI
– Release electrical connectors -arrows- and pull all connectors
off ignition coils simultaneously.
Audi TT 2007 ➤
– Using puller -T40039- , pull all ignition coils out of spark plug
apertures.
– Remove spark plugs using spark plug socket and extension
-3122 B-.
– Install new spark plugs with spark plug socket and extension
-3122 B-.
– Fit all ignition coils loosely into spark plug apertures.
– Align ignition coils with electrical connectors and plug all con‐
nectors simultaneously onto coils.
– Push ignition coils evenly onto spark plugs by hand (do NOT
attempt to knock in coils with any kind of tool).

– Remove engine cover panel ⇒ page
permitted unless36 onwards.
– Remove both bolts -1-.
– Push connector -2- towards pencil-type ignition coil, press
catch down by hand and pull off connector.
– Use puller -T40039- to detach pencil-type ignition coils from
spark plugs.
-3122 B-.
-3122 B-.
Note
Press pencil-type ignition coils into the openings provided on the

cylinder head cover by hand.
– Fit the ignition coils and turn them slightly - make sure you feel
them engage.

– Unplug electrical connector -6- for Hall sender 3 -G300- .
– Remove both bolts -arrows-.
Audi TT 2007 ➤
– Release electrical connectors and pull connectors off ignition

coils -1 ... 5- simultaneously.
– Slide puller -T40039- onto ignition coil with output stage and
pull off ignition coil -arrow-.
-3122 B-.
-3122 B-.
Installing:
– Fit all ignition coils loosely into spark plug apertures.
– Align ignition coils with electrical connectors and plug all con‐
nectors simultaneously onto coils.
– Push ignition coils evenly onto spark plugs by hand (do NOT
attempt to knock in coils with any kind of tool).
– Secure guide for ignition coil wiring to cylinder head cover.
Note
Press pencil-type ignition coils into the openings provided on the

cylinder head cover by hand.
– Fit the ignition coils and turn them slightly - make sure you feel
them engage.
Securing bolts for wiring guide 5
Audi TT 2007 ➤
4 Type plate, vehicle identification number

The vehicle identification number -B- is stamped on the cross-
piece section of the plenum chamber.
The type plate -A- is secured to the wing mounting flange (right-
side).
Information encoded in vehicle identification number:

WAU ZZZ 8J Z 7 A 000 001
Manufactur‐ Filler charac‐ Type Filler charac‐ Model year Production lo‐ Serial number
er's mark ters ters 2007 cation
Vehicle data sticker

The vehicle data sticker can be found in the customer's Service
Schedule, and also on the vehicle in the spare wheel well or on
the floor panel.
64 4. Type plate, vehicle identification number

Audi TT 2007 ➤
The sticker contains the following vehicle data:

1 - Vehicle identification number
2 - Model identification code/ production control number
3 - Model code
4 - Engine output/ emissions standard/ gearbox
5 - Engine and gearbox code letters (not specified on some export
models)
6 - Paint number/ interior equipment identification number
7 - Identification numbers for optional extras
8 - Unladen weight/ fuel consumption/ CO2 emission level (not
specified on some export versions)
Engine code and engine number
Note
The “engine code” is also listed on the vehicle data stickers in the
Service Schedule and in the spare wheel well or on the floor pan‐
el.
There is also a sticker on the toothed belt guard giving the engine
code and engine number.
4-cylinder engines:
The engine number (“engine code” and “serial number”) is at the
front of the joint between engine and gearbox.
5-cylinder engines:
The engine number (“engine code letters” and “serial number”) is
located at the rear of the joint between cylinder block and sump
(top section) -arrow-.
4. Type plate, vehicle identification number 65

Audi TT 2007 ➤
6-cylinder engines:
The engine number and engine code -arrow- are stamped onto
cylinder block, next to vibration damper.
66 4. Type plate, vehicle identification number

Audi TT 2007 ➤
5 Lifting the vehicle
WARNING
♦ Before driving on to a lifting platform ensure there is suf‐

ficient clearance between low-mounted vehicle compo‐
nents and the lifting platform.
♦ To avoid damage on TTS or S line vehicles, we recom‐
mend using the drive-on ramps T 40081 if the support
arms of the lifting platform are too thick.
♦ Before driving a vehicle onto a lifting platform it must be
ensured that the vehicle weight does not exceed the per‐
missible lifting capacity of the platform.
♦ To avoid damaging the vehicle underbody and to prevent
the vehicle from tipping, the vehicle should only be lifted
at the points shown in the illustration.
♦ Never start engine and engage gear with vehicle lifted, so
long as even one driven wheel has contact with the floor.
There is a risk of accident if this is not observed.
♦ If work is to be performed under the vehicle, it must be
securely supported by suitable stands.
Trolley jack
Always use suitable rubber or wooden blocks to avoid damage.
A trolley jack may only be applied at the lifting points as illustrated.
On no account should vehicle be lifted at engine sump, gearbox
or on front or rear axle, as this may cause serious damage.
Lifting points for lifting platform and trolley jack
Front:
Lifting point (front):
On longitudinal floor panel reinforcement below marking.
Rear:
Lifting point (rear):

On aluminium casting in front of rear axle mounting
5. Lifting the vehicle 67

Audi TT 2007 ➤
6 Tow-starting/towing
– Attach tow rope or tow bar only to the following towing eyes:
Front towing eye
– Open cover.
Screw in towing eye by hand and tighten ANTI-CLOCKWISE with
wheel bolt spanner.
68 6. Tow-starting/towing
Audi TT 2007 ➤
Rear towing eye

The rear towing eye is located below the rear bumper (right side).
– Screw in towing eye by hand and tighten ANTI-CLOCKWISE
with wheel bolt spanner.
Tow-starting/ towing the vehicle
Note
♦ Tow-ropes or bars must only be attached to aforementioned

towing eyes.
♦ The tow rope should be slightly elastic to reduce the risk of
damage to both vehicles. It is advisable to only use synthetic
fibre ropes or ropes of similar elastic material. However, it is
safer to use a tow bar.
♦ Always avoid excessive towing forces and do not jerk. During
towing operations on unsurfaced roads there is always a dan‐
ger that the attachment parts will be over-stressed and dam‐
aged.
♦ The vehicle should only be tow-started if it is not possible to
start the engine using jump leads.
If the vehicle has to be towed or tow-started, please note the fol‐

lowing points:
♦ Legal regulations concerning towing must be observed.
♦ Both drivers must be familiar with towing procedures. Inex‐
perienced drivers should not attempt to tow-start or tow.
♦ When using a tow rope, the driver of the towing vehicle must
engage the clutch very gently when moving off and changing
gear.
♦ The driver of the vehicle being towed must ensure that the tow
rope is always taut.
♦ Both vehicles must switch on their hazard warning lights, un‐
less otherwise specified by local regulations.
♦ The ignition must be switched on so that the steering wheel is
free and the turn signals, horn and windscreen wiper and
washer system can be used.
♦ Because the brake servo only works when the engine is run‐
ning, considerably more pressure is required on the brake
pedal when the engine is not running.
♦ As power-assisted steering does not work when the engine is
not running, more force is required to turn the steering wheel
when the engine is off.
♦ If there is no lubricant in the manual or automatic gearbox, the
vehicle must be towed with the driven wheels raised off the
ground.
Important notes on tow-starting:
In general it is not recommended to tow-start vehicles. Instead
you should use jump leads.
There are several reasons why tow-starting should be avoided:
♦ Tow-starting involves a high risk of accidents, e.g. collision
with towing vehicle.
♦ On vehicles with petrol engine, unburnt fuel could enter the
catalytic converter and cause damage.
6. Tow-starting/towing 69
Audi TT 2007 ➤
♦ For technical reasons, it is not possible to tow-start a vehicle

with an automatic gearbox.
If you should decide to tow-start although it is not recommended,
please note the following:
– Before moving off, engage 2nd or 3rd gear, press clutch pedal
and hold.
– When both vehicles are moving, release clutch pedal.
– As soon as the engine starts, depress clutch and move gear
lever to neutral to avoid running into the towing vehicle.
Note
Vehicles with a catalytic converter (petrol engines only) must not

be tow-started over a distance of more than 50 m if the catalytic
converter has already reached operating temperature. Other‐
wise, unburnt fuel may enter the catalytic converter and cause
damage.
When towing vehicles with automatic gearbox, please also note

the following:
♦ Selector lever must be in position “N”.
♦ Do not tow vehicle at a speed of more than 50 km/h.
♦ The maximum towing distance is 50 kilometres.
If towing over greater distances, the vehicle must be lifted at the
front.
Reason: When the engine is not turning the gearbox oil pump will
not work - the gearbox will therefore not be adequately lubricated
for higher speeds or longer distances.
When using a breakdown vehicle, the vehicle can only be towed
with the front wheels raised.
Reason: If vehicle is towed when raised at rear, the drive shafts
will turn backwards. As a result, the planetary gears in the auto‐
matic gearbox will then turn at such high speeds that the gearbox
will be severely damaged in a short time.
Note
If it is not possible to tow the vehicle normally, it must be trans‐

ported by a special transporter or trailer. This also applies to
distances greater than 50 kilometres.
70 6. Tow-starting/towing
Audi TT 2007 ➤
7 Vehicle tests carried out as part of in‐

spection services and maintenance
We recommend using the dialogue receipt and inspection unit
VAS 5000 and the performance test stand V.A.G 1858 for the
vehicle tests.
Brake test
For information on carrying out brake tests on front-wheel drive
and four-wheel drive vehicles refer to the appropriate "Brake sys‐
tem" workshop manual.
Performance test
Please carry out the performance tests on the performance test
stands recommended by Audi. These performance test stands
take into account the corrective figures for automatic gearbox and
four-wheel drive. Vehicles with four-wheel drive must only be tes‐
ted on a four-wheel performance test stand.
Speedometer test
During the speedometer test the vehicle is driven by its own
wheels. Vehicles with four-wheel drive must only be tested on a
four-wheel test stand.
Shock absorber test
For information on shock absorber tests refer to the appropriate
workshop manual on "Running gear".
7. Vehicle tests carried out as part of inspection services and maintenance 71

Service
Workshop Manual
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail -
generation II), mechanics
Engine ID
CFG
B
Edition 05.2010

Service
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
26 - Exhaust system

Copyright © 2010 Audi AG, Ingolstadt D3E8029FA9E

Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II), mechanics - Edition 05.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1 Working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Using testers and measuring instruments during a road test . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Rules for cleanliness when working on fuel supply system, injection system and
turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Checking for leaks in the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.5 Installing radiators, condensers and charge air coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Separating engine from manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 Assembly mountings - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Removing and installing engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3 Checking adjustment of assembly mountings (engine/gearbox mountings) . . . . . . . . . . . . 41
5.4 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.1 Poly V-belt drive without air conditioner compressor - exploded view . . . . . . . . . . . . . . . . 46
1.2 Removing and installing poly V-belt - vehicles without air conditioner compressor . . . . . . 47
1.3 Poly V-belt drive for vehicles with air conditioner compressor and tensioner - exploded
view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.4 Removing and installing poly V-belt - vehicles with air conditioner compressor and
tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.5 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.6 Poly V-belt drive for vehicles with air conditioner compressor and tensioning roller - exploded
view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.7 Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioning
roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.8 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.9 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.10 Sealing flange (pulley end) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.11 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.12 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2 Cylinder block (gearbox end) Protected . . . . .by. copyright.
. . . . . .Copying
. . . . for
. .private
. . . .or. commercial
. . . . . . purposes,
. . . . . .in. part
. . or
. .in.whole,
. . . .is.not
.. 65
2.1 Dual-mass flywheel and sealingwith flange
respect(gearbox end)
to the correctness - exploded
of information in thisview
document.. .Copyright
. . . . .by. .AUDI
. . .AG.
.... 65
2.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.3 Renewing sealing flange (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Contents i
Audi TT 2007 ➤
3.1 Crankshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.5 Extracting needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.6 Pulling spur gear off crankshaft and shrink-fitting new spur gear . . . . . . . . . . . . . . . . . . . . 78
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.1 Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2 Measuring piston projection at “TDC” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.4 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.1 Toothed belt - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.1 Cylinder head cover - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.3 Renewing injector seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.4 Cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.5 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.1 Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.2 Measuring axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.3 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.4 Renewing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.5 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.6 Checking hydraulic valve compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.7 Renewing valve stem oil seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . 135
3.8 Renewing valve stem oil seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . 139
3.9 Valve dimensions Protected
. . . . . by
. .copyright.
. . . . . Copying
. . . . .for. private
. . . . or. commercial
. . . . . . .purposes,
. . . . .in. part
. . .or.in. whole,
. . . .is.not
.......... 142
3.10 Machining valve seats . .unless
permitted . . . authorised
. . . . . . by. .AUDI
. . .AG.. .AUDI
. . . AG
. .does
. . .not
. .guarantee
. . . . . or. .accept
. . . any
. . liability
............ 142
3.11 Checking valve guides ....................................................
142
3.12 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1 Oil pump, sump, balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.1 Oil pump, sump, balance shaft assembly - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 147
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.5 Removing balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.6 Installing a new balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.7 Re-installing a used balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2 Oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.1 Oil filter bracket and engine oil cooler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.2 Removing and installing oil filter bracket with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . 160
2.3 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.4 Checking oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.5 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2.6 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.7 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
ii Contents
Audi TT 2007 ➤
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.1 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.2 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2 Coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.1 Coolant pump and thermostat - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.3 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.4 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3 Coolant pipes, coolant temperature senders, coolant circulation pump . . . . . . . . . . . . . . . . 184
3.1 Coolant pipes, coolant temperature senders, coolant circulation pump - exploded view . . 184
3.2 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 185
3.3 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 187
3.4 Removing and installing pump for exhaust gas recirculation cooler V400 . . . . . . . . . . . . 188
3.5 Removing and installing coolant pipe (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3.6 Removing and installing coolant pipe (top front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.7 Removing and installing coolant pipe (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.8 Removing and installing coolant pipe (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4 Radiator and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4.1 Radiator and radiator fans - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4.2 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4.3 Removing and installing radiator fans V7 and V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1.1 Diagram of vacuum connections . . . . . . . . . . . . . . . .............................
206
1.2 Turbocharger
with respect - exploded
to the correctness of view
information in this . . .Copyright
document. . . . . . by
. .AUDI
. . .AG.
....
............................. 207
1.3 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2 Charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.1 Charge air cooler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.2 Removing and installing charge pressure sender G31 / intake air temperature sender G42
........................................................................ 213
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

1 Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1.1 Silencers - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1.2 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
1.3 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.4 Aligning tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2 Exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.1 Exhaust gas temperature control - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.2 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 225
3 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3.1 Diagram of vacuum connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3.2 Exhaust gas recirculation with exhaust gas recirculation cooler - exploded view . . . . . . . . 229
3.3 Checking exhaust gas recirculation cooler change-over . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3.4 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Contents iii
Audi TT 2007 ➤
iv Contents
Audi TT 2007 ➤
1 Engine number
♦ The engine number (“Engine code” and “Serial number”)
-arrow- can be found at the front of the joint between engine
and gearbox.
♦ There is also a sticker on the toothed belt cover showing the
“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.
Note
♦ 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 810 .
1. Engine number 1
Audi TT 2007 ➤
2 Engine data
Code letters CFGB
Capacity ltr. 1.968
Power output kW at rpm 125/4200
Torque Nm at rpm 350/1750 … 2500
Bore ∅ in mm 81.0
Stroke mm 95.5
Compression ratio 16.5
CN not less than 51
Firing order 1-3-4-2
Exhaust gas recirculation yes
Exhaust gas temperature control yes

Turbocharging/supercharging Turbocharger
Glow plugs Steel glow plugs
Charge air cooling yes
Lambda control 1 Lambda probe
Particulate filter yes
Valves per cylinder 4
Note
Audi TT models with a TDI engine (2.0 ltr. 4-valve common rail)
are always equipped with steel glow plugs.

Audi TT 2007 ➤
3.1 Working on the fuel system

WARNING


glow plug system.
♦ Entries are stored in event memory of engine control unit if
electrical connectors were unplugged and engine was started:
Interrogate event memory in Vehicle self-diagnosis
⇒ vehicle diagnostic tester .
Caution

battery. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 .
Audi TT 2007 ➤
3.2 Working on the cooling system

When working on the cooling system note the following:
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 fans 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.

♦ Close filler cap on coolant expansion
permitted unless authorised tank
by AUDI(make
AG. AUDI sure
AG doesit not guarantee or accept any liability
engages). with respect to the correctness of information in this document. Copyright by AUDI AG.
3.3 Working on vehicles with start/stop sys‐

tem
When performing repairs on vehicles with start/stop system, note
the following:
WARNING

start/stop system.

Audi TT 2007 ➤

WARNING

erly secured.
secured.
tem -VAS 5052 A- or diagnosis system -VAS 5053- .
thighs (as shown inwith

illustration) and must be operated by Copyright by AUDI AG.
respect to the correctness of information in this document.
the passenger.
3.5 Working on the exhaust system

When working on the exhaust system note the following:
Caution
Avoid damage to flexible joint.

♦ Do not bend flexible joint more than 10°.
♦ Install flexible joint so that it is not under tension.
♦ Take care not to damage wire mesh on flexible joint.
Audi TT 2007 ➤

fuel supply system, injection system and
turbocharger
supply system, injection system and turbocharger:
opening.
♦ Seal off open pipes/lines and connections using engine bung
set -VAS 6122- .
cover them over. Do not use fluffy cloths.
that have not been stored in the proper packaging (e.g. in tool
boxes etc.).
♦ When the system is open: Do not work with compressed air.
4.2 Checking for leaks in the fuel system

Procedure
– Allow engine to run for several minutes at moderate rpm.
– Check complete fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.
– Road-test vehicle and accelerate with full throttle at least once.
– Then inspect high-pressure section of Protected
fuel system again
by copyright. for for private or commercial purposes, in part or in whole, is not
Copying
leaks. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
used.
Note the following:

Audi TT 2007 ➤

warranty.
4.4 Routing and attachment of pipes, hoses

and wiring
♦ Mark fuel lines, hydraulic lines, vacuum lines, lines for activa‐
ted charcoal filter system 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.
♦ 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).
4.5 Installing radiators, condensers and

charge air coolers
Even when the radiator, condenser and charge air cooler are cor‐
rectly 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, charge air cooler or condenser.

Procedure
– Check
permitted all vacuum
unless authorised by AUDIlines in the
AG. AUDI AG doescomplete vacuum
not guarantee or accept system
any liability for:
♦ Cracks
– If a fault is stored in the event memory, check the vacuum lines
leading to the relevant component and also check the remain‐
ing vacuum lines in the system.
– If it is not possible to build up a vacuum with the hand vacuum
pump -VAS 6213- or if the vacuum pressure drops again im‐
mediately, check the hand vacuum pump and connecting
hoses for leaks.

Audi TT 2007 ➤
10 – Removing and installing engine

1 Removing engine

equipment required
♦ Removal lever -80 - 200-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Stepladder -VAS 5085-
♦ Engine bung set -VAS
6122-
♦ Drip tray for workshop hoist
-VAS 6208-
♦ Hook -2024 A /1- of lifting tackle -2024 A-
8 Rep. Gr.10 - Removing and installing engine

Audi TT 2007 ➤
♦ Engine bracket -T10012-
♦ Locking pin -T10060 A- for vehicles with air conditioner com‐

pressor and tensioner
♦ Safety goggles
♦ Protective gloves
Procedure
♦ The engine is removed from underneath together with the
gearbox.
♦ Fit heat insulation sleeves in the original positions when in‐
stalling.
1. Removing engine 9
Audi TT 2007 ➤
Caution

– Disconnect earth cable -arrow- from battery terminal ⇒ Elec‐

trical system; Rep. Gr. 27 .
WARNING

hot.
– Open filler cap on coolant expansion tank.

Audi TT 2007 ➤
bottom -2-.

– Remove bolts -arrows- and detach air duct -1- from lock car‐
rier.
Audi TT 2007 ➤
– Remove bolts -top arrows- for radiator cowl.
Note
The bolts -bottom arrows- are removed at a later stage.
– Remove both front wheels.

– Remove bottom sections of wheel housing liners (left and

right) ⇒ Rep. Gr. 66 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– TT Roadster: Remove noise insulation frame -arrow- ⇒ Rep.

Gr. 50 .

Audi TT 2007 ➤
– Release hose clips -1- and -2- and remove air hose.
– Seal off open pipes/lines and connections with clean plugs
from engine bung set -VAS 6122- .

– Remove bolts -bottom arrows- and take out air cowl down‐
wards.
Note
Collect drained coolant in a clean container for re-use or disposal.
– Place drip tray for workshop hoist -VAS 6208- beneath engine.
– Lift retaining clip -arrow-, disconnect coolant hose (bottom
right) from radiator and drain off coolant.
Audi TT 2007 ➤
– Open hose clip -arrow-, disconnect coolant hose (bottom)

leading to pump for exhaust gas recirculation cooler -V400-
and drain off coolant.
– Release hose clip -arrow-, disconnect coolant hose at oil filter

housing and drain off remaining coolant.
– Remove bolts -bottom arrows- on rear side of radiator.
Note
The bolts -top arrows- are removed at a later stage.
– Remove bolts -arrows- and detach bracket -1- for air cleaner
housing.

Audi TT 2007 ➤
– Press release tabs and disconnect crankcase breather hose

-1- from cylinder head cover.
– Move clear vacuum hoses -arrows- at air pipe.
– Remove bolt -2-, swivel air pipe with connection to rear and
detach from turbocharger.
– Detach vacuum hose -2- from vacuum unitunless
permitted of turbocharger.
– Disconnect vacuum hose -3-.
Note
Disregard -item 1-.
– Detach vacuum hose -arrow- from brake servo.
Note
Place a cloth underneath heat exchanger to catch escaping cool‐

ant.
– Lift retaining clips -arrows- and detach coolant hoses from

heat exchanger.
Audi TT 2007 ➤
– Detach electrical connector -1- from bracket and unplug.

– Move clear electrical wiring.
Note
– Slacken bolt -2- and remove clamp.
Note
– Remove top bolt -1- at bracket for particulate filter.
– Unplug electrical connector -2- at pressure differential sender

-G505- .
Note
Disregard -arrows-.

Audi TT 2007 ➤
– Unplug electrical connector -2- on fuel temperature sender -

G81- .
WARNING
– Release hose clips -1- and -3- and disconnect fuel supply hose
and fuel return hose.
Note
Disregard -item 4-.
– Release hose clip -arrow- and detach coolant hose.

Disregard -item 1-.
– Disengage fuel hose -3- at bracket.

– Pull off bracket for fuel lines towards right -arrow- and move
clear to one side.
– Unplug electrical connector -1- at supplementary fuel pump -
V393- .
– Remove bolts -2- and -4-, detach bracket with supplementary
fuel pump -V393- and move clear to one side.
Audi TT 2007 ➤
– Release hose clip -1-, detach coolant hose from coolant ex‐
pansion tank and move coolant hose clear -arrow-.
– Lift retaining clip -arrow- and disconnect coolant hose (top left)
from radiator.
– Unplug electrical connector -A- at high-pressure sender -G65-

-item B-.
Note
Disregard -item C-.
– Detach sealing lip at lock carrier (top).

Audi TT 2007 ➤
– Remove bolts -top arrows- at rear and lift out radiator.

– Release electrical connector -1- for engine wiring harness
-arrow- and detach ⇒ Rep. Gr. 23 ; Removing and installing
engine control unit -J623- .
– Release wiring protector -1- for engine wiring harness

-arrow- and lift off.
– Move clear and unplug electrical connector -1-.

– Open wiring duct bracket -arrows-, use removal lever -80 -
200- to unclip wiring and press wiring to side.
– Unclip wiring duct.
– Unclip electrical connector -1- from bracket and unplug.

– Open wiring duct bracket located underneath.
– Protected
Unclipbywiring harness
copyright. Copying forfor engine
private control
or commercial unit infrom
purposes, part orwiring
in whole,duct.
is not
– Place engine
with respect to the wiring harness
correctness with
of information engine
in this control
document. unit
Copyright on top
by AUDI AG. of
engine.
– Secure engine control unit to prevent it falling.
Audi TT 2007 ➤
– Remove nut -arrow-, detach terminal 30 wire from electronics

box in engine compartment and move it clear.
Note
Disregard -arrows-.
– Unplug electrical connector -7- (push retainer to the rear and

press down release catch).
– Push back protective sleeve -6-.
– Remove nut -1- and detach B+ wire -item 2- from starter sol‐
enoid switch.
– Remove nut -5- and detach earth wire -4-.
Note
Disregard -item 3-.

Audi TT 2007 ➤
– Lift clip and detach retaining clip -3- for gear selector cable
from gearbox selector lever -1-.
– Detach gear selector cable -2- from pin -arrow-.
• To prevent damage to gate selector cable, cable end-piece

must be detached from gate selector cable before removing.
– Pull locking device forwards onto stop -arrow 1- and lock by
turning anti-clockwise -arrow 2-.
– Press selector relay lever towards front -arrow 3-.
– Remove nut -1- and bolts -2-, detach cable support bracket
and place to one side (selector cables remain fitted).
– Vehicles with plastic pipe between clutch master cylinder and

slave cylinder: clamp off supply hose at brake fluid reservoir
using hose clamp -3094- .
Audi TT 2007 ➤
– Vehicles with pipe/hose assembly between clutch master cyl‐

inder and slave cylinder: clamp off hose -A- at pipe/hose
assembly using hose clamp -3094- .
Note
Disregard -arrow-.
Note
Make sure brake fluid does not come into contact with starter or
gearbox when performing the following operations. If it does,
clean affected area thoroughly.
– Pull out clip -arrow- as far as stop.

– Pull plastic pipe or pipe/hose assembly -A- out of bleeder con‐
nection for clutch slave cylinder.
Note
Disregard -item B-.

Caution
Risk of contamination by escaping brake fluid.

♦ Do not operate clutch pedal after detaching pipe from
bleeder screw on clutch slave cylinder.
Vehicles with start/stop system:

– Unplug electrical connector -3- for gearbox neutral position
sender -G701- .
All vehicles (continued): permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Unplug electrical connector -2- at reversing light switch -F4- .
– Unscrew nut -1- and detach bracket for electrical connectors.

Audi TT 2007 ➤
– Unscrew bolts -arrows- at engine mounting approx. 2 turns.
– Loosen bolts -arrows- at gearbox mounting approx. 2 turns.
Vehicles with air conditioner compressor and tensioner:
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-tipped pen for re-installation.
– To slacken poly V-belt turn tensioner in clockwise direction

-arrow-.
– Lock tensioner with locking pin -T10060 A-
– Take off poly V-belt.
Vehicles with air conditioner compressor and tensioning roller:
Caution Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove bolt -arrow- and detach tensioner to slacken poly V-

belt.
Audi TT 2007 ➤
All vehicles with air conditioner compressor (continued):

– Unplug electrical connector -2- on air conditioner compressor
regulating valve -N280- .
Caution
Make sure that air conditioner compressor and refrigerant

pipes and hoses are not damaged.
♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Remove bolts -arrow-, detach air conditioner compressor -1-

with refrigerant lines connected and tie up to front.

– Unplug electrical connector -1- at oil level and oil temperature
sender -G266- .
– Unclip bracket -2- for wire to oil level and oil temperature
sender -G266- from subframe.
– Remove bolts -arrows- and detach heat shield for drive shaft
(right-side).
– Detach drive shaft (left-side) from flange shaft of gearbox and
tie up.
– Detach drive shaft (right-side) from flange shaft of bevel box.
– Remove bolts -1, 2, 3- and remove pendulum support.

Audi TT 2007 ➤
– Mark position of nuts -arrows- securing swivel joint.

– Remove nuts for swivel joint (right-side).
– If fitted, remove nut on bracket for front right vehicle level
sender -G289- .
– Detach swivel joint from wishbone.
– Swing suspension strut (right-side) outwards and support with

extension -2024 A /1- as shown in illustration.
Accident risk from loose components of support bracket.
♦ Secure retaining pin and swivel joint with locking pin

-arrow- and nut -1-.
Note
The illustration shows the installation position on front suspension

(left-side).
– Mark position of flexible coupling and flange for bevel box in

relation to each other.
– Unbolt flexible coupling for propshaft at bevel box -arrows-
(counterhold using a suitable lever at the triangular flange).
– Push engine/gearbox assembly forward slightly (towards front

end) and pull propshaft off bevel box.
Caution
Make sure not to damage the seal -arrow- in the propshaft

flange.
♦ Push the propshaft horizontally to the rear and towards the
right side of vehicle as far as possible.
Note
The propshaft must be renewed if oil seal is damaged.
Audi TT 2007 ➤
– Unfasten nuts -arrows- for clamp.
– Remove nuts -1- and -2- and detach bottom bracket for par‐
ticulate filter.
– Tie up particulate filter to rear.

– Move coolant hose -3- clear.
– Loosen hose clip -2-.
– Unplug electrical connector -1- at charge pressure sender -
G31- / intake air temperature
permitted unlesssender
authorised-G42-
by AUDIand detach
AG. AUDI AG doesairnot
pipe
(right-side). with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi TT 2007 ➤
– Remove bolt -arrow- and push pump for exhaust gas recircu‐
lation cooler -V400- to the side.
Note
– Release fasteners -arrows- and remove noise insulation -1-

for sump.
– Secure engine bracket -T10012- to cylinder block with bolt

-1- and nut -2- (tightening torque: approx. 20 Nm).
– Insert engine and gearbox jack -V.A.G 1383 A- in engine sup‐
port -T10012- and raise engine/gearbox assembly slightly.
Note
To unscrew bolts for assembly mounting use stepladder -

VAS 5085- .
– Remove bolts -arrows- securing engine mounting.
Audi TT 2007 ➤
– Remove bolts -arrows- securing gearbox mounting.
Caution
Danger of damage to hydraulic lines, vacuum lines or electrical

wiring and to engine compartment.
♦ Check that all hydraulic lines, vacuum lines and electrical
wiring between engine, gearbox, subframe and body have
been detached.
♦ Carefully guide out engine/gearbox assembly with sub‐
frame from engine compartment when lowering.
– First lower engine/gearbox assembly only slightly.

– Then swing gearbox end of engine/gearbox assembly for‐
wards and only then lower further.

Audi TT 2007 ➤
2 Separating engine from manual gear‐

box
♦ Hooks -10 - 222 A /2-
♦ Workshop hoist -VAS 6100-
♦ Lifting tackle -T40013-
Procedure
• Engine/gearbox assembly removed and attached to engine
bracket -T10012- .
– Unscrew bolts -arrows- and detach gearbox support.
2. Separating engine from manual gearbox 29

Audi TT 2007 ➤
– Unscrew bolts -1- and -2- and remove starter from gearbox.
– Remove bolts -arrows 2, 3- securing bracket for bevel box.
Note
Disregard -arrows 1-.
– Attach lifting tackle -T40013- to gearbox and close lock.

– Attach workshop hoist -VAS 6100- with hooks -10 - 222 A /2-
to the lifting tackle.
– Remove bolts -1, 3, 4, 5- securing gearbox to engine.
Note
Disregard -items 2, A-.

– Detachwithgearbox from
respect to the engine.

Audi TT 2007 ➤
3 Securing engine to engine and gearbox support

equipment required
♦ Engine and gearbox sup‐
port -VW 540-
♦ Lifting tackle -3033-
port -VAS 6095-
♦ Workshop hoist -
VAS 6100-
Procedure
• Gearbox detached from engine ⇒ page 29 .
– Attach lifting tackle -3033- to engine and workshop hoist -
VAS 6100- as shown in illustration.
– Lift engine off engine bracket -T10012- using workshop hoist
-VAS 6100- .
3. Securing engine to engine and gearbox support 31

Audi TT 2007 ➤
– Secure engine to engine and gearbox support -VAS 6095- us‐

ing engine and gearbox support -VW 540- .

Audi TT 2007 ➤
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 %.
Tightening torques ⇒ page 37

Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
Securing manual gearbox to engine
Item Bolt 1) Nm
1 2) M12x55 80
2 2) M12x165 80
3 M10x105
Protected by copyright. Copying40for private or commercial purposes, in part or in whole, is not
4 M10x50 40 of information in this document. Copyright by AUDI AG.
with respect to the correctness
5 3) M12x65 80
A Dowel sleeves for centralising
• 1) Renew bolts.
• 2) Bolt with M8 threaded pin
• 3) Screwed into gearbox from engine side
4. Installing engine 33
Audi TT 2007 ➤
Heat shield for drive shaft (right-side) - tightening torque

– Tighten bolts -arrows- to 35 Nm.
Procedure
• Engine/gearbox assembly attached to engine bracket -
T10012- .
Note
♦ Renew the bolts tightened with specified tightening angle.

♦ Renew self-locking nuts and bolts as well as seals, gaskets
and O-rings.
♦ To secure the air hoses at their connections, spray rust re‐
mover onto the worm thread of the used hose clips before
installing.
– If not already fitted, install dowel sleeves for centring engine

and gearbox in cylinder block.
– Ensure that intermediate plate is engaged on sealing flange
and pushed onto dowel sleeves -arrows-.
– Remove needle bearing in crankshaft if fitted ⇒ page 78 .
– Renew clutch release bearing if worn ⇒ Rep. Gr. 30 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Lubricate splines of gearbox input shaft lightly with grease for
clutch plate splines ⇒ Electronic parts catalogue .
– Make sure that clutch plate is properly centred.
– Secure gearbox to engine.
– Install gearbox support ⇒ Rep. Gr. 34 .
– Attach engine/gearbox assembly to engine bracket -T10012- .
– Install bracket for bevel box ⇒ Rep. Gr. 34 .
– Guide engine/gearbox assembly into body.
– Initially screw in bolts -arrows- for engine mounting by hand

until they make contact.

Audi TT 2007 ➤
– Initially screw in bolts -arrows- for gearbox mounting by hand

until they make contact.
Note
The bolts are tightened to final torque only after adjusting the as‐
sembly mountings ⇒ page 42 .
– Remove engine support -T10012- from engine.

– Install starter ⇒ Electrical system; Rep. Gr. 27 .
– Install pump for exhaust gas recirculation
permitted unlesscooler
authorised-V400-
by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 184 . with respect to the correctness of information in this document. Copyright by AUDI AG.
– Install air pipe ⇒ page 212 .

– Install air hoses with screw-type clips ⇒ page 213 .
– Install particulate filter ⇒ page 219 .
– Bolt flexible coupling on propshaft to bevel box flange ⇒ Rear
final drive 02D, 0AV, 0BR and 0BY; Rep. Gr. 39 .
– Install drive shafts, wishbones and coupling rod ⇒ Rep. Gr.
40 .
– Install pendulum support ⇒ Rep. Gr. 34 .
– Install heat shield for drive shaft (right-side) ⇒ page 34 .
– Install air conditioner compressor ⇒ Rep. Gr. 87 .
– Install poly V-belt
⇒ “1.4 Removing and installing poly V-belt - vehicles with air
conditioner compressor and tensioner”, page 49 ,
conditioner compressor and tensioning roller”, page 55 .
– Connect clutch slave cylinder ⇒ Rep. Gr. 30 .
– Install gear selector cable and gate selector cable ⇒ Rep. Gr.
34 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install engine control unit ⇒ Rep. Gr. 23 .
– Install radiator ⇒ page 204 .
– Adjust assembly mountings ⇒ page 42 .
– Install supplementary fuel pump -V393- ⇒ Rep. Gr. 20 .
– Connect coolant hoses with plug-in connector to heat ex‐
changer ⇒ page 202 .
– Connect vacuum hoses ⇒ page 206 .
– Install air pipe with connection ⇒ page 207 .
– Install bottom sections of wheel housing liners ⇒ Rep. Gr. 66 .
– Fit front wheels ⇒ Rep. Gr. 44 .
– Install radiator cowl ⇒ page 202 .
– Install air cleaner housing ⇒ Rep. Gr. 23 .
– Observe notes on procedure for connecting the battery ⇒ Rep.
Gr. 27 .
– Check oil level ⇒ Maintenance ; Booklet 810 .
Audi TT 2007 ➤
Caution
Risk of damage to control units because of excessive voltage.

♦ Never use battery charging equipment for boost starting.
– Fill up with coolant ⇒ page 173 .
Note
♦ Drained-off coolant may only be used again if the original cyl‐

inder head and cylinder block are re-installed.
♦ Contaminated or dirty coolant must not be used again.
– Install noise insulation frame ⇒ Rep. Gr. 50 .


Audi TT 2007 ➤
5 Assembly mountings
5.1 Assembly mountings - exploded view
1 - Bolt
❑ Gearbox support to
gearbox
❑ Tightening torque ⇒
Rep. Gr. 34
2 - Bolts
❑ Pendulum support
permitted to
gearboxwith respect to the correctness of information in this document. Copyright by AUDI AG.
Rep. Gr. 34
3 - Engine support
❑ Version fitted in vehicle
may differ from illustra‐
tion
4 - Bolt
❑ Engine support to en‐
gine
❑ Renew
❑ Tightening torque and
sequence ⇒ page 38
5 - Engine mounting
❑ With support arm
⇒ page 38
6 - Bolt
❑ Engine mounting to
body
❑ Renew
❑ 40 Nm +90° further
7 - Connecting bracket
8 - Bolt
❑ Connecting bracket to engine mounting
❑ Renew
9 - Bolt
❑ Connecting bracket to body
❑ Renew
10 - Bolt
❑ Engine mounting to body
❑ Renew
11 - Bolt
❑ Engine mounting to engine support
❑ Renew
5. Assembly mountings 37
Audi TT 2007 ➤
12 - Pendulum support
13 - Bolt
❑ Pendulum support to subframe
❑ Tightening torque ⇒ Rep. Gr. 34
14 - Bolt
❑ Gearbox mounting to gearbox support
15 - Bolt
❑ Gearbox mounting to body
16 - Gearbox mounting
17 - Bolt
❑ Gearbox support to gearbox
18 - Bolt
19 - Gearbox support
Engine support - tightening torque and sequence

Renew the bolts tightened with specified tightening angle.
– Tighten bolts in 3 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 180° further
5.2 Removing and installing engine mount‐

ings
♦ Support bracket -10 - 222 A-

Audi TT 2007 ➤
♦ Eye-head bolt -3368-
♦ Engine support bracket (supplementary set) -T40093-
♦ Protected
Nut from spindle
by copyright. -T40150/6-
♦ Flange nut M10 or nut M10 with washer

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

panels using the following tools:
♦ Rack -10 - 222 A /1- (2x)
♦ Spindle -10 - 222 A /11- (2x)
♦ Adapter -T40093/6- (2x)
♦ Nut from spindle -T40150/6-
– Replace wing nut from spindle -10 - 222 A /11- (rear right) with
nut -arrow- from spindle -T40150/6- .
– Attach hook of spindle to engine lifting eye (left-side).
WARNING
Risk of accident because of loose bolt connections.

♦ Screw on flange nut or nut with washer -arrow- at least 6
turns to ensure that eye-head bolt -3368- is properly se‐
cured.
– Secure eye-head bolt -3368- with flange nut M10 or nut with
washer to engine support as shown in illustration.
– Attach spindle -10 - 222 A /11- (right-side) to eye-head bolt
-3368- .
– Take up weight of engine evenly with both spindles (but do not
raise engine).
– Detach electrical connector -1- for coolant shortage indicator
switch -F66- and move coolant expansion tank to side.

clear to one side.
V393- .

Audi TT 2007 ➤
– Loosen bolt -1-.

– Remove nut -2- and bolt -3-.
– Detach hose retainer -arrow- from fuel filter and move fuel filter
-8- clear to one side with fuel hoses -4 ... 7- connected.
– Remove bolts -1- and -2- and remove connecting bracket.

– Remove bolts -3 ... 6- and detach engine mounting.
Installing
⇒ “5.1 Assembly mountings - exploded view”, page 37
– Check adjustment of assembly mountings (engine/gearbox
mountings) ⇒ page 41 .
5.3 Checking adjustment of assembly

mountings (engine/gearbox mountings)
Procedure

clear to one side.
V393- .
Audi TT 2007 ➤

The following specifications must be obtained:

• There must be a distance of -a- = 13.5 mm between engine
support -2- and longitudinal member (right-side).
• The side of the engine support casting -2- must be aligned
parallel to the support arm -1- (distance -x- = distance -x-).
Note
Distance -a- = 13.5 mm can also be checked with a metal rod of

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

mountings must be adjusted ⇒ page 42 .
Assembling
– Install fuel filter and supplementary fuel pump -V393- ⇒ Rep.
Gr. 20 .
5.4 Adjusting assembly mountings


Audi TT 2007 ➤
Procedure

clear to one side.
V393- .

– Remove air cleaner housing ⇒ Rep. Gr. 23 .

housing.
Audi TT 2007 ➤
– Position support bracket -10 - 222 A- with spindles -10 - 222

A /11- on bolted flanges of wing panels as shown in illustration.
– Attach hooks of spindles to engine lifting eyes.
– Take up weight of engine/gearbox assembly evenly with both
spindles (do not raise assembly).
– Remove bolts -arrows- for engine mounting one by one and

renew (if they were not renewed when installing engine).
– Initially fit bolts hand-tight.
– Remove bolts -arrows- for gearbox mounting one by one and

renew (if they were not renewed when installing engine).
– Using assembly lever, adjust engine/gearbox assembly be‐

tween engine mounting and support arm -1- until specifica‐
tions listed below are attained:
support -2- and longitudinal member (right-side). with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

– Tighten bolts for engine mounting

Audi TT 2007 ➤
– Ensure that the edges of the support arm (on the gearbox as‐
sembly mounting) -1- and gearbox mounting -2- are parallel.
• Dimension -x- = dimension -x-.
– Tighten bolts for gearbox mounting.
Gr. 20 .
Audi TT 2007 ➤
13 – Crankshaft group
1 Cylinder block (pulley end)
1.1 Poly V-belt drive without air conditioner compressor - exploded view
1 - Poly V-belt
❑ Renew.
⇒ page 47
2 - Vibration damper
❑ With poly V-belt pulley
❑ Installation position:
hole in vibration damper
must be positioned over
raised section of crank‐
shaft sprocket
⇒ page 56
3 - Bolt
❑ Renew
❑ Use only genuine bolts
⇒ Electronic parts cata‐
logue
4 - Dowel sleeve
❑ 2x
❑ Ensure correct seating
in bracket for ancillaries
5 - Bolt
Rep. Gr. 23
6 - Bolt
❑ Tightening torque
⇒ ItemProtected
20 (page 90)
7 - Idler roller with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ For toothed belt
8 - Bolt
9 - Idler roller
12 - Bolt
❑ Different lengths ⇒ page 49
❑ Tightening torque and sequence ⇒ page 49
46 Rep. Gr.13 - Crankshaft group

Audi TT 2007 ➤
13 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. Gr. 27
14 - Bolt
❑ Tightening torque ⇒ Electrical system; Rep. Gr. 27
1.2 Removing and installing poly V-belt - ve‐

hicles without air conditioner compres‐
sor
♦ Poly V-belt repair set with assembly tool ⇒ Electronic parts
catalogue
Procedure
Note
The poly V-belt repair set with assembly tool contains the assem‐
bly tool -T10367- and illustrated instructions.
– Remove bottom section of wheel housing liner (right-side) ⇒

Rep. Gr. 66 .
– Follow procedure specified in illustrated instructions (included
in poly V-belt repair set with assembly tool ).
– Install right wheel housing liner (bottom section) and noise in‐
sulation ⇒ Rep. Gr. 66 .
1. Cylinder block (pulley end) 47

Audi TT 2007 ➤
1.3 Poly V-belt drive for vehicles with air conditioner compressor and tensioner
- exploded view
1 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen
❑ Do not kink
❑ When installing, make
sure it is properly seated
on pulleys.
2 - Poly V-belt tensioner
⇒ page 52
shaft sprocket
⇒ page 56
4 - Bolt
❑ Renew
logue
5 - Bolt
Rep. Gr. 27
6 - Dowel sleeve
❑ Ensure correct seating in bracket for ancillaries
7 - Bolt
8 - Bolt
9 - Idler roller
10 - Bolt
11 - Idler roller

Audi TT 2007 ➤
14 - Bolt
❑ 23 Nm
15 - Bolt
16 - Alternator
17 - Bolt
18 - Air conditioner compressor
19 - Bolt
20 - Dowel sleeve
Bracket for ancillaries - tightening torque and tightening sequence
– Fit bolts in the following sequence:

♦ Bolts -1- and -2- M10x52.
♦ Bolts -3- and -6- M10x30.
♦ Bolts -4- and -5- M10x60.
1. -1 … 6- Screw in bolts by hand until they make
contact.
2. -1 … 6- 40 Nm
3. -3- and -6- turn 45° further
4. -1, 2, 4, 5- turn 90° further

hicles with air conditioner compressor
and tensioner

Audi TT 2007 ➤
♦ Locking pin -T10060 A-
Removing
– Remove bottom
Protectedsection of Copying
by copyright. wheelforhousing liner (right-side)
private or commercial ⇒ or in whole, is not
purposes, in part
Rep. Gr. 66permitted
. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi TT 2007 ➤
Caution


-arrow-.
Installing
Note
Before fitting poly V-belt, make sure all mechanical units (alter‐
nator and air conditioner
Protected by compressor) are
copyright. Copying for firmly
private in position.
– Fit poly V-belt on all poly V-belt pulleys:

1- Crankshaft
2- Tensioner
3- Alternator
4- Air conditioner compressor
– Hold tensioner with ring spanner and remove locking pin -

T10060 A- .
– Slacken tensioner.
– Check that poly V-belt is properly seated.
– Start engine and check that belt runs properly.

Audi TT 2007 ➤
1.5 Removing and installing tensioner for

poly V-belt
Removing
– Detach poly V-belt from tensioner
conditioner compressor and tensioner”, page 49 .

G31- / intake air temperature sender -G42- and detach air pipe
(right-side).
– Remove bolt -2- and take off tensioner -1- for poly-V-belt.
Installing
– Install poly V-belt ⇒ page 49 .

Audi TT 2007 ➤
1.6 Poly V-belt drive for vehicles with air conditioner compressor and tensioning
roller - exploded view
1 - Poly V-belt
❑ Check for wear
❑ Removing and
Protected installing
⇒ pagepermitted
55 unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Do not kink

on pulleys.
2 - Tensioning roller
❑ For poly V-belt
stalling poly V-belt - ve‐
hicles with air condition‐
er compressor and ten‐
sioning roller”,
page 55
❑ Coat contact surfaces
with lubricating paste;
for lubricating paste re‐
fer to ⇒ Electronic parts
catalogue
shaft sprocket
⇒ page 56
4 - Bolt
5 - Dowel sleeve
6 - Bolt
7 - Bolt
8 - Idler roller
9 - Bolt
10 - Idler roller

Audi TT 2007 ➤
❑ Version shown in illustration corresponds to version fitted in vehicle
13 - Bolt
14 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. Gr. 27
15 - Bolt
❑ Tightening torque ⇒ Electrical system; Rep. Gr. 27
17 - Bolt
18 - Dowel sleeve
19 - Bolt
Tensioning roller for poly V-belt - tightening torque and tightening

sequence
Note

♦ Use a brush to coat guide surfaces of tensioning roller with
lubricating paste; lubricating paste ⇒ Electronic parts cata‐
logue .
– Tighten bolt in 5 stages:permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Stage Bolt Tightening torque/tightening angle

1. -arrow- Screw in bolt by hand until it makes
contact.
• The poly V-belt is tensioned
2. -arrow- Turn until the pin on the tensioning

roller has contacted the stop
• The poly V-belt is tensioned further
3. -arrow- Loosen by 90°

4. -arrow- 30 Nm
5. -arrow- turn 90° further

Audi TT 2007 ➤

hicles with air conditioner compressor
and tensioning roller
Removing
Caution

– Remove tensioning bolt -arrow- and detach tensioning roller

to slacken poly V-belt.
Installing
Note
♦ Renew bolt for tensioning roller.

♦ Before fitting poly V-belt, make sure all mechanical units (al‐
ternator and air conditioner compressor) are firmly in position.

1- Vibration damper
2- Tensioning roller
3- Alternator
– Use a brush to coat guide surfaces of tensioning roller with
lubricating paste; lubricating paste ⇒ Electronic parts cata‐
logue .
– Protected
Insertbytensioning roller with pin into guide on bracket for ancil‐
laries.

Audi TT 2007 ➤
– Tightening bolt for tensioning roller ⇒ page 54 .
– Check that end of bolt for tensioning roller protrudes beyond

contact surface of tensioning roller as far as dimension -a-.
• Distance -a- = approx. 2.5 mm.
• This ensures that the pin is at its limit stop.
1.8 Removing and installing vibration damp‐

er
Removing
Vehicles without air conditioner compressor:
– Remove poly V-belt ⇒ page 47 .
Vehicles with air conditioner compressor:
– Vehicles with air conditioner compressor and tensioning roller:
Remove bottom
Protected section
by copyright. of wheel
Copying housing
for private liner
or commercial (right-side)
purposes, in part or in⇒
whole, is not
Rep. Gr. 66 .unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
– Remove poly V-belt
conditioner compressor and tensioning roller”, page 55 .

– Counterhold by applying ring spanner to bolt for crankshaft
sprocket and slacken bolts for vibration damper.
– Remove bolts and take off vibration damper.

Audi TT 2007 ➤
Installing
⇒ “1.3 Poly V-belt drive for vehicles with air conditioner com‐
pressor and tensioner - exploded view”, page 48 .
Note
Renew bolts for vibration damper.
• Installation position: hole -arrow- in vibration damper must be

positioned over raised section of crankshaft sprocket.
– Install poly V-belt
⇒ “1.2 Removing and installing poly V-belt - vehicles without
air conditioner compressor”, page 47 ,
conditioner compressor
Protected byand tensioning
copyright. Copying forroller”, page 55purposes,
private or commercial . in part or in whole, is not
– Install right wheel housing
with respect liner (bottomofsection)
to the correctness ⇒thisRep.
information in Gr. Copyright by AUDI AG.
document.
66 .
1.9 Removing and installing bracket for an‐

cillaries
Removing
– Remove engine mounting ⇒ page 38 .
– Remove alternator ⇒ Electrical system; Rep. Gr. 27 .
– Remove high-pressure pump ⇒ Rep. Gr. 23 .

Audi TT 2007 ➤
– Remove bolt -3- on engine support.

– Pull engine upwards with spindle and replace bolt.
Note
– Remove bolt -arrow-.
– Remove bolts -1- and -2- and remove idler rollers for toothed
belt.
– Remove bolts -1 ... 6- and detach bracket for ancillaries.

Installing
Note
– Check that dowel sleeve at top right between bracket for an‐
cillaries and cylinder block is fitted; insert dowel sleeve if
necessary.
– Tighten bolts for bracket for ancillaries ⇒ page 49 .
– Install engine support ⇒ page 37 .
– Install high-pressure pump ⇒ Rep. Gr. 23 .
– Install toothed belt (adjust valve timing) ⇒ page 95 .
– Install alternator ⇒ Electrical system; Rep. Gr. 27 .
– Install engine mountings ⇒ page 37 .

Audi TT 2007 ➤
1.10 Sealing flange (pulley end) - exploded view
1 - Bolt
⇒ Item 25 (page 90)
2 - Crankshaft sprocket
❑ Contact surface be‐
tween sprocket and
crankshaft must be free
of oil
❑ Can only be installed in
one position
3 - Oil seal for crankshaft (pul‐
ley end)
❑ Renewing ⇒ page 59 by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
❑ Do not lubricate with oil to the correctness of information in this document. Copyright by AUDI AG.
with respect
4 - Sealing flange (pulley end)

❑ Should be positioned on
dowel pins
⇒ page 61
5 - Cylinder block
6 - Dowel pin
❑ 2x
7 - Bolt
Sealing flange (pulley end) - tightening torque and sequence

Stage Bolts Tightening torque
contact.
2. -1 … 6- Tighten in stages and in diagonal se‐
quence; final torque 15 Nm.
3. -7 … 10- 15 Nm
1.11 Renewing crankshaft oil seal (pulley

end)

Audi TT 2007 ➤
♦ Oil seal extractor -3203-
♦ Counterhold tool -3415-
Procedure
– Remove toothed belt ⇒ page 91 .
– Loosen bolt for crankshaft sprocket using counterhold tool
-3415- .
– Remove bolt and detach crankshaft sprocket.

Audi TT 2007 ➤
– Adjust inner section of oil seal extractor -3203- so it is flush

with the outer section and lock in position with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and screw it into oil seal as far as possible (applying firm
pressure).
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Clamp flats of oil seal extractor in vice and use pliers to remove
oil seal.
– Clean contact surface and sealing surface for oil seal.
– Remove oil residue from crankshaft journal with a clean cloth.
Note
Do not lubricate sealing lip and outer rim of oil seal before press‐
ing in.
– Fit guide sleeve -T10053/1- onto crankshaft journal.

– Push oil seal over guide sleeve onto crankshaft journal.
– Press in oil seal using boltunless
permitted for crankshaft sprocket
authorised by AUDI AG. AUDIandAG doesthrust
not guarantee or accept any liability
sleeve of assembly tool -T10053-
with respect until flush.
– Install crankshaft sprocket ⇒ page 89 .

1.12 Removing and installing sealing flange

(pulley end)

Audi TT 2007 ➤
♦ Electric drill with plastic brush attachment

♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue
Removing
-3415- .
– Remove bolts -1 ... 10- and carefully release sealing flange

from bonded joint.
– Drive out oil seal with sealing flange removed.
Installing
Caution
Make sure sealant residue does not enter lubrication system.

♦ Place a clean cloth over the exposed section of the sump.
– Carefully remove sealant residue on cylinder block and sump.
WARNING
Protect eyes against injuries.
– Use e.g. rotating plastic brush to remove sealant residue on

sealing flange.
– Clean sealing surfaces; they must be free of oil and grease.

Audi TT 2007 ➤
Note
Note the use-by date of the sealant.
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 2

mm).
– Apply a thin bead of sealant at the edge of the joint between

the cylinder block and the sump -arrows-.
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

sealing flange as shown in illustration.
• Thickness of sealant bead: 2 ... 3 mm
– Apply a thin coat of sealant to bottom sealing surface

-shaded- on sealing flange.
Note
The sealing flange must be installed within 5 minutes after apply‐

ing the sealant.
– Carefully fit sealing flange onto dowel pins in cylinder block.

Audi TT 2007 ➤
– Tighten sealing flange bolts ⇒ page 59 .

– Install crankshaft oil seal (pulley end) ⇒ page 59 .

Audi TT 2007 ➤
2 Cylinder block (gearbox end)
Note
Servicing clutch ⇒ Rep. Gr. 30
2.1 Dual-mass flywheel and sealing flange (gearbox end) - exploded view
1 - Bolt
❑ Renew
❑ 60 Nm + 90°
2 - Dual-mass flywheel
⇒ page 66
one position
3 - Sender wheel
❑ For engine speed send‐
er -G28-
⇒ “2.3 Renewing seal‐
ing flange (gearbox
end)”, page 67
ing flange (gearbox
end)”, page 67
5 - Bolt
❑ 4.5 Nm
6 - Dowel pin
❑ 2x
7 - Intermediate plate
❑ Should be positioned
with on
dowel pins
❑ Do not damage or bend
when assembling
❑ Engaging on sealing
flange ⇒ page 66
8 - Sealing flange (gearbox
end)
❑ With oil seal
❑ Renewing ⇒ page 67
9 - Bolt
2. Cylinder block (gearbox end) 65

Audi TT 2007 ➤
Installing intermediate plate

– Engage intermediate plate on sealing flange -top arrow- and
push onto dowel sleeves -bottom arrows-.
Sealing flange (gearbox end) - tightening torque and sequence

Stag Bolts Tightening torque
e
contact.
Note
2.2 Removing and installing dual-mass fly‐

wheel

Audi TT 2007 ➤
Removing
• Gearbox removed.
Caution
Make sure dual-mass flywheel is not damaged.

♦ 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 dual-mass flywheel.
♦ Rotate the dual-mass flywheel -A- so that the bolts -B-
align centrally with the holes -arrows-.
– Insert counterhold tool -3067- in hole on cylinder block

-item B-, slacken bolts for dual-mass flywheel.
– Remove bolts and take off dual-mass flywheel.
Installing
⇒ “2.1 Dual-mass flywheel and sealing flange (gearbox end) -
exploded view”, page 65 .
Note
– Insert counterhold -3067- in hole on cylinder block -item A-.

2.3 Renewing sealing flange (gearbox end)


Audi TT 2007 ➤
♦ Depth gauge -VAS 6082-
♦ Bolt M6x35 (3x)

♦ Bolt M7x35 (2x)
Pressing out sealing flange with sender wheel
– Remove dual-mass flywheel ⇒ page 66 .
Note
For illustration purposes, the following procedure is shown with

the engine removed.
– Detach intermediate plate at sealing flange and dowel sleeves

-arrows-.
– Rotate crankshaft by turning bolt for toothed belt sprocket until

crankshaft is positioned at “TDC”, as shown in illustration.
– Remove sump ⇒ page 147 .

Audi TT 2007 ➤
– Remove engine speed sender -G28- -item 1- ⇒ Rep. Gr. 28 .
– Remove bolts -1 ... 6- for sealing flange.
Note
Note
The sealing flange is pressed off the crankshaft together with the
sender wheel.
– To press off, screw 3 bolts M6x35 -arrows- alternately into

sealing flange not more than 1/2 turn at a time.
– Take off sealing flange with sender wheel.
Pressing in sealing flange with sender wheel
Note
♦ The sealing flange with PTFE oil seal is fitted with a sealing lip
support ring. This support ring acts as an assembly sleeve and
must not be removed before installation.
♦ Sealing flange and sender wheel 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 must always
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.

Audi TT 2007 ➤
Construction of assembly tool -T10134-

A - Tightening flats
B - Hexagon nut
C - Assembly housing
D - Locating pin
E - Hexagon socket-head bolt
F - Guide pin for diesel engines (black handle)
G - Guide pin for petrol engines (red handle)
A - Fitting sealing flange with sender wheel onto assembly tool -

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

-A- of threaded spindle.
– Press assembly housing -C- downwards so that it lies on hex‐
agon nut -B- -arrow-.
• Inner part of assembly device and assembly housing must
align (be level) with each other.
– Remove the securing clip -arrow- from new sealing flange.
Note
The sender wheel must not be taken out of the sealing flange or
rotated out of position.

Audi TT 2007 ➤
• The locating hole -A- on the sender wheel -C- must align with
the marking -B- on the sealing flange.
– Place the sealing flange (with the front side downwards) on a
clean flat surface.
– Press the sealing lip support ring -A- downwards in direction

of -arrows- until it lies against the flat surface.
• The upper edge of the sender wheel and the front edge of the
sealing flange must align -arrows-.
– Place front side of sealing flange on assembly tool -T10134- ,

so that locating pin -B- can be inserted in hole -A- in sender
wheel.
• Ensure the sealing flange lies flat on the assembly tool.

Audi TT 2007 ➤
– Press the sealing flange and sealing lip support ring -B- onto
the surface of the assembly tool -T10134- while tightening the
3 knurled screws -A- so that the locating pin will not slip out of
the hole in the sender wheel.
• Ensure that the sender wheel remains fixed on the assembly
tool when installing the sealing flange.
B - Installing assembly tool -T10134- with sealing flange on crank‐

shaft flange:
• Crankshaft flange must be free of oil or grease.
• Engine is at “TDC” position.
– Screw hexagon nut -B- to end of threaded spindle.
– Press the threaded spindle of assembly tool -T10134- in di‐
rection of -arrow- until the hexagon nut -B- lies on the assem‐
bly housing -A-.
– Position flat edge of assembly housing towards sealing sur‐

face for sump on cylinder block.
– Secure assembly tool -T10134- to crankshaft flange by screw‐
ing hexagon socket head bolts -A- approx. 5 threads into
crankshaft flange.
– Screw two bolts M7×35 mm -item A- into cylinder block to

guide sealing flange.

Audi TT 2007 ➤
C - Securing assembly tool -T10134- onto crankshaft flange:

– Press the assembly housing -C- by hand in the direction of the
-arrow- until the sealing lip support ring -B- lies on the surface
of the crankshaft flange -A-.
Caution
Do not interchange components.

♦ The guide pin for PETROL engines (red handle) -F- MUST
NOT be inserted into the threaded hole in the crankshaft.
– Push guide pin for diesel engine (black handle) -D- into hole
in crankshaft. This brings the sender wheel into its final instal‐
lation position.
– Tighten the two hexagon socket head bolts on assembly tool
hand-tight.
– Screw hexagon
Protected nut -E- onto
by copyright. threaded
Copying spindle
for private or commercialbypurposes,
hand until it in whole, is not
in part or
lies against the assembly housing -C-.
D - Pressing sender wheel onto crankshaft flange with assembly

tool -T10134- :
– Tighten hexagon nut on assembly tool -T10134- to 35 Nm.
• A small air gap must be present between cylinder block and
sealing flange after tightening hexagon nut to 35 Nm.
E - Checking installation position of sender wheel on crankshaft:

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

Audi TT 2007 ➤
– Measure distance between crankshaft flange -A- and sender

wheel -B-.
• Specification: Distance -a- = 0.5 mm.
– Press sender wheel in further if distance -a- is too small
⇒ page 74 .
– If reading matches specification, continue with assembly
⇒ page 75 .
F - Pressing sender wheel in further:

– Secure assembly tool -T10134- to crankshaft flange by tight‐
ening hexagon socket head bolts -A- hand-tight.
– Press assembly tool onto sealing flange by hand.
– Screw hexagon nut -E- onto threaded spindle by hand until it


– Check installation position of sender wheel on crankshaft
again ⇒ page 73 .
– If distance “a” is still to small, tighten hexagon nut on assembly
tool -T10134- to 45 Nm.
again ⇒ page 73 .

Audi TT 2007 ➤
Assembling:
– Install engine speed sender -G28- ⇒ Rep. Gr. 28 .
– Install sump ⇒ page 147 .
– Install intermediate plate ⇒ page 66 .
– Install dual-mass flywheel ⇒ page 66 .

Audi TT 2007 ➤
3 Crankshaft
Note
When carrying out repairs, secure engine with engine and gear‐
box support -VW 540- to engine and gearbox support
⇒ page 31 .
3.1 Crankshaft - exploded view
1 - Bearing shell
❑ For cylinder block (with
oil groove)
❑ Renew used bearing
shells
2 - Spur gear
3 - Bearing shell
❑ For bearing cap (without
oil groove)
shells
4 - Thrust washers
❑ For bearing No. 3
❑ Different types for cylin‐
der block and bearing
cap
❑ Note location
5 - Bolts
❑ Renew
6 - Bearing cap
❑ Bearing cap 1: Pulley
end Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Bearing cap 3 with re‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
cesses for thrust wash‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
ers
❑ Installation position: re‐
taining lugs on bearing
shells in cylinder block
and bearing caps must
be on the same side
7 - Crankshaft
❑ No needle bearing must be fitted in the crankshaft; remove needle bearing if necessary ⇒ page 78
❑ Measuring axial clearance ⇒ page 77
❑ Measuring radial clearance ⇒ page 77
❑ Crankshaft dimensions ⇒ page 77
❑ With spur gear for balance shaft assembly

Audi TT 2007 ➤
3.2 Crankshaft dimensions

Main bearing journal ∅ Conrod journal ∅
mm mm
Basic dimen‐ 54.00 –0.022 50.90 –0.022
sion –0.042 –0.042
3.3 Measuring axial clearance of crankshaft

♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge -VAS 6079-
Procedure
– Bolt dial gauge -VAS 6079- with universal dial gauge bracket
-VW 387- onto cylinder block (as shown in illustration) and set
it against crank web.
– Press crankshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Push crankshaft away from dial gauge and read off value.
Axial clearance:
• New: 0.07 ... 0.17 mm
• Wear limit: 0.37 mm
3.4 Measuring radial clearance of crank‐

shaft
♦ Plastigage
Procedure
– Remove bearing cap and clean bearing journal.
3. Crankshaft 77
Audi TT 2007 ➤
– Place a length of Plastigage corresponding to the width of the

bearing on the bearing journal or in the bearing shell.
• The Plastigage must be positioned in the centre of the bearing
shell.
– Fit bearing cap and tighten to 30 Nm. Do not rotate crankshaft.
– Remove bearing cap again.
– Compare width of Plastigage with measurement scale.
Radial clearance:
• New: 0.03 ... 0.08 mm
3.5 Extracting needle bearing for crankshaft
Note
There should be no needle bearing fitted in the crankshaft on ve‐

hicles with manual gearbox ⇒ Electronic parts catalogue .

♦ -1- Internal puller Kukko 21/1
♦ -4- Counter-support Kukko 22/1

Pulling out
– Remove needle bearing using internal puller Kukko 21/1 and
counter-support Kukko 22/1.
3.6 Pulling spur gear off crankshaft and

shrink-fitting new spur gear

Audi TT 2007 ➤
♦ Fitting tool -10 - 203-
♦ Puller -T10392-
♦ Temperature gauge -VAS 6519-

♦ Hotplate (commercially available)
– Remove sealing flange (pulley end) ⇒ page 61 .

Note
If the balance shaft assembly does not have to be renewed, it is

sufficient just to remove the idler gear.
– Remove balance shaft assembly ⇒ page 153 .
3. Crankshaft 79
Audi TT 2007 ➤
Pulling off spur gear

– Insert thrust piece -T10392/1- in end of crankshaft.
– Insert puller -T10392- in holes in spur gear, turn clockwise

-arrow- and screw in locating pins -A-.
– Counterhold crankshaft with ring spanner -A- and pull spur

gear off end of crankshaft by screwing in spindle with ring
spanner -B-.
Shrink-fitting spur gear
Note
♦ While heating up the new spur gear, monitor the temperature

with the temperature gauge -VAS 6519- .
♦ When the temperature reaches 200 °C, you have approx. 4
seconds to fit the spur gear on the crankshaft.
♦ A higher temperature increases the amount of time available
(220 °C = approx. 6 seconds).
♦ Make sure the end of the crankshaft is clean.
Caution
Do not exceed Protected

a maximum temperature of 240 °C; otherwise
the spur gear can become discolouredby AUDIand distorted.
permitted unless authorised AG. AUDI AG does not guarantee or accept any liability

Audi TT 2007 ➤
– Place the new spur gear flat on a hotplate (commercially avail‐

able) and heat it to at least 200 °C, but not more than 240 °C.
The lettering must face upwards.
– Set temperature gauge -VAS 6519- to measuring range 2.
– Position temperature sensor -VAS 6519/1- on collar of spur
gear (as shown) and read off temperature at temperature
gauge.
WARNING
Risk of burns. Use suitable protective gloves for the following

steps.
– When the required temperature has been reached, pick up the

spur gear with pliers as illustrated.
Note
Take care not to damage the teeth of the spur gear.
– With the aid of fitting tool -10 - 203- , slide spur gear by hand
onto end of crankshaft as far as stop.Protected
This must be done with‐
out delay, taking care to keep the gear straight.
– Wait a few minutes to allow the spur gear to cool down, and
then install the balance shaft assembly.
⇒ “1.6 Installing a new balance shaft assembly”, page 154
⇒ “1.7 Re-installing a used balance shaft assembly”, page 157
3. Crankshaft 81
Audi TT 2007 ➤
4 Pistons and conrods
Note
Oil spray jet and pressure relief valve ⇒ page 85
4.1 Pistons and conrods - exploded view
1 - Bolt
❑ Renew
❑ Lubricate threads and
contact surface
2 - Conrod bearing cap
❑ Due to the cracking
method used to sepa‐
rate the bearing cap
from the conrod in man‐
ufacture, the caps only
fit in one position and
only
Protected on theCopying
by copyright. appropriate
conrod
❑ Mark cylinder allocation
in colour -B-
Markings -A- face to‐
wards pulley end
3 - Bearing shell
⇒ page 84
shells
❑ Note version: Upper
bearing shell (closest to
piston) is constructed
from a more wear-re‐
sistant material. Distin‐
guishing feature on new
bearing shells: black
marking on bearing sur‐
face near joint
❑ Check that it is securely
seated
4 - Conrod
❑ Only renew as a complete set
❑ With industrially cracked conrod bearing cap
❑ Separating parts of new conrod ⇒ page 85
❑ Mark cylinder allocation in colour -B-
❑ Installation position: Markings -A- face towards pulley end
❑ Axial clearance: wear limit: 0.37 mm
5 - Circlip
❑ Renew

Audi TT 2007 ➤
6 - Piston pin
❑ If difficult to move, heat piston to approx. 60 °C
❑ Remove and install using drift -VW 222 A-
7 - Piston
❑ With combustion chamber
❑ Mark installation position and cylinder number ⇒ page 84
❑ Install using piston ring clamp
❑ Piston and cylinder dimensions ⇒ page 87
❑ Measuring cylinder bore ⇒ page 84
❑ Measuring piston projection at “TDC” ⇒ page 85
8 - Piston rings
❑ Compression rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to remove and install
❑ Installation position: marking “TOP” or side with lettering faces towards piston crown
❑ Measuring ring gap ⇒ page 83
❑ Measuring ring-to-groove clearance ⇒ page 83
9 - Piston ring
❑ Oil scraper ring
❑ Offset gap 120° from bottom compression ring
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 0.25 … 0.40 1.00
2nd compression ring 0.25 … 0.40 1.00
Oil scraper ring 0.25 … 0.50 1.00
Measuring ring-to-groove clearance

– Clean groove in piston before checking clearance.
mm mm
4. Pistons and conrods 83

Audi TT 2007 ➤
Checking piston
– Using a micrometer (75 ... 100 mm), measure approx. 15 mm
from the lower edge, perpendicular to the piston pin axis.
• Maximum deviation from nominal dimension: 0.04 mm.
Nominal dimension
⇒ “4.3 Piston and cylinder dimensions”, page 87 .
Note
Renew piston if cracking is visible on piston skirt.
Installation position of pistons and allocation of piston/cylinder

• Arrow on piston crown points to pulley end -arrows-.
Measuring cylinder bore

– Use a cylinder gauge -VAS 6078- to take measurements at 3
points in transverse direction -A- and in longitudinal direction
-B-.
Nominal dimension
Installation position of bearing shells in conrods

– Insert bearing shells centrally in conrod and conrod bearing
cap.
• Distance -a- = 2.5 mm.

Audi TT 2007 ➤
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-.
Oil spray jet and pressure relief valve

1- Bolt with pressure relief valve, 27 Nm
2- Oil spray jet (for cooling of pistons)
• Installation position: align locating edge of oil spray jet with
machined surface of cylinder block.
Note
♦ Take care not to bend oil spray jets.

♦ Always renew bent oil spray jets.
4.2 Measuring piston projection at “TDC”
Note
Piston projection at “TDC” must be measured when installing new

pistons or a short engine.

Audi TT 2007 ➤

equipment required
♦ Measuring bridge -
VW 382/7- from measuring
tool -VW 382-
♦ Measuring plate -
VW 385/17- from universal
measuring tool -VW 385-

Audi TT 2007 ➤
Procedure
– Secure dial gauge -VAS 6079- with measuring bridge -
VW 382/7- and measuring plate -VW 385/17- to cylinder block
as shown in illustration.
– Measure projection at each piston at both locations marked
with -arrows- (seen in longitudinal direction of engine: at front
and rear of piston).
Note
If the measured values for piston projection are not the same for
all pistons, use the highest value to determine the correct gasket
size.
– Depending on piston projection, install corresponding cylinder

head gasket according to following table:
Piston projection above top sur‐ Identification
face of cylinder block (No. of holes)
mm
0.91 … 1.00 1
1.01 … 1.10 2
1.11 … 1.20 3
Identification of cylinder head gasket

1- Part number
2- Holes
3- Ignore
all pistons, use the highest value to determine the correct cylinder
head gasket size.
4.3 Piston and cylinder dimensions

Piston ∅ Cylinder bore ∅
mm mm
Basic dimension 80.96 1) 81.01
• 1)Dimensions including coating (thickness 0.02 mm). The
coating will wear down in service.
4.4 Measuring radial clearance of conrods

♦ Plastigage

Audi TT 2007 ➤
Procedure
– Remove conrod bearing cap. Clean bearing cap and bearing
journal.
– Fit conrod bearing caps and tighten to 30 Nm without rotating
crankshaft.
– Remove conrod bearing cap again.
Radial clearance:
• Wear limit: 0.08 mm.
– Renew conrod bolts.

Audi TT 2007 ➤
15 – Cylinder head, valve gear

1 Toothed belt drive
1.1 Toothed belt - exploded view
1 - Toothed belt
❑ Check for wear
❑ Removing ⇒ page 91
❑ Installing (adjusting
valve timing)
⇒ page 95
2 - Idler roller
3 - Nut
❑ 20 Nm
4 -respect
Tensioning rollerof information in this document. Copyright by AUDI AG.
with to the correctness
5 - Nut
6 - Bolt
❑ 20 Nm
7 - Idler roller
8 - Bolt
❑ 25 Nm
9 - Camshaft sprocket
10 - Bolt
❑ Slacken and tighten with
counterhold tool -
T10051-
❑ 100 Nm
11 - Camshaft hub
stalling camshafts”,
page 129
12 - Plug
13 - Toothed belt cover (rear)
14 - Bolt
❑ 9 Nm
15 - High-pressure pump hub
16 - Nut
1. Toothed belt drive 89

Audi TT 2007 ➤

18 - Bolt
19 - Idler roller
20 - Bolt
❑ Renew
21 - O-ring
❑ Renew
22 - Coolant pump
23 - Bolt
❑ Contact surface between sprocket and crankshaft must be free of oil
❑ Can only be installed in one position
25 - Bolt
❑ Renew
❑ Slacken and tighten with counterhold tool -3415-
❑ Do not additionally oil threads and shoulder
Toothed belt cover (bottom) - tightening torque

90 Rep. Gr.15 - Cylinder head, valve gear

Audi TT 2007 ➤
1.2 Removing and installing toothed belt

equipment required
♦ 2x Diesel injection pump
locking pin -3359-
♦ Crankshaft stop -T10050-
♦ Special wrench, long reach
-T10264-
♦ Locking tool -T10265-
♦ Bit XZN 10 -T10385-
Removing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi TT 2007 ➤
– Remove front right wheel.


Gr. 50 .
-G505- .
Note
Ignore items marked -1- and -arrows-.

clear to one side.
V393- .

Audi TT 2007 ➤

– Unplug electrical connector -3- at radiator outlet coolant tem‐

perature sender -G83- .
– Move coolant pipe (right-side) -arrows- to side (coolant hoses
remain connected).
– Release retaining clips -arrows- and detach toothed belt cover

(top).
– Remove vibration damper ⇒ page 56 .

– Detach toothed belt cover (bottom).

Audi TT 2007 ➤
Caution
Irreparable damage can be caused if the toothed belt slips.

♦ Turn crankshaft only in direction of engine rotation.
– Rotate crankshaft by turning bolt on crankshaft sprocket until

camshaft sprocket is positioned at “TDC”.
– Lock camshaft hub with diesel injection pump locking pin
-3359- . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
Disregard -arrows-.
– Lock crankshaft sprocket in position with crankshaft stop -

T10050- .
• The markings on the sprocket -2- and the crankshaft stop -1-
must align -arrow-. The pin of the crankshaft stop must engage
in the aperture in the sealing flange.
Note
The crankshaft stop can only be pushed onto the sprocket from
the front face of the teeth.
– Slacken bolts -arrows- for camshaft sprocket approx. 90°.
– Remove bolt -1- for coolant pipe.

– Using bit XZN 10 -T10385- , loosen bolts -2- for high-pressure
pump sprocket approx. 90°.

Audi TT 2007 ➤
– Loosen nut -1- for tensioning roller.

– Turn eccentric adjuster of tensioning roller with special
wrench, long reach -T10264- anti-clockwise -arrow- until ten‐
sioning roller can be secured with locking tool -T10265- .
– Then use special wrench, long reach -T10264- to turn eccen‐

tric adjuster of tensioning roller clockwise -arrow- as far as stop
and tighten nut -1- by hand.
Caution

♦ Before removing, mark direction of rotation of toothed belt
– Take off toothed belt first from idler roller and then from re‐
maining sprockets.
Installing (adjusting valve timing)
⇒ “1.1 Toothed belt - exploded view”, page 89
Note
Perform adjustments on toothed belt only when engine is cold.
Caution
Avoid damage to valves and piston crowns.
♦ The crankshaft must not be at “TDC” at any cylinder when

the camshaft is turned.
Requirements:
• Tensioning roller is locked with locking tool -T10265- and se‐
cured at right stop with nut.

Audi TT 2007 ➤
• Camshaft hub locked with diesel injection pump locking pin

-3359- .
• Bolts -arrows- are fitted but not tightened.
• It should just be possible to turn the sprocket on the camshaft
without axial movement.
• Crankshaft is locked in position with crankshaft stop -T10050- .
• Hub of high-pressure pump locked with diesel injection pump
locking pin -3359- .
• Bolts -1- are fitted but not tightened.
• The high-pressure pump sprocket should still just turn, but
there must be no axial movement.
Note
If necessary, apply a screwdriver -arrows- to bolt heads -1- and

turn the high-pressure pump hub until it can be locked with the
locking pin.

Audi TT 2007 ➤
– Turn the camshaft sprocket and high-pressure pump sprocket

in their elongated holes clockwise as far as the stop.
– Install toothed belt in the specified sequence:
1- Crankshaft sprocket
3- Camshaft sprocket
4- Coolant pump sprocket
5- High-pressure pump sprocket
6- Idler roller
– Loosen nut -1- for tensioning roller and detach locking tool -
T10265- .
Note
Disregard -arrow-.
Note
Ensure that tensioning roller is seated properly in toothed belt

cover (rear) -arrow-.
– Position counterhold tool -T10172- on camshaft sprocket as

shown in illustration.
– Apply force to counterhold tool in anti-clockwise direction
-arrow- and maintain tension. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Tighten bolts -1- for camshaft sprocket and
with respect bolts
to the -2- for
correctness high- in this document. Copyright by AUDI AG.
of information
pressure pump sprocket in this position.
• Tightening torque: 20 Nm.

Audi TT 2007 ➤
– Carefully turn eccentric adjuster of tensioning roller clockwise

-arrow- using special wrench, long reach -T10264- until point‐
er -2- aligns with the centre of the slot on the base plate.
• Nut -1- must not turn.
– Hold tensioning roller in this position and tighten nut.
– Remove locking pins -3359- and crankshaft stop -T10050- .
Checking valve timing:
Caution

– Turn crankshaft two rotations in direction of engine rotation by

turning bolt for crankshaft sprocket until crankshaft is just be‐
fore “TDC”.
– Fit crankshaft stop -T10050- to crankshaft sprocket again.

– Then turn the crankshaft in direction of engine rotation until the
pin -arrow- on the crankshaft stop engages in the sealing
flange as the crankshaft rotates.
• It should now be possible to lock camshaft hub with diesel in‐

jection pump locking pin -3359- .
Note
Disregard -arrows-.
• It is very difficult to reproduce the locking position of the high-

pressure pump hub. However, a slight deviation -arrow- does
not influence engine operation.

Audi TT 2007 ➤
• Pointer -2- on tensioner roller must be centred between tabs

-1- and -3- on base plate.
Note
The maximum permissible sideways deviation from the specified

position is 5 mm.
♦ Re-adjust valve timing if requirements are not met

⇒ page 99 .
♦ If requirements are met, continue with procedure after adjust‐
ing valve timing correctly as described below ⇒ page 99 .
Re-adjusting valve timing:
– If camshaft hub cannot be locked, withdraw crankshaft stop -
T10050- until pin is clear of bore.
– Turn crankshaft in opposite direction of engine rotation slightly
past “TDC”.
– Now turn crankshaft slowly in direction of engine rotation until
it is possible to lock camshaft hub.
– Loosen bolts for camshaft sprocket after locking hub.
A - If pin of crankshaft stop -T10050- is on left side of bore:

– Tighten camshaft sprocket bolts to 20 Nm.
B - If pin of crankshaft stop -T10050- is on right side of bore:
– Turn crankshaft slightly in opposite direction to engine rota‐
tion.
– Turn crankshaft in direction of engine rotation
Protected again
by copyright. untilforpin
Copying private or commercial purposes, in part or in whole, is not
of crankshaft stop engages in sealing flange
permitted asauthorised
unless crankshaftby AUDIro‐
tates. with respect to the correctness of information in this document. Copyright by AUDI AG.

Procedure after adjusting valve timing correctly:
– Remove diesel injection pump locking pin -3359- and crank‐
shaft stop -T10050- .
fore “TDC”.
– Check valve timing once again ⇒ page 98 .

Audi TT 2007 ➤
– If camshaft hub can now be locked, tighten camshaft sprocket

bolts -1- to final torque ⇒ Item 8 (page 89) .
– Tighten bolts -2- for high-pressure pump sprocket to final tor‐
que ⇒ Rep. Gr. 23 .
Assembling
Note
♦ Renew seals and/or gaskets.

– Install vibration damper ⇒ page 56unless
permitted . authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Install coolant pipe (right-side) ⇒ page 198 .
Gr. 20 .
– Fit front wheel (right-side) ⇒ Rep. Gr. 44 .

Audi TT 2007 ➤
2 Cylinder head
Note
2.1 Cylinder head cover - exploded view
1 - Gasket
❑ Renew if damaged or
leaking
2 - Cylinder head cover
⇒ page 102
3 - O-ring
❑ Renew
4 - Hose
❑ For crankcase breather
❑ Press release tabs to
detach
5 - Sealing bush
❑ For fuel rail
leaking
6 - Bracket
❑ For electrical wiring
7 - Grommet
8 - Clamping piece
Rep. Gr. 23
10 - Fuel rail
❑ Observe rules for clean‐
liness ⇒ page 6
❑ Do not attempt to bend
high-pressure pipes to a
different shape
❑ Installing high-pressure
pipes ⇒ Rep. Gr. 23
11 - Bolt
12 - Bolt
14 - O-ring
❑ Renew
15 - Injector
❑ Observe rules for cleanliness ⇒ page 6
2. Cylinder head 101

Audi TT 2007 ➤

16 - O-ring
❑ Renew
17 - Insulating seal
❑ Renew
18 - Seal
❑ For injector
19 - Filler cap
20 - Seal
❑ For filler cap
21 - Grommet
22 - Bracket
23 - Bolt
❑ Renew if seal is damaged
Cylinder head cover - tightening torque and sequence

– Tighten bolts for cylinder head cover in the sequence -1 ... 6-
to 9 Nm.
2.2 Removing and installing cylinder head

cover
Removing
Note
Secure the heat insulation sleeve in the original position when

installing.

Audi TT 2007 ➤

-G505- .
Note
– Unfasten clips -arrows- and press toothed belt cover (top) to

right side.
– Remove injectors and fuel rail ⇒ Rep. Gr. 23 .

-1- Protected
from cylinder head
by copyright. cover.
Note

– Unplug electrical connector -arrow- at position sender for
charge pressure positioner -G581- .
– Detach vacuum lines from bracket at cylinder head cover.

Audi TT 2007 ➤
– Slacken cylinder head cover bolts in the sequence -6 ... 1- and

remove.
– Detach cylinder head cover.
Installing
Note
♦ Renew gasket for cylinder head cover and bolts for cylinder
head cover if damaged or leaking.
♦ Fit new O-ring.
♦ Renew grommets and seals for injectors if damaged or leak‐
ing.
– Tighten cylinder head cover bolts ⇒ page 102 .
– Make sure that cylinder head cover is clipped properly to

toothed belt cover -arrows-.
Note
For illustration purposes, the installation position is shown with

the camshaft sprocket removed.
– Make sure there is a clearance between hub and toothed belt

cover. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Install fuel rail and injectors ⇒ Rep. Gr. 23 . with respect to the correctness of information in this document. Copyright by AUDI AG.
2.3 Renewing injector seals


Audi TT 2007 ➤
♦ Carrier -3390-
Procedure
– Remove cylinder head cover ⇒ page 102 .
– Apply carrier -3390- and short extension -1- at bottom and
press out injector seal upwards.
– Apply carrier -3390- and short extension -1- at top and press
new injector seal in as far as stop.
– Install cylinder head cover ⇒ page 102 .

Audi TT 2007 ➤
2.4 Cylinder head - exploded view
1 - Cylinder head gasket

❑ Renewing
stalling cylinder head”,
page 109
❑ Identification of cylinder
head gasket
⇒ page 108
❑ If renewed, change
coolant and engine oil
2 - Bolt
❑ Apply locking fluid when
installing; refer to ⇒
Electronic parts cata‐
logue
❑ 10 Nm
❑ For camshaft position
4 - Cylinder head
❑ Protected
Removing andCopying
by copyright. installing
⇒ page
unless
❑ To prevent damage to
glow plugs, always

place cylinder head on a
soft foam surface after
removal.
❑ Checking for distortion
⇒ page 107
❑ Must not be machined
❑ Before installing, check
that the two dowel
sleeves for centring cyl‐
inder head are fitted on
cylinder block
❑ If renewed, change coolant and engine oil
5 - Washer
6 - Bolt
❑ Renew
❑ Correct sequence when slackening ⇒ page 117
7 - Oil pressure switch -F1-
❑ Opening/closing pressure 0.3 ... 0.6 bar
❑ 20 Nm
8 - Seal
❑ Renew
9 - Bolt
❑ 20 Nm

Audi TT 2007 ➤
10 - Engine lifting eye

11 - Seal
❑ Renew
12 - Screw plug
❑ 20 Nm
13 - Gasket
❑ Renew
14 - Exhauster pump
15 - Bolt
16 - Connection
❑ For coolant hoses
❑ with coolant temperature sender -G62- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
18 - Gasket
❑ Renew
19 - Bolt
❑ 20 Nm
Checking cylinder head for distortion

– Use straight edge 500 mm -VAS 6075- and feeler gauge to
measure cylinder head for distortion at several points.
• Max. permissible distortion: 0.1 mm.
Note
Cylinder heads must not be reworked on TDI engines.

Audi TT 2007 ➤

1- Part number
2- Holes
3- Ignore
Note
Cylinder head gaskets of different thicknesses are fitted depend‐

ing on the amount of piston projection ⇒ page 85 . When renewing
only the cylinder head gasket, the new gasket should have the
same identification as the old one.
Cylinder head - tightening torque and sequence
Note

1. -1 … 10- 30 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2. -1 … 10- 50 Nm
3. -1 … 10- turn 90° further
4. -1 … 10- turn 90° further

Audi TT 2007 ➤

equipment required
♦ Diesel injection pump lock‐
ing pin -3359-
-VAS 6208-
♦ Puller -T10052-
♦ Bit XZN 10 -T10385-
Removing
Caution

– Disconnect earth cable -arrow- from battery terminal ⇒ Elec‐

trical system; Rep. Gr. 27 .
– Drain coolant ⇒ page 170 .
– Remove radiator cowl ⇒ page 202 .

Audi TT 2007 ➤
housing.

-1-.
– Move clear vacuum hoses -arrows-.
– Detach vacuum hose -2- from vacuum unit of turbocharger.

Note
Disregard -item 1-.

Audi TT 2007 ➤
– Move clear wiring harnesses -arrows- and electrical connector

-1- at bracket.
– Remove bolts -2, 5- and -arrows-.

– Using removal lever -80 - 200- , move clear electrical wiring
and hoses at air pipe (left-side).
– Loosen hose clip -3- and detach air pipe (left-side).
Note
– Remove bolts -arrows- and detach pulsation damper -2-.
Note
Disregard -item 1-.

Audi TT 2007 ➤
– Unplug electrical connector -1- on oil pressure switch -F1- .

– Detach vacuum hose from brake servo -arrow-.
– Unplug electrical connector -4- at coolant temperature sender

-G62- .
– Release hose clips -1- and -2- and disconnect coolant hoses
from connection.
Note
Disregard -item 3-.
– Unplug electrical connector -2- at throttle valve module -J338-

-arrow-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Note

Audi TT 2007 ➤
– Move clear electrical connector -1- for exhaust gas tempera‐

ture sender 1 -G235- and electrical wiring.
Note
Note
-G505- .
Note

(right-side).

Audi TT 2007 ➤
– Remove nuts -2-, tie up particulate filter to rear.
Note
Disregard -item 1-.
Note
– Place drip tray for workshop hoist -VAS 6208- under connec‐
tion.
heat exchanger.
– Guide coolant hoses downwards and drain off Protected
coolant. by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove bolts and detach exhaust gas recirculation pipes

-A-.
– Unscrew union nut -2- and bolt -3-.
Note
Disregard -item 1-.

Audi TT 2007 ➤
– Remove bolt -arrow- for toothed belt cover (rear).

– Take toothed belt off camshaft sprocket ⇒ page 91 .
– Remove nut -1-.
Note
Disregard -arrow- and -T10264- .
– Unplug electrical connector -arrow- at Hall sender -G40- .

– Unclip electrical wiring harness from bracket -arrow- and move

clear.

Audi TT 2007 ➤
– Take exhaust gas recirculation cooler change-over valve -

N345- -left arrow- out of bracket and move clear to one side.
Note
Disregard -arrow- on right-side of illustration.
– Remove bolts -1- and detach camshaft sprocket.
– Counterhold using counterhold tool -T10051- and loosen bolt

-1- for camshaft hub.
– Unscrew bolt approx. 2 turns.
– Apply puller -T10052- to camshaft hub and and screw bolts

-1- into hub.
– Counterhold on hexagon flats (30 mm) of puller and screw in
bolt -2- to pull off camshaft hub.
– Detach hub from taper of camshaft.

Audi TT 2007 ➤
– Slacken cylinder head bolts in the sequence -1 ... 10-.
Note
A second mechanic is required for removal of the cylinder head.
– Swivel cylinder head to left and out of rear toothed belt cover
and detach tensioning roller at the same time.
– Take care not to damage oil return line for turbocharger.
– Take care to place cylinder head down without bending oil re‐
turn line. If necessary, place a block of wood below exhaust
manifold.
Caution
Risk of damage to glow plugs when putting down cylinder

head.
♦ After removal, the cylinder head must not be put down on
the gasket side with the glow plugs still installed, because
the glow plugs project slightly beyond the gasket surface.
Note
Installing
⇒ “2.4 Cylinder head - exploded view”, page 106

Audi TT 2007 ➤
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.
Risk of leaks at cylinder head gasket.
♦ Carefully remove any sealant residue from the cylinder
head and cylinder block. Ensure that no long scores or
scratches are made on the surfaces.
♦ Carefully remove any remaining emery and abrasive 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.
Avoid damage to open valves.
♦ When installing an exchange cylinder head, the plastic
protectors fitted to protect the open valves should
Protectednot be Copying for private or commercial purposes, in part or in whole, is not
by copyright.
removed until the cylinder head is ready to be fitted.unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
Avoid damage to valves and piston crowns after working on
valve gear.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
Note

♦ Renew self-locking nuts as well as seals, gaskets and O-rings.
♦ Cylinder heads must not be reworked on TDI engines.
♦ When installing an exchange cylinder head, the contact sur‐
faces between roller rocker fingers and cams must be oiled.
♦ After fitting a new cylinder head or cylinder head gasket,
change the engine oil and the coolant in the entire cooling
system.
– Before fitting cylinder head, remove crankshaft stop -T10050-

and turn crankshaft against normal direction of rotation until
all pistons are positioned approximately equally below “TDC”.

Audi TT 2007 ➤
– If not already fitted, install dowel sleeves in cylinder block for

centring cylinder block and cylinder head.
– Note cylinder head gasket identification:

1- Part number
2- Holes
3- Ignore
Note
♦ If the cylinder head gasket or cylinder head have been re‐

placed, select the new cylinder head gasket according to the
number of holes on the old gasket.
♦ If parts of the crankshaft drive
Protected have been
by copyright. Copyingrenewed, the newpurposes, in part or in whole, is not
for private or commercial
cylinder head gasket must
permittedbe selected
unless authorisedby measuring
by AUDI AG. AUDI AG thedoes
pis‐
ton projection at “TDC” with
⇒ page
respect 85
to the. correctness of information in this document. Copyright by AUDI AG.
– Fit cylinder head gasket onto dowel sleeves -arrows- in cylin‐

der block.
• Installation position of cylinder head gasket: the word
“oben” (top) or the part number should face towards the cyl‐
inder head.
– Swivel cylinder head so that stud for toothed belt tensioning
roller is inserted into aperture in toothed belt cover (rear) and
attach tensioning roller at the same time.
Note
Make sure that electrical wiring to Hall sender -G40- is properly

routed.
– Fit cylinder head.

– Screw in cylinder head bolts by hand until they make contact.
– Tighten cylinder head bolts ⇒ page 108 .
Note
Cylinder head bolts do not have to be torqued down again later

after repair work.
– Install rear toothed belt cover, camshaft hub and sprocket

⇒ page 89 .

Audi TT 2007 ➤

-3359- .
Note
Disregard -arrows-.
– Lock high-pressure pump hub with diesel injection pump lock‐

ing pin -3359- .
Note
Disregard -item 1-.

Audi TT 2007 ➤
– Then turn crankshaft in direction of engine rotation until pin

-arrow- on crankshaft stop -T10050- engages in sealing flange
as crankshaft rotates.
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install support for turbocharger with oil supply line
⇒ page 207 .
– Install exhaust gas recirculation pipes ⇒ page 229 .
– Install air pipes ⇒ page 212 .
– Install dipstick guide tube ⇒ page 144 .
– Install vacuum line to exhaust gas recirculation cooler
⇒ page 229 .
– Install air pipe with connection and pulsation damper
⇒ page 207 .
– Observe notes on procedure for connecting the battery ⇒
Electrical system; Rep. Gr. 27 .
– Change engine oil ⇒ Maintenance ; Booklet 810 .
– Fill cooling system with fresh coolant ⇒ page 173 .
2.6 Checking compression Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Special tools and workshop equipment required with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Jointed spanner -3220-

Audi TT 2007 ➤
♦ Compression tester -V.A.G 1763- with adapter -V.A.G 1763/8-
Procedure
• Engine oil temperature approx. 80 °C.
– Unplug electrical connector -arrow- for fuel pressure regulat‐

ing valve -N276- at fuel rail.
– Briefly start engine to relieve fuel pressure in fuel rail.
– Remove all glow plugs ⇒ Rep. Gr. 28 .

Audi TT 2007 ➤
– Screw in adapter -V.A.G 1763/8- in place of corresponding

glow plug and connect compression tester -V.A.G 1763- .
Note
Using the compression tester ⇒ Operating instructions .
– Have a 2nd mechanic operate starter until tester shows no

further pressure increase.
– Repeat procedure on each cylinder.
Compression pressure bar
When new 25.0 … 31.0
Wear limit 19.0
Maximum difference between cylinders 5.0
Assembling
– Install glow plugs ⇒ Rep. Gr. 28 .
– Entries are stored in event memory of engine control unit be‐
cause electrical connectors were unplugged and engine was
started: Interrogate event memory in Vehicle self-di-
agnosis ⇒ vehicle diagnostic tester .

Audi TT 2007 ➤
3 Valve gear
Caution

valve gear.
♦ The hydraulic tappets have to settle; wait for approx. 30
minutes after installing camshafts before starting engine.
operated.
Note
Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
3.1 Valve gear - exploded view
1 - Valve
❑ Must not be machined;
only grinding-in is per‐
missible
❑ Mark installation posi‐
tion for re-installation
❑ Valve dimensions
⇒ page 142
❑ Checking valve guides
⇒ page 142
2 - Cylinder head
3 - Valve stem oil seal
❑ Renewing with cylinder
head installed
⇒ page 135
❑ Renewing with cylinder
head removed
⇒ page 139
4 - Valve spring
5 - Valve spring plate
6 - Valve cotters
7 - Sealing cap
❑ Renew
❑ Removing sealing cap
with retaining frame in‐
stalled: pierce on one
side with an awl and pry
out
❑ Installing: drive in with‐
out sealant using suita‐
ble thrust piece

Audi TT 2007 ➤
❑ Installation depth 1 ... 2

mm
8 - Oil seal
9 - Exhaust camshaft
10 - Bolt
❑ Correct sequence when slackening ⇒ page 130
11 - Retaining frame
❑ With integrated camshaft bearings
❑ Removing and installing ⇒ “3.5 Removing and installing camshafts”, page 129
12 - Inlet camshaft
13 - Roller rocker finger
❑ Mark installation position for re-installation
❑ Check roller bearings for ease of movement
❑ Lubricate contact surfaces before installing
14 - Securing clip
❑ For hydraulic compensation element
15 - Hydraulic valve compensation element
Retaining frame - tightening torque and sequence

contact.
• The retaining frame should make
contact with the cylinder head over
the full surface
2. -1 … 24- 10 Nm
3.2 Measuring axial clearance of camshafts

3. Valve gear 125

Audi TT 2007 ➤
♦ Dialwithgauge -VAS
respect to 6079- of information in this document. Copyright by AUDI AG.
the correctness
Procedure
– Remove retaining frame
⇒ “3.5 Removing and installing camshafts”, page 129 .
– Secure dial gauge -VAS 6079- with universal dial gauge brack‐
et -VW 387- to cylinder head as shown in illustration.
– Press camshaft against dial gauge by hand.
– Press camshaft away from dial gauge and read off value:
Axial clearance on inlet camshaft and exhaust camshaft:
• Specification: 0.048 … 0.118 mm.
3.3 Measuring radial clearance of cam‐

shafts
♦ Plastigage
Procedure
– Remove roller rocker fingers
– Clean bearing and bearing journal.
bearing on the bearing journal or bearing shell to be measured.
• The Plastigage must be positioned in the centre of the bearing.
– Fit retaining frame and tighten to 10 Nm without rotating cam‐
shafts ⇒ page 125 .

Audi TT 2007 ➤
– Remove retaining frame again.

• Radial clearance: 0.035 ... 0.085 mm
3.4 Renewing camshaft oil seal

♦ Bolt M12x1.5x75
Procedure
– Remove camshaft sprocket and hub
– Detach electrical connector -1- for coolant shortage indicator
3. Valve gear 127

Audi TT 2007 ➤
– Insert thrust piece -3240/1- in camshaft.
– Screw inner section of oil seal extractor -3240- two turns out
of outer section (approx. 3 mm) and lock with knurled screw.
pressure).
– Loosen knurled screw and turn inner section against camshaft
until oil seal is pulled out.
oil seal.
– Clean contact surface and sealing surface.
Note
The sealing lip of the oil seal must not be additionally oiled or
greased.
– Apply guide sleeve of fitting tool -10 - 203- to camshaft as

shown in illustration. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Carefully push oil seal -1- over guide sleeve with
andrespect
ontoto cam‐
shaft.
– Press in oil seal onto stop using thrust piece of fitting tool -10
- 203- and bolt M12×1.5×75.
– Install camshaft sprocket and hub

Audi TT 2007 ➤
3.5 Removing and installing camshafts

equipment required
♦ Puller -T10052-
♦ Camshaft fitting tool -
T40094-
T40095-
♦ Clamping tool -T40096/1-
♦ Electric drill with plastic
brush attachment
♦ Safety goggles
♦ Sealant ⇒ Electronic parts
catalogue
Removing
• Cylinder head installed.
– Remove engine cover panel -arrows-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Take toothed belt off camshaft sprocket and high-pressure
pump sprocket ⇒ page 91 .
3. Valve gear 129

Audi TT 2007 ➤


-1- into hub.
– Remove exhauster pump ⇒ Rep. Gr. 47 .
– Slacken retaining frame bolts in the sequence -24 ... 1-.

– Remove bolts and carefully release retaining frame from bon‐
ded joint.
– Mark fitting location of camshafts for re-installation and re‐
move.
Installing
⇒ “3.1 Valve gear - exploded view”, page 124
Caution
Make sure axial bearings in retaining frame are not damaged.

♦ The camshafts MUST be installed using the camshaft fit‐
ting tool -T40094- as described in the following.

Audi TT 2007 ➤
Caution
Protect lubrication system and bearings against contamina‐

tion.
♦ Cover exposed parts of the engine.
WARNING

– Remove remaining sealant from cylinder head and retaining

frame using rotating plastic brush or similar.
– Oil running surfaces of both camshafts.
Set up camshaft fitting tool -T40094- as follows:

– Secure supports -T40094/9- and -T40094/10- (with -
T40094/11- ) to base plate, as shown in illustration. If neces‐
sary, remove any supports already attached at these posi‐
tions.
– Fit support -T40094/1- onto position -F- and support -

T40094/2- onto position -A-.
3. Valve gear 131

Audi TT 2007 ➤
– Place inlet camshaft in supports -T40094/1- and -T40094/2- .

– Turn inlet camshaft in such a way that it can be locked in “TDC”
position using locking device -arrow 1-.
• Recess -arrow 2- for cylinder head bolt must face outwards.
– Place exhaust camshaft in supports -T40094/9- and -

T40094/10- .
– Lock exhaust camshaft with top section -T40094/11- .
• The lug -1- on the top section must engage in the slot -2- in
the camshaft,
– Place clamping tool -T40096/1- on teeth of exhaust camshaft
in such a way that the two arms of the tool engage on the two
halves of the gear (one in each half, as shown in illustration).
• The wider arm must engage in the wider half of the gear.
– Tighten the clamping tool using the knurled wheel so that the
faces of the gear teeth are in alignment.
– Slide inlet camshaft towards exhaust camshaft, until gear
teeth engage -arrows-.
– Fit retaining frame on camshafts.

• All camshaft bearings must be seated on the camshafts.
– Position camshaft fitting tool -T40095- and fix camshafts inunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
position in retaining frame, as shown in illustration. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Detach top section -T40094/11- .

Audi TT 2007 ➤
Note

mm).
Caution
Make sure excess sealant does not contaminate camshaft

bearings.
♦ The beads of sealant must not be thicker than specified.
– Apply beads of sealant onto clean sealing surfaces of cylinder

head as shown in illustration.
• Thickness of sealant beads: 2 ... 3 mm.
Note
♦ The retaining frame should be fitted and secured without de‐

lay, as the sealant starts hardening immediately.
♦ After installing the retaining frame, wait about 30 minutes for
the sealant to dry.
– Take camshafts together with retaining frame, camshaft fitting

tool -T40095- and clamping tool -T40096/1- out of camshaft
fitting tool -T40094- and insert components carefully into cyl‐
inder head.
3. Valve gear 133

Audi TT 2007 ➤
– Screw in retaining frame bolts in the sequence -1 ... 24- evenly

by hand until they make contact.
• The retaining frame should make contact with the cylinder
head over the full surface.
– Tighten bolts ⇒ page 125 .
– Remove camshaft fitting tool -T40095- and clamping tool -
T40096/1- .
note the following:
– Install camshaft oil seal ⇒ page 127 .
– Drive new sealing cap ⇒ Item 7 (page 124) into cylinder head
to a depth of approx. 1 ... 2 mm using suitable thrust piece.
– Install exhauster pump ⇒ Rep. Gr. 47 .
Caution

valve gear.
♦ Turn the crankshaft carefully at least 2 rotationsProtected
to ensureby copyright. Copying for private or commercial purposes, in part or in whole, is not
that none of the valves make contact when the starter is authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless
operated. with respect to the correctness of information in this document. Copyright by AUDI AG.
3.6 Checking hydraulic valve compensation

elements
Note
♦ The hydraulic compensation elements cannot be serviced.

♦ Irregular valve noises when starting engine are normal.

♦ Feeler gauge
Procedure
– Start engine and run until radiator fan has started up once.
– Increase engine speed to approx. 2500 rpm for 2 minutes
(perform road test if necessary).
Note
If irregular valve noise disappears but repeatedly re-occurs when

travelling short distances, renew oil retention valve. The oil re‐
tention valve is located in the oil filter bracket
⇒ Item 10 (page 159) .
– If the compensation elements are still noisy, locate the defec‐

tive compensation element as follows:

Audi TT 2007 ➤

cam of supporting element to be tested is facing upwards.
– Press roller rocker finger down -arrow- to determine clearance
between cam and roller rocker finger.
– If it is possible to insert a feeler gauge of 0.20 mm between
cam and roller rocker finger, renew hydraulic compensation
element
Additional steps required
3.7 Renewing valve stem oil seals with cyl‐

inder head installed
♦ Valve stem seal puller -3364-
♦ Valve stem seal fitting tool -3365-
♦ Removal and installation device for valve cotters -VAS 5161-

with guide plate -VAS 5161/23- and sleeve -VAS 5161/23-1- .
3. Valve gear 135

Audi TT 2007 ➤
♦ Bolt M6x30 (2x)

Procedure
– Remove camshafts ⇒ page 129 .
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Set piston of appropriate cylinder to “bottom dead centre”.
– Fit guide plate -VAS 5161/23- onto cylinder head.
– Secure guide plate on intake manifold side with knurled screw
-VAS 5161/12- and 2 M6x30 bolts -item 1- by hand until they
make contact.
– Screw sealing pin -VAS 5161/10- into guide plate.

– Screw adapter -VAS 5161/11- hand-tight into corresponding
glow plug thread.
– Insert drift -VAS 5161/3- into guide plate and use plastic-head‐
ed hammer to release sticking valve cotters.

Audi TT 2007 ➤
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Slide sleeve -VAS 5161/23-1- onto assembly cartridge -
VAS 5161/8- .
– Connect adapter to compressed air line using a commercially
available connection piece, and apply constant air pressure.
• Minimum pressure: 6 bar
– 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 off assembly cartridge with knurled spacer ring.
– Detach valve spring with valve spring plate.
– Pull off valve stem oil seal with valve stem seal puller -3364- .
Caution
Make sure valve stem oil seals are not damaged when instal‐
ling.
♦ New valve Protected
stem oil seals -B- are supplied with plastic
sleeve; fit plastic
permittedsleeve -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- .
– Take off plastic sleeve.
3. Valve gear 137

Audi TT 2007 ➤
If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Insert valve spring and valve spring plate.
– Press assembly cartridge onto insertion device from above
and take up valve cotters.
– Insert assembly cartridge in guide plate -VAS 5161/23- again.

– Press down pressure fork andProtected
pull knurled screw
by copyright. Copyingupwards
while turning screw in both directions - thisauthorised
permitted unless will insert theAG.
by AUDI valve
cotters. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Release the pressure fork with knurled screw still in pulled po‐
sition.
– Repeat procedure for each valve.
Assembling
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.
– Install camshafts ⇒ page 129 .

Audi TT 2007 ➤
3.8 Renewing valve stem oil seals with cylinder head removed

equipment required
♦ Valve stem seal puller
-3364-
♦ Valve stem seal fitting tool
-3365-
♦ Removal and installation
device for valve cotters -
VAS 5161- with guide plate
-VAS 5161/23- and sleeve -
VAS 5161/23-1- .
port -VAS 6095-
♦ Cylinder head tensioning
device -VAS 6419-
♦ Bolt M6x30 (2x)
Procedure
– Insert cylinder head tensioning device -VAS by 6419-
AUDI AG.into
AUDIengine
permitted unless authorised AG does not guarantee or accept any liability
and gearbox support -VAS with6095- . the correctness of information in this document. Copyright by AUDI AG.
respect to
– Secure cylinder head in cylinder head tensioning device, as

– Connect cylinder head tensioning device to compressed air.
– Using lever -arrow-, slide air pad under combustion chamber
where valve stem oil seal is to be removed.
– Apply just enough compressed air to bring air pad into contact
with valve heads.
3. Valve gear 139

Audi TT 2007 ➤

-VAS 5161/12- and 2 M6x30 bolts -item 1- by hand until they
make contact.

– Slide sleeve -VAS 5161/23-1- onto assembly cartridge -
VAS 5161/8- .
clockwise until tips engage in valve cotters. with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi TT 2007 ➤
Caution
ling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.



– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
sition.
Assembling
– Install camshafts ⇒ pagewith129 . to the correctness of information in this document. Copyright by AUDI AG.
respect
3. Valve gear 141

Audi TT 2007 ➤
3.9 Valve dimensions
Note
Inlet and exhaust valves must not be machined. Only grinding-in

is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 28.10 26.00
∅b mm 5.975 5.965
c mm 99.30 99.10
α ∠° 45 45
3.10 Machining valve seats
Note
Valve seats may not be machined due to the very small toleran‐
ces.
3.11 Checking valve guides


Audi TT 2007 ➤
Procedure
Note
♦ If the valve has to be renewed as part of a repair, use a new

valve for the measurement.
♦ Only insert inlet valve into inlet guide and exhaust valve into
exhaust guide, as the stem diameters are different.
– Attach dial gauge -VAS 6079- with dial gauge bracket -

VW 387- to cylinder head.
– Insert valve into guide.
• End of valve stem must be flush with guide.
– Measure the amount of sideways play.
– 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.
3.12 Checking valves

– Visually inspect for scoring on valve stems and valve seat sur‐
faces.
– Renew valve if scoring is clearly visible.
3. Valve gear 143

Audi TT 2007 ➤
17 – Lubrication
1 Oil pump, sump, balance shaft as‐
sembly
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 fur‐
ther 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.
♦ Refer to ⇒ Maintenance tables for engine oil capacity, oil
specifications and viscosity grades.
♦ Oil spray jet and pressure relief valve ⇒ page 85
1.1 Oil pump, sump, balance shaft assembly - exploded view
1 - Seal
❑ Renew
2 - Oil drain plug
❑ 30 Nm
3 - Sump
⇒ page 147
4 - Bolt
❑ 9 Nm
5 - Suction pipe
❑ Clean strainer if dirty
6 - O-ring
❑ Renew
7 - Oil pump
⇒ page 152
that the two dowel
sleeves for centring oil
pump are fitted onto bal‐
ance shaft assembly
8 - Drive shaft permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ For oil pump
9 - Circlip
❑ Must fit securely in
groove
❑ Renew circlip if dam‐
aged or stretched
10 - Spur gear
❑ For balance shaft
144 Rep. Gr.17 - Lubrication

Audi TT 2007 ➤
11 - Bolt
❑ Renew
12 - Thrust washer
❑ For idler gear
❑ Renew
❑ When installing idler gear, apply grease to hold washer on balance shaft assembly
13 - Idler gear
❑ Renew
❑ To achieve the correct backlash a suitably thick coating is already applied to the new idler gear; the
required clearance is achieved as the coating is worn down
❑ Installation position: Part No. must be visible.
❑ Make sure thrust washer is properly seated ⇒ page 146
14 - Bolt
❑ With washer
❑ Renew
15 - Hub with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ For idler gear
❑ Renew
16 - Crankshaft gear
17 - Balance shaft assembly
❑ Re-installing "old" balance shaft assembly ⇒ page 157
❑ Installing new balance shaft assembly ⇒ page 154
❑ Before installing, check that the two dowel sleeves for centring balance shaft assembly are fitted on
cylinder block
18 - Bolt
❑ Renew
19 - Dowel sleeves
20 - Bolt
❑ 9 Nm
21 - Oil intake pipe
22 - Bolt
❑ 9 Nm
23 - Seal
❑ Renew
24 - Oil level and oil temperature sender -G266-
25 - Bolt
❑ Self-locking
❑ Renew
❑ 9 Nm
26 - Bolt
1. Oil pump, sump, balance shaft assembly 145

Audi TT 2007 ➤
Sump - tightening torque and sequence

– Tighten bolts in 3 stages:
1. -1 … 20- 5 Nm in diagonal sequence
2. -arrows- 40 Nm using Allen key, long reach -
T10058-
Installation position of thrust washer
Caution
Thrust washer can slip out of position behind idler gear.
♦ Make sure that thrust washer -A- does not slip out of the
recesses in the balance shaft assembly -arrows- when fit‐
ting the idler gear. If this is neglected, the thrust washer
can become trapped. If necessary, apply grease to hold
washer on balance shaft assembly.
Balance shaft assembly - tightening torque and sequence
Note

contact.
2. -1 … 8- 6 Nm
3. -5- and -7- 13 Nm
4. -1, 2, 3, 4, 6, 8- 20 Nm
5. -1 … 8- turn 90° further

Audi TT 2007 ➤
1.2 Removing and installing oil level and oil

Removing
• Engine oil drained ⇒ Maintenance ; Booklet 810 .
– Unplug electrical connector -arrow- at oil level and oil temper‐
ature sender -G266- .

for sump.
– Remove bolts -1- and detach oil level and oil temperature
sender -G266- -item 4-.
Note
Disregard -item 3-.
Installing
⇒ “1.1 Oil pump, sump, balance shaft assembly - exploded
view”, page 144
Note
Renew seal -2- and self-locking bolts -1-.
– Fill with engine oil and check oil level ⇒ Maintenance ; Booklet
810 .
1.3 Removing and installing sump


Audi TT 2007 ➤
♦ T-bar and socket, 10 mm -3185-
♦ Allen key, long reach -T10058-
♦ Electric drill with plastic brush

♦ Safety goggles
Removing
• Engine oil drained ⇒ Maintenance ; Booklet 810 .
Gr. 50 .
– Release hose clip -2-, lift retaining clip -1- and remove air hose.

Audi TT 2007 ➤

G31- and detach air pipe (right-side).
Note
– Remove bolt -arrow- at air pipe (left-side).


Audi TT 2007 ➤

for sump.
– Remove bolts -arrows- securing sump to gearbox using Allen

key, long reach -T10058- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Slacken bolts -1 ... 20- in diagonal sequence and remove.
– Carefully release sump from bonded joint.

Installing
Caution

tion.
WARNING

– Remove sealant residue from sump and cylinder block using

rotating plastic brush or similar.

Audi TT 2007 ➤
Note

mm).
Caution

– Apply bead of sealant onto clean sealing surface of sump as

illustrated.
Note
♦ Take particular care when applying sealant bead in area of

rear sealing flange -arrows-.
♦ The sump must be installed within 5 minutes after applying the
sealant.

Audi TT 2007 ➤
– Fit sump and tighten bolts ⇒ page 146 .

• The sump must make flush contact with intermediate plate/
gearbox flange.
Note
♦ When installing sump with engine removed from vehicle, en‐

sure that sump is positioned flush with cylinder block at fly‐
wheel end.
♦ After fitting sump assembly, the sealant must dry for approx.
30 minutes. Then (and only then) fill the engine with engine
oil.
– Install pump for exhaust gas recirculation cooler

Protected by copyright. -V400-
⇒ page 184 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
810 .
1.4 Removing and installing oil pump

♦ Circlip pliers, commercially available
♦ Bolt M3
Removing
– Remove bolts -arrows- and detach suction pipe from oil pump.

Audi TT 2007 ➤
– Remove circlip -1- using circlip pliers.

– Pull drive shaft -2- out of oil pump using a magnet -arrow-.
– Remove bolts -3, 4, 5- and detach oil pump.
Caution
The bolt on the idler gear must NOT be loosened.
Installing
view”, page 144
Note
♦ Fit new O-ring.

♦ Renew circlip if damaged or stretched.
♦ Circlip must fit securely in groove.
– Insert dowel sleeves -arrows- in oil pump, if not fitted.

– If no dowel sleeves for centring the oil pump are fitted in the
balance shaft assembly, install missing dowel sleeves.
1.5 Removing balance shaft assembly

Procedure

Audi TT 2007 ➤
Caution


crankshaft is positioned at “TDC”.
– Lock crankshaft in position with crankshaft stop -T10050- .
Note
– Loosen bolts in the sequence -8 ... 1-.

– Remove bolts and detach balance shaft assembly with oil
pump.
Note
♦ Installing a new balance shaft assembly ⇒ page 154 .

♦ Re-installing the "old" balance shaft assembly ⇒ page 157 .
1.6 Installing a new balance shaft assembly


Audi TT 2007 ➤
Procedure
view”, page 144
• Crankshaft locked in position with crankshaft stop -T10050- .
Note
♦ The spur gear drive of the balance shaft assembly must be

installed with a backlash of 0.038 ... 0.072 mm.
♦ To achieve the correct backlash, a suitably thick coating is al‐
ready applied to the new idler gear. The coating is applied to
the teeth on parts of the circumference.
♦ The coating is worn down rapidly and the backlash is then
correct.
♦ A new balance shaft assembly must always be installed in
conjunction with a new idler gear which has the correct coat‐
ing.
Caution

♦ Before positioning balance shaft assembly, slacken off
bolt for idler gear as specified below, but not further. In‐
stallation position of thrust washer
Protected ⇒ page
by copyright. Copying146
– Slacken bolt -1- for idler gear by approx. 45°.

– If not already fitted, fit dowel sleeves into cylinder block for
centring balance shaft assembly.
– Attach balance shaft assembly to cylinder block.
• Take care not to damage the coating of the idler gear.

Audi TT 2007 ➤
– Tighten bolts securing balance shaft assembly ⇒ page 146 .
– Lock balance shaft with locking tool -T10255- , turning balance

shaft as required.
• The lug of the locking tool must engage in the groove of the
balance shaft.
– Carefully fit balance shaft gear onto balance shaft; to do so,

push idler gear slightly to one side.
• The threaded holes in the balance shaft should be aligned as
centrally as possible with the elongated holes in the balance
shaft gear.
Note
If it is not possible to align the elongated holes in the balance shaft

gear with the threaded holes, you must turn the gear some teeth
further as required and then fit it again.
– Tighten bolts -arrows- for balance shaft gear.

– Remove locking tool -T10255- . with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi TT 2007 ➤
Note
The following three steps have to be performed simultaneously

(a second mechanic is therefore required):
– Push idler gear -3- firmly in direction of -arrow- into teeth on

spur gear -2- and balance shaft gear -1-. If necessary use a
wooden rod to do so.
– At the same time, turn balance shaft gear slightly anti-clock‐
wise.
– Tighten bolt securing idler gear.
– Remove crankshaft stop -T10050- .
Note
After installation the idler gear must have no backlash. This can
be checked by exerting light pressure by hand.

note the following:
– Install vibration damper ⇒ page 56 .
1.7 Re-installing a used balance shaft as‐

sembly
Procedure
Note
♦ If re-installing the "old" balance shaft assembly and neither the

spur gear on the crankshaft nor the crankshaft itself have been
renewed, proceed as described in the following. It is also es‐
sential that the idler gear has NOT been slackened.
♦ If the bolt for the idler gear has been slackened or the spur
gear on the crankshaft or the crankshaft itself have been re‐
newed, you must install a new idler gear with the appropriate
coating. Procedure for installation
⇒ “1.6 Installing a new balance shaft assembly”, page 154 .
♦ Renew bolts securing balance shaft assembly.

Audi TT 2007 ➤

shaft as required.
balance shaft.
• With the balance shaft locked in position, the idler gear must
engage in the spur gear on the crankshaft.
• Idler gear must have noticeable backlash.

note the following:
– Install sump
permitted ⇒ pageby147
unless authorised AUDI. AG. AUDI AG does not guarantee or accept any liability

Audi TT 2007 ➤
2 Oil filter bracket and engine oil cooler
2.1 Oil filter bracket and engine oil cooler - exploded view
1 - Sealing cap
❑ 25 Nm
2 - O-ring
❑ Renew
3 - O-ring
❑ Renew
4 - O-ring
❑ Renew
5 - Oil filter element
❑ See note ⇒ page 144
⇒ Maintenance ; Book‐
let 810
6 - Engine oil cooler
❑ Diagram of coolant hose
connections
⇒ page 169
stalling oil filter bracket
with engine oil cooler”,
page 160
❑ If renewed, refill system
with fresh coolant
7 - Bolt
❑ 11 Nm
8 - Gaskets
❑ Renew
9 - Bolt
❑ Renew
10 - Oil filter bracket
❑ With integrated oil retention valve
⇒ “2.2 Removing and installing oil filter bracket with engine oil cooler”, page 160
11 - Gaskets
❑ Renew
2. Oil filter bracket and engine oil cooler 159

Audi TT 2007 ➤
Oil filter bracket - tightening torque and sequence
Note
– Fit bolts at top left and bottom right first.

1. -arrows- 14 Nm in diagonal sequence
2. -arrows- Turn 90° further in diagonal sequence
2.2 Removing and installing oil filter bracket

with engine oil cooler
♦ Used oil collection and extraction unit -V.A.G 1782-
♦ Drip tray for workshop hoist -VAS 6208-

Audi TT 2007 ➤
Removing
– Remove oil filter element ⇒ Maintenance ; Booklet 810 .

Audi TT 2007 ➤

– Move coolant hose
permitted -3-
unless clear.by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
(right-side).
– Pull oil dipstick out slightly and remove bolt -1-.

– Release clip -2- with removal lever -80 - 200- .
– Pull guide tube for oil dipstick upwards out of cylinder block
and push to one side.

Audi TT 2007 ➤
– Place drip tray for workshop hoist -VAS 6208- under connec‐
tion.
– Release hose clip -1- and detach coolant hose.
– Position used oil collection and extraction unit -V.A.G 1782-
below engine.
– Unscrew bolts -arrows- and remove oil filter bracket with en‐
gine oil cooler.
Installing
⇒ “2.1 Oil filter bracket and engine oil cooler - exploded view”,
page 159
Note
♦ Renew gaskets, seals and O-rings.


– Install oil filter element, fill up with engine oil and check oil level
⇒ Maintenance ; Booklet 810 .
– Fill up cooling system (or change coolant if the engine oil cool‐
er has been renewed) ⇒ page 173 .
2.3 Removing and installing oil pressure

switch -F1-
Removing

Audi TT 2007 ➤

-1-.
– Release hose clip -3- and detach air pipe from air cleaner
housing.
– Remove bolts -2- and -3- and detach engine lifting eye -1-.
– Unplug electrical connector -arrow-.
– Unscrew oil pressure switch -F1- .
Installing
⇒ “2.4 Cylinder head - exploded view”, page 106
Note
Renew seal. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Install vacuum line to exhaust gas recirculation cooler

⇒ page 229 .
2.4 Checking oil pressure switch -F1-

♦ Oil pressure tester -V.A.G 1342-

Audi TT 2007 ➤
♦ Voltage tester -V.A.G 1527B-

Audi TT 2007 ➤
Procedure
• Oil level OK
– Remove oil pressure switch -F1- ⇒ page 163 .
– Connect oil pressure tester -V.A.G 1342- to bore for oil pres‐
sure switch.
– Screw oil pressure switch -F1- -item 2- into threaded hole in
oil pressure tester.
– Connect brown wire -1- of oil pressure tester to earth (–).
– Connect voltage tester -V.A.G 1527B- with adapter lead from
auxiliary measuring set -V.A.G 1594C- to oil pressure switch
-F1- and battery positive (+).
• LED should not light up.
Note
Renew oil pressure switch -F1- if LED lights up at this stage.
– Start engine.
Note
Observe oil pressure tester and LED while starting engine, as

switching point of oil pressure switch may already be exceeded
when starting.
• LED should light up at 0.3 ... 0.6 bar.

– Renew oil pressure switch -F1- if LED does not light up
⇒ page 163 .
2.5 Checking oil pressure

Procedure
• Oil level OK
– Connect oil pressure tester -V.A.G 1342- to threaded hole for
oil pressure switch -F1- .

Audi TT 2007 ➤
– Screw a used oil pressure switch into threaded hole on oil

pressure tester -V.A.G 1342- to seal hole.
– Start engine.
• Oil pressure at idling speed: at least 0.8 bar.
• Oil pressure at 2000 rpm: at least 2.0 bar.
2.6 Engine oil

Refer to ⇒ Maintenance tables for engine oil capacity, oil speci‐
fications and viscosity grades.
2.7 Checking oil level

Check oil level ⇒ Maintenance ; Booklet 810 .

Audi TT 2007 ➤
19 – Cooling
1 Cooling system
WARNING

hot.
Note
♦ The arrow markings on coolant pipes and on ends of hoses
must align.
168 Rep. Gr.19 - Cooling

Audi TT 2007 ➤
1.1 Diagram of coolant hose connections
Note
♦ Blue = Large coolant circuit.

♦ Red = Small coolant circuit.
♦ Brown = Heating circuit.
1 - Radiator
with fresh coolant
2 - Pump for exhaust gas re‐
circulation cooler -V400-
4 - Thermostat
5 - Radiator outlet coolant tem‐
perature sender -G83-
6 - Coolant pump
7 - Cylinder head and cylinder
block
with fresh coolant
8 - Coolant expansion tank
❑ With filler cap
lief valve in filler cap
⇒ page 177
cooler
with fresh coolant
10 - Heat exchanger for heater
❑ If renewed, refill system Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
with fresh coolant

11 - Coolant temperature
sender -G62-
1. Cooling system 169

Audi TT 2007 ➤
1.2 Draining and filling cooling system

equipment required
♦ Adapter for cooling system
tester -V.A.G 1274/8-
♦ Cooling system charge unit
-VAS 6096- with -
VAS 6096/1-
-VAS 6208-
♦ Engine bung set -VAS 6122-

Audi TT 2007 ➤
♦ Safety goggles
Draining
WARNING

♦ Even when the ignition is switched off, the radiator fans
can start up without warning due to accumulated heat in
the engine compartment, etc.
WARNING

hot.

Audi TT 2007 ➤
Note
Collect drained coolant in a clean
permittedcontainer for re-use
unless authorised or AUDI
by AUDI AG. disposal.
– Lift retaining clip -arrow-, disconnect coolant hose (bottom)
from radiator and drain off coolant.


Audi TT 2007 ➤
– Release hose clip -arrow-, disconnect coolant hose from en‐

gine oil cooler and drain off remaining coolant.
Filling
Note
♦ The cooling system is filled all year round with a mixture of

water and coolant additive. Mixture ratio ⇒ page 173 .
♦ Use only the coolantProtected
additive listed in the ⇒ Electronic parts
catalogue . Other coolant additives could seriously
AG. AUDIimpair
AG doesin
permitted unless authorised by AUDI not guarantee or accept any liability
particular the anti-corrosion properties.
with respect Theofresulting
to the correctness information indamage
could lead to loss of coolant and consequently to serious en‐
gine damage.
♦ The specified coolant (based on recommended mixture ratio)
⇒ page 173 prevents frost and corrosion damage and stops
scaling. Such additives also raise the boiling point of the cool‐
ant. For these reasons the cooling system must be filled all
year round with the correct coolant/anticorrosion additive.
ical climates.
♦ Frost protection is required down to about –25 °C (in countries
with arctic climate: down to about –35 °C).
coolant concentration must be at least 40 %.
coolant concentration can be increased, but only up to 60%
(this gives frost protection down to about –40 °C). If the con‐
centration exceeds 60%, frost protection decreases again and
cooling efficiency is also impaired.
♦ Use only clean tap water for mixing coolant.
♦ Drained-off coolant must not be used again if the radiator, heat
exchanger, cylinder head, cylinder head gasket or cylinder
block are renewed.
♦ To check anti-freeze protection in cooling system, use refrac‐
tometer -T10007- .
Recommended mixture ratio for coolant

• Coolant (40 %) and water (60 %) for frost protection to –25 °
C
C
C
♦ Coolant ⇒ Electronic parts catalogue

Audi TT 2007 ➤
Procedure
– Connect coolant hose with plug-in connector to radiator (bot‐
tom) ⇒ page 202 .
– Connect coolant hose (bottom) at pump for exhaust gas re‐

circulation cooler -V400- -arrow-.
– Connect coolant hose (top) to engine oil cooler -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 cool‐
ant expansion tank.with respect to the correctness of information in this document. Copyright by AUDI AG.
– 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 TT 2007 ➤
– 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.

Audi TT 2007 ➤
– Top up coolant to “max” mark.
Note
Hose connections and air pipes and hoses must be free of oil and
grease before assembly.

– On vehicles with auxiliary heater, switch heater on (for about
30 seconds) and then off again.
– Set temperature to “HI”.
– Switch off air conditioner compressor (press ECON button).
– Start engine and run for 2 minutes (maximum) at approx. 1500
rpm.
– Top up coolant to overflow hole on expansion tank with engine
running.
– Close filler cap on coolant expansion tank (make sure it en‐
gages).
– Allow engine to run at idling speed until two large coolant ho‐
ses at radiator become warm.
– Switch off ignition and allow engine to cool down.
– Check coolant level.

• The coolant level must be between the “min” and “max” mark‐
ings when the engine is cold.
• The coolant level can be at the “max” marking when the engine
is warm.
– Top up with coolant again if necessary.
1.3 Checking cooling system for leaks

♦ Cooling system tester -V.A.G 1274 B-

Audi TT 2007 ➤
♦ Adapter for cooling system tester -V.A.G 1274/8-
Procedure
• Engine must be warm.
WARNING

hot.
♦ Cover filler cap on coolant expansion tank with a cloth and
open carefully to dissipate pressure.

– Fit cooling system tester -V.A.G 1274 B- with adapter -
V.A.G 1274/8- onto coolant expansion tank.
– Using hand pump on cooling system tester, build up a pres‐
sure 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.
– Renew filler cap if pressure relief valve does not open as de‐
scribed.with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi TT 2007 ➤
2 Coolant pump and thermostat
2.1 Coolant pump and thermostat - exploded view
1 - Coolant pump
⇒ page 179
2 - Bolt
❑ 15 Nm
3 - O-ring
❑ Renew
4 - O-ring
❑ Renew
5 - 4/2-way valve with thermo‐
stat
❑ The thermostat is loca‐
ted in the interior of the
4/2-way valve and can‐
not be renewed sepa‐
rately
❑ Removing and installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 179 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
6 - Bolt
❑ 15 Nm

Audi TT 2007 ➤
2.2 Removing and installing coolant pump

Removing
– Unscrew bolts -1- and remove coolant pump -2-.
– Detach O-ring -3-.
Installing
⇒ “2.1 Coolant pump and thermostat - exploded view”,
page 178
Note
Fit new O-ring.
– Clean and smoothen sealing surface for O-ring.

– Lightly lubricate O-ring
permitted -3-authorised
unless with coolant.
– Fit coolant pump -2-.
• Installation position: Sealing plug in housing faces down‐
wards.
2.3 Removing and installing 4/2-way valve

with thermostat
2. Coolant pump and thermostat 179

Audi TT 2007 ➤
Removing
housing. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi TT 2007 ➤

– Unclip wiring harness from retainer -arrow-.

-1- at bracket.

Note

Audi TT 2007 ➤
– Release hose clips -1- and detach coolant hoses.
Note
– Take electrical connector -1- for Hall sender -G40- out of re‐
tainer.
– Remove bolts -arrows-, pull off coolant pipe (front) from 4/2-
way valve to left side and leave in installation position.
Note
– Remove bolts
permitted -arrows-.
(right-side).

Audi TT 2007 ➤
– Pull oil dipstick out slightly and remove bolt -1-.

– Release clip -2- with removal lever -80 - 200- .
– Pull guide tube for oil dipstick upwards out of cylinder block
and push to one side.
– Remove bolts -2-.

– Loosen hose clips -1, 3, 4-, detach coolant hoses and remove
4/2-way valve with thermostat.
Installing
page 178
– Install coolant pipe (front) ⇒ page 190 .
2.4 Checking thermostat

– Heat removed thermostat in water bath.
Starts to open Fully open Opening travel
approx. 92 °C approx. °C 1) unless
107permitted atauthorised
least 7 bymmAUDI AG. AUDI AG does not guarantee or accept any liability
• 1) Cannot be tested.

Audi TT 2007 ➤
3 Coolant pipes, coolant temperature

senders, coolant circulation pump
3.1 Coolant pipes, coolant temperature senders, coolant circulation pump - ex‐
ploded view
1 - Grommet
❑ Not supplied separately
2 - Sleeve
3 - Bolt
❑ 2.7 Nm
4 - Bolt
❑ 40 Nm
5 - Bracket
❑ For pump for exhaust
gas recirculation cooler
-V400-
6 - Coolant pipe (front)
⇒ page 190
7 - O-ring
❑ Renew
8 - Bolt
❑ 9 Nm
9 - Coolant pipe (right-side)
⇒ page 198
10 - O-ring
11 - Retaining clip with respect to the correctness of information in this document. Copyright by AUDI AG.
12 - Radiator outlet coolant

⇒ page 187
13 - Bolt
❑ 9 Nm
14 - Nut
❑ 9 Nm
15 - Bolts
❑ 9 Nm
16 - Coolant pipe
17 - Seal
❑ Renew
18 - Connection
❑ For coolant hoses

Audi TT 2007 ➤
19 - O-ring
❑ Renew
21 - Centre hex stud
❑ 9 Nm
22 - Bolt
❑ 9 Nm
Protected23 - Retaining
by copyright. Copyingclip
24 - toCoolant
with respect pipeof (left-side)
the correctness information in this document. Copyright by AUDI AG.

25 - Nut
❑ 9 Nm
26 - Bolt
❑ 9 Nm
27 - Bolt
❑ 9 Nm
28 - Nut
❑ 9 Nm
29 - Coolant pipe (top front)
3.2 Removing and installing coolant temper‐

ature sender -G62-
3. Coolant pipes, coolant temperature senders, coolant circulation pump 185

Audi TT 2007 ➤
Removing
• Engine cold.
– Open filler cap on coolant expansion tank briefly and allow re‐
sidual pressure in cooling system to dissipate.

– Release hose clip -3- and push air pipe (left-side) with coolant
pipe towards the left.
Note
Disregard -items 1, 2, 4 and 5-.

Audi TT 2007 ➤

-G62- .
Note
Place a cloth underneath the connection to catch escaping cool‐

ant.
– Pull off retaining clip -3- and pull coolant temperature sender
-G62- out of connection.
Note
Installing
Note
♦ Fit new O-ring.

♦ To avoid loss of coolant, insert new coolant temperature send‐
er -G62- immediately into connection.

– Check coolant level ⇒ page 176 .
3.3 Removing and installing radiator outlet

coolant temperature sender -G83-
Removing
• Engine cold.

Audi TT 2007 ➤

Place a cloth underneath to catch escaping coolant.
– Pull off retaining clip -1- and pull radiator outlet coolant tem‐
perature sender -G83- out of connection on coolant pipe.
Installing
Note
♦ Fit new O-ring.

♦ To avoid loss of coolant, fit new radiator outlet coolant tem‐
perature sender -G83- into coolant pipe immediately.
3.4 Removing and installing pump for ex‐

haust gas recirculation cooler -V400-

Audi TT 2007 ➤
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove noise insulation ⇒ Rep. Gr. 66 . with respect to the correctness of information in this document. Copyright by AUDI AG.

– Release hose clip -2- and push right air pipe towards the right.
Note

Audi TT 2007 ➤
Note
Place a cloth underneath pump for exhaust gas recirculation cool‐

er -V400- to catch escaping coolant.
– Clamp off coolant hoses using hose clamps -3094- , release

hose clips -3- and disconnect coolant hoses.
– Unscrew bolts -1- and remove pump for exhaust gas recircu‐
lation cooler -V400- .
Disregard -arrow-.
Installing
⇒ “3.1 Coolant pipes, coolant temperature senders, coolant
circulation pump - exploded view”, page 184
3.5 Removing and installing coolant pipe

(front)

Audi TT 2007 ➤
Removing
housing.


Audi TT 2007 ➤

-1- at bracket.

Note

Audi TT 2007 ➤
– Release hose clips -1- and detach coolant hoses.
Note
– Take electrical connector -1- for Hall sender -G40- out of re‐
tainer.
– Detach bracket from coolant pipe (front).
– Release hose clips -2- and -3- and disconnect coolant hoses.
– Remove bolts -arrows- and detach coolant pipe (front) from
4/2-way valve to left side.
Installing
Note


– Lightly lubricate O-ring with coolant and slide O-ring onto cool‐
ant pipe (front).
– Push coolant pipe (front) into 4/2-way valve.
(top front)

Audi TT 2007 ➤
Removing

Audi TT 2007 ➤

– Detach coolant pipe (top front).
Installing
Note


(left-side)

Audi TT 2007 ➤
Removing

Audi TT 2007 ➤

-1- at bracket.

hose clips -1- and -4- and disconnect coolant hoses from cool‐
ant pipe (left-side).
– Detach coolant pipe (left-side).
Installing
Note

– Install noise insulation ⇒ Rep. Gr. 66 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi TT 2007 ➤

(right-side)
Removing

Audi TT 2007 ➤

– Remove noise insulation ⇒ Rep. Gr.
permitted 66authorised
unless . by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove bottom section of wheel housing liner (right-side) ⇒

Rep. Gr. 66 .

Audi TT 2007 ➤
hose clips -arrows- and disconnect coolant hoses from coolant
pipe (right-side).
– Remove nut -1- and bolt -2- and take off coolant pipe (right-
side).
Installing
Note
– Install right wheel housing liner (bottom section) ⇒ Rep. Gr.

66 .
– Install fuel filter ⇒ Rep. Gr. 20 .

Audi TT 2007 ➤
4 Radiator and radiator fans
WARNING

4.1 Radiator and radiator fans - exploded view
1 - Radiator fan -V7-

❑ With radiator fan control
unit -J293-
❑ Removing
Protected and for
by copyright. Copying installing
permitted⇒ page
unless 204 by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
2 - Nut
❑ 5 Nm
3 - Radiator cowl
⇒ page 202
4 - Coolant hose (top)
❑ Lift retaining clip to de‐
tach
❑ Connecting to radiator
⇒ page 202
5 - O-ring
❑ Renew
6 - Radiator
⇒ page 204
with fresh coolant
7 - O-ring
❑ Renew
8 - Coolant hose (bottom)
❑ Lift retaining clip to de‐
tach
⇒ page 202
9 - Bolt
❑ 5 Nm
10 - Nut
❑ 5 Nm
11 - Bolt
❑ 5 Nm
12 - Radiator fan 2 -V177-
4. Radiator and radiator fans 201

Audi TT 2007 ➤
Connecting coolant hose with plug-in connector

– Remove old O-ring -2- from coolant hose -3-.
– Lightly lubricate new O-ring with coolant and fit O-ring in cool‐
ant hose.
– Press coolant hose onto connection -1- until it engages audi‐
bly.
– Press coolant hose in again and then pull to check that plug-
in connector is correctly engaged.
4.2 Removing and installing radiator cowl

Removing
bottom -2-.

Audi TT 2007 ➤
– Remove bolts -arrows- and detach air duct from lock carrier.
Note
♦ The bolts -bottom arrows- are removed at a later stage.

♦ Disregard -item 1-.

– Remove bolts -bottom arrows- and lift out air cowl.
Installing
⇒ “4.1 Radiator and radiator fans - exploded view”, page 201
– Install air duct ⇒ Rep. Gr. 23 .

Audi TT 2007 ➤
4.3 Removing and installing radiator fans -

V7- and -V177-
Removing
– Unplug electrical connector -1- and move clear.
– Unscrew nuts -arrows- and remove radiator fans.
Installing
Note
Fit all cable ties in the original positions when installing.
4.4 Removing and installing radiator

Removing
If there are slight impressions on the fins, refer to ⇒ page 7 .


from radiator.

Audi TT 2007 ➤

-item B-.
Note
Disregard -item C-.
– Remove bolts -arrows- at rear and lift out radiator.
Installing
Note
Renew seals and O-rings.
– Connect coolant hose with plug-in connector to radiator

⇒ page 202 .

Audi TT 2007 ➤
21 – Turbocharging/supercharging
1 Turbocharger
– Observe rules for cleanliness ⇒ page 6 .
1.1 Diagram of vacuum connections
Caution
Risk of engine failure.

♦ When routing vacuum lines, make sure they are not
kinked, twisted or crushed.
1 - Vacuum unit
❑ On turbocharger
❑ With position sender for
charge pressure posi‐
tioner -G581-
2 - Charge pressure control
solenoid valve -N75-
3 - Noise insulation
4 - Air cleaner housing
5 - To brake servo
6 - Connection piece
❑ On exhauster pump
7 - Non-return valve
❑ Note installation posi‐
tion
N345-
❑ Checking change-over
function ⇒with
page 230

10 - Vacuum unit
❑ For change-over func‐
tion for exhaust gas re‐
circulation cooler
206 Rep. Gr.21 - Turbocharging/supercharging

Audi TT 2007 ➤
1.2 Turbocharger - exploded view
1 - Pipe for exhaust gas recir‐

culation
❑ With flexible joint; do not
bend joint - risk of crack‐
ing
2 - Gasket
❑ Renew
3 - Ribbed bolt
❑ Renew
❑ 17 Nm
4 - Oil supply pipe
❑ Check for obstructions
❑ Before installing, fill tur‐
bocharger with engine
oil at connection for oil
supply pipe
❑ Tighten union nuts to 22
Nm.
5 - Oil return pipe
6 - Gasket
❑ Renew
7 - Nut
❑ 24 Nm
8 - Heat shield
9 - Turbocharger
❑copyright.
Protected by Can only
Copyingbeforrenewed to‐
permitted unlessgether
authorisedwith exhaust
manifold and vacuum
unit as one unit

⇒ page 208
10 - Retaining ring
11 - O-ring
❑ Renew
12 - Pulsation damper
13 - Bolt
❑ 9 Nm
14 - Intake connecting pipe
15 - Bolt
❑ 9 Nm
❑ Captive in intake connecting pipe
16 - O-ring
❑ Renew
17 - Bracket
1. Turbocharger 207
Audi TT 2007 ➤
18 - Bolt
❑ 15 Nm
19 - Heat shield
20 - Gasket
❑ Renew
21 - Nut
❑ Renew
❑ 24 Nm
23 - Bolt
❑ 20 Nm
24 - Support
❑ For turbocharger
25 - Bolt
❑ 9 Nm
26 - O-rings
❑ Different diameters
❑ Renew
27 - Banjo bolt
❑ 40 Nm
28 - O-rings
29 - Banjo bolt with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 30 Nm
30 - O-rings
❑ Renew
31 - Nut
❑ 24 Nm
1.3 Removing and installing turbocharger


Audi TT 2007 ➤
Removing
Note

installing.
Caution
If the turbocharger hasunless
permitted suffered
authorisedmechanical
by AUDI AG. AUDIdamage
AG does not (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 intake
hoses for dirt and foreign 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.
– Remove particulate filter ⇒ page 219 .


1. Turbocharger 209
Audi TT 2007 ➤

– Unplug electrical connector -1- at position sender for charge
pressure positioner -G581- .
– Move clear electrical connector -1- for exhaust gas tempera‐

ture sender 1 -G235- and electrical wiring.
Note

– Loosen hose clip -1- and detach pulsation damper -2-.

-A-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi TT 2007 ➤
– Remove bolts -1, 3-, union nut -2- and banjo bolts -4, 5- and
detach support for turbocharger with oil supply line.
– Remove bolts -arrows- and detach heat shield.
– Remove nuts -arrows- and detach turbocharger with exhaust

manifold from cylinder head.
Installing
⇒ “1.2 Turbocharger - exploded view”, page 207
Note
♦ Renew seals, gaskets, O-rings and self-locking nuts.

♦ Fill turbocharger with engine
Protected by copyright. oilprivate
Copying for at connection for oil supply
pipe. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ 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.

1. Turbocharger 211
Audi TT 2007 ➤
2 Charge air cooling
Note
♦ Check that all air pipes and hoses and vacuum lines are cor‐
rectly fitted and that there are no leaks before carrying out tests
or repairs.
♦ 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.
2.1 Charge air cooler - exploded view
1 - Air hose
2 - Air pipe (left-side)
3 - Sleeve
4 - Bolt
❑ 9 Nm
5 - Grommet
6 - Air hose
7 - Seal
8 - Charge air cooler
⇒ page 214
9 - Seal
❑ 5 Nm
11 - Mounting
12 - Mounting
13 - Air hose
14 - Air hose
15 - Air pipe (right-side)
16 - Bolt
❑ 5 Nm
17 - Charge pressure sender -
sender -G42-
⇒ page 213
18 - O-ring
❑ Renew

Audi TT 2007 ➤
Installing air hoses with screw-type clips
Note
To ensure that the air hoses can be properly secured at their con‐
nections, 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
2.2 Removing and installing charge pres‐

sure sender -G31- / intake air tempera‐
ture sender -G42-
Removing
– Unplug electricalProtected
connector -2-. Copying for private or commercial purposes, in part or in whole, is not
by copyright.
– Remove bolts -1- and pull charge
with respect pressure
to the correctness sender
of information -G31-
in this / in‐
take air temperature sender -G42- out of air pipe.
Installing
⇒ “2.1 Charge air cooler - exploded view”, page 212
Note
Fit new O-ring.
2. Charge air cooling 213

Audi TT 2007 ➤
2.3 Removing and installing charge air cool‐

er
Removing
– Remove radiator ⇒ page 204 .
– Remove bumper cover (front) ⇒ Rep. Gr. 63 .
– Release hose clips -1- and -2- and remove air hose on both
sides.
– Release air ducts (left and right) and push to one side in order
to remove bolts -arrows-.
– Push top edge of charge air cooler slightly towards rear.
– Lift charge air cooler out of bottom mounting points.
– Push charge air cooler towards engine. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Support charge air cooler from below to prevent charge
with respect air
cooler from dropping.
WARNING
Risk of injury caused by refrigerant.

♦ The air conditioner refrigerant circuit must not be opened.
Caution
Make sure that condenser and refrigerant pipes and hoses are
not damaged.
– Remove bolts -arrows- and -1-.

– Detach condenser from charge air cooler and take charge air
cooler out from below.
Installing
– Install condenser ⇒ Rep. Gr. 87 .
– Install bumper cover (front) ⇒ Rep. Gr. 63 .

Audi TT 2007 ➤
2.4 Checking charge air system for leaks

♦ Charge air system tester -V.A.G 1687- with adapters -V.A.G
1687/11- and -V.A.G 1687/16-
Procedure

-1-.
housing.
– Connect adapter -V.A.G 1687/11- with -V.A.G 1687/16- to tur‐

bocharger.
– Connect hose -1- of charge air system tester -V.A.G 1687- to
adapter.

Audi TT 2007 ➤
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 setauthorised
permitted unless too high.by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ 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
♦ A small amount of air escapes through the valves and enters

the engine. Therefore it is not possible to perform a pressure
retention test.
♦ For operation of ultrasonic tester -V.A.G 1842- , refer to ⇒
Operating instructions .
♦ Release pressure in test circuit by detaching hose coupling
from adapter before removing adapter.
Assembling
Note
♦ Renew gasket and O-rings.


Audi TT 2007 ➤
26 – Exhaust system
1 Silencers
Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that it has sufficient clearance from the
body. If necessary, loosen clamp and align silencers and ex‐
haust pipe so that sufficient clearance is maintained to the
body at all points and the mountings are evenly loaded.
♦ Use screwdriver to unfasten and tighten lock washers for heat
shields. Tightening torque: 2 Nm.
1.1 Silencers - exploded view
1 - Centre silencer
❑ CombinedProtectedwith rear si‐
lencerpermitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Align exhaust system so
it is free of stress
⇒ page 223
2 - Rubber mounting
3 - Rubber mounting
4 - Bracket
5 - Bolt
❑ 23 Nm
6 - Mounting
7 - Nut
❑ 23 Nm
8 - Bracket (bottom)
❑ For particulate filter
9 - Nut
❑ 23 Nm
10 - Bracket (top)
11 - Bolt
❑ 23 Nm
12 - Nut
❑ 23 Nm
13 - Nuts
❑ 9 Nm
1. Silencers 217
Audi TT 2007 ➤
14 - Heat shield
15 - Clamp
❑ Renew
❑ 7 Nm
16 - Seal
❑ Renew
❑ After renewing, perform Adaption in Guided Functions ⇒ vehicle diagnostic tester
18 - Clamp (front)
❑ Before tightening, align exhaust system so it is free of stress ⇒ page 223
❑ Tighten bolt connections evenly
19 - Nut
❑ 23 Nm
20 - Bolt
❑ 23 Nm
22 - Bracket
23 - Nut
❑ 23 Nm
24 - Bolt
❑ 23 Nm
Installation position of front clamp
– Fit the clamp at the angle shown.
• Angle -α- = approx. 20°
• Bolt connections facing towards right
• Nuts facing upwards
218 Rep. Gr.26 - Exhaust system

Audi TT 2007 ➤
Installation position of clamp for particulate filter

• Angle -α- = 0 ± 10°
• Bolt connection faces to rear
1.2 Removing and installing particulate filter


with respect toequipment
the correctness required
♦ Engine support -3300 A-
Removing
– Remove Lambda probe ⇒ Rep. Gr. 23 .
– Remove propshaft ⇒ Rear final drive 02D, 0AV, 0BR and 0BY;
Rep. Gr. 39 .
1. Silencers 219
Audi TT 2007 ➤
– Remove bevel box ⇒ Rep. Gr. 34 .
– Unplug electrical connector -3- for exhaust gas temperature

sender 3 -G495- and move electrical wiring clear.
Note
Note

– Remove bolt -1- and nuts -arrows- and push pressure differ‐
ential sender -G505- clear to one side.

Audi TT 2007 ➤
– Unscrew exhaust gas temperature sender 4 -G648- -arrow-

from exhaust pipe behind particulate filter.
ticulate filter.
– Remove bolts and nuts -arrows-.

– Detach heat shield to rear.
1. Silencers 221
Audi TT 2007 ➤
– Using engine support -3300 A- , push engine/gearbox assem‐

bly forwards by distance -a-.
– Remove particulate filter by rotating through 180° around its

own axis -arrow-.
Installing
⇒ “1.1 Silencers - exploded view”, page 217
Note
♦ Renew gaskets, self-locking nuts and clamp for particulate fil‐

ter.
– Note sequence when installing particulate filter:

1. Fit particulate filter to turbocharger, attach clip -1- without
tightening
2. Fit bolts -2 ... 5- by hand without tightening
• It must still be possible to move particulate filter and
bracket
3. Tighten clip -1-

4. Tighten bolts -2- and -5-.
5. Tighten bolts -3- and -4-.
– Install head shield ⇒ Rep. Gr. 66 .
– Install exhaust gas temperature sender 4 -G648-
⇒ page 227 .
– Install bevel box ⇒ Rep. Gr. 34 .
– Install propshaft ⇒ Rear final drive 02D, 0AV, 0BR and 0BY;
Rep. Gr. 39 .
– Install Lambda probe -G39- and pressure differential sender -
G505- ⇒ Rep. Gr. 23 .
– Align the exhaust system so it is free of stress ⇒ page 223 .
– After renewing particulate filter, perform Adaption in Guided
Functions
Protected ⇒ vehicle
by copyright. Copying fordiagnostic tester
private or commercial .

Audi TT 2007 ➤
1.3 Stress-free alignment of exhaust system

Procedure
• The exhaust system must be aligned when it is cool.
– Loosen bolt connections on front clamp.
– Push exhaust system towards front of vehicle until preloading
at mounting for rear silencer -a- = 11 ... 13 mm.

– Tighten
permittedbolt connections
unless onAG.
authorised by AUDI clamp evenly.
1.4 Aligning tailpipes

Procedure
– Align rear silencer so that there is an equal distance -a- and
-b- between bumper cut-out and tailpipes.
– Unfasten rear silencer mounting to align tailpipes.
1.5 Checking exhaust system for leaks

Procedure
– 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.
1. Silencers 223
Audi TT 2007 ➤
2 Exhaust gas temperature control
2.1 Exhaust gas temperature control - ex‐

ploded view
Caution
Risk of malfunctions caused by improperly secured exhaust

gas temperature senders.
♦ The threads of the exhaust gas temperature senders -
G495- and -G648- are coated. It is important that you do
NOT grease them additionally with high-temperature
paste and that you tighten them to the specified torque.
1 - Turbocharger
3 - Hose
-G505-
⇒ Rep. Gr. 23
5 - Bolt
❑ 8 Nm
6 - Bracket
❑ For pressure differential
sender -G505-
7 - Nut
❑ 9 Nm
sender 3 -G495-
⇒ page 226
❑ The thread of the ex‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
haust gas temperature permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
sender is coated; it must with respect to the correctness of information in this document. Copyright by AUDI AG.
not be be additionally
greased with high-tem‐
perature paste
❑ 60 Nm
⇒ Rep. Gr. 23
sender 4 -G648-
❑ The thread of the exhaust gas temperature sender is coated; it must not be be additionally greased with
❑ 60 Nm

Audi TT 2007 ➤

❑ Coat thread with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts catalogue
❑ 45 Nm

temperature sender 1 -G235-

Note
2. Exhaust gas temperature control 225

Audi TT 2007 ➤
Note
The connection can be accessed from below.
– Unscrew exhaust gas temperature sender 1 -G235- -item 1-

from exhaust manifold.
Note
Disregard -arrows-.
Installing
⇒ “2.1 Exhaust gas temperature control - exploded view”, page
224
Note
Coat threads of exhaust gas temperature sender with high-tem‐

perature paste; for high-temperature paste refer to ⇒ Electronic
parts catalogue .
Installation position of exhaust gas temperature sender -G235- :
• The angled part of the pipe must have a clearance of -a- = 3

… 5 mm from the bolt on the turbocharger support.

Removing
– Remove Lambda probe -G39- ⇒ Rep. Gr. 23 .

Audi TT 2007 ➤

Note
– Remove exhaust gas temperature sender 3 -G495- -item 1-.
Note
Installing
224 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation is carried out in the reverse order; with
note thetofollowing:
respect the correctness of information in this document. Copyright by AUDI AG.
Caution

– Align exhaust gas temperature sender 3 -G495- with as much

clearance from surrounding components as possible.
– Install Lambda probe -G39- ⇒ Rep. Gr. 23

Removing
Note

Audi TT 2007 ➤
– Unscrew exhaust gas temperature sender 4 -G648- -arrow-

Installing
224
Caution



Audi TT 2007 ➤
3 Exhaust gas recirculation system

⇒ “1.1 Diagram of vacuum connections”, page 206 .
3.2 Exhaust gas recirculation with exhaust gas recirculation cooler - exploded
view
1 - Bolt
❑ 9 Nm
culation
ing
3 - Bolt
❑ 9 Nm
4 - Gasket
❑ Renew
5 - Vacuum line Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Do not alter shape with respect to the correctness of information in this document. Copyright by AUDI AG.
6 - Bolt
❑ 9 Nm
7 - Gasket
❑ Renew
culation
ing
9 - Bolt
❑ 9 Nm
10 - Clamp
❑ 5 Nm
cooler
❑ With integrated exhaust
gas recirculation valve -
N18- with exhaust gas recirculation potentiometer -G212-
❑ Checking change-over function ⇒ page 230
12 - Bolt
❑ 9 Nm
13 - Gasket
❑ Renew
14 - Gasket
❑ Renew
3. Exhaust gas recirculation system 229

Audi TT 2007 ➤
15 - Pipe for exhaust gas recirculation

❑ With flexible joint; do not bend joint - risk of cracking
16 - Bolt
❑ 9 Nm
17 - Bolt
❑ 9 Nm
18 - Gasket
❑ Renew
3.3 Checking exhaust gas recirculation

cooler change-over
Special tools andProtected
workshop equipment required
Procedure
– Disconnect vacuum hose from vacuum unit and connect hand
vacuum pump -VAS 6213- in its place.
– Operate hand vacuum pump to produce a vacuum.
• The linkage of the exhaust gas recirculation cooler change-
over should move -arrows-.
If the linkage does not move or only moves jerkily:
♦ The vacuum unit is defective.
♦ The change-over flap for exhaust gas recirculation is sticking.
Note

installing.
3.4 Removing and installing exhaust gas re‐

circulation cooler

Audi TT 2007 ➤
Removing
Note

installing.

-1-.
housing.

Audi TT 2007 ➤

– Loosen hose clip -1- and detach pulsation damper -2-.

-A-.
– Remove bolts -1, 3-, union nut -2- and banjo bolts -4, 5- and
detach support for turbocharger with oil supply line.

Audi TT 2007 ➤
– Clamp off coolant hoses -1- and -3- using hose clamps -3094- ,
release hose clips and disconnect coolant hoses from exhaust
gas recirculation cooler.
– Detach heat insulation sleeve, disconnect vacuum hose -4-
from vacuum unit and move clear.
– Remove bolts -arrows- and detach exhaust gas recirculation
cooler.
Installing
⇒ “3.2 Exhaust gas recirculation with exhaust gas recirculation
cooler - exploded view”, page 229
Note
♦ Renew gaskets, seals and self-locking nuts.

– Install support for turbocharger with oil supply line, pulsation

damper and air pipe with connection ⇒ page 207 .

Service
Workshop Manual
Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail),
mechanics
Engine ID
CBB
B
Edition 04.2010

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system


Audi TT 2007 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics - Edition 04.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Checking for leaks in the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.5 Routing and attachment of pipes,
Protected hoses Copying
by copyright. and wiring
for private.or. commercial
. . . . . . purposes,
. . . . . .in.part
. . or. .in .whole,
. . . is. not
...... 6

1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Separating engine from manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.1 Poly V-belt drive with tensioner and air conditioner compressor - exploded view . . . . . . . . 43
1.2 Removing and installing poly V-belt - vehicles with tensioner and air conditioner
compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.4 Poly V-belt drive without air conditioner compressor - exploded view . . . . . . . . . . . . . . . . 48
1.5 Removing and installing poly V-belt - vehicles without air conditioner compressor . . . . . . 48
1.10 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.1 Dual-mass flywheel and sealing flange (gearbox end) - exploded view . . . . . . . . . . . . . . . . 59
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.5 Extracting and driving in needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.6 Pulling spur gear off crankshaft and shrink-fitting new spur gear . . . . . . . . . . . . . . . . . . . . 74
4.2 Measuring piston projection at “TDC” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Contents i
Audi TT 2007 ➤

1.1 Toothed belt - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.1 Cylinder head cover - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3 Valve gear
Protected . . . . Copying
by copyright. . . . . .for. .private
. . . or
. .commercial
. . . . . . purposes,
. . . . . in
. .part
. . or. in. .whole,
. . . is. .not. . . . . . . . . . . . . . . . . . . . . . . 116
3.1 Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . any
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept . . liability
......................... 116

3.4 Renewing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.6 Checking hydraulic tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.9 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.10 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.11 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.12 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1 Oil pump, sump, balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.1 Oil pump, sump, balance shaft assembly - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.5 Removing balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.6 Installing a new balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.7 Re-installing a used balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2 Oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.1 Oil filter bracket and engine oil cooler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.2 Removing and installing oil filter bracket with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . 153
2.6 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2 Coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.1 Coolant pump and thermostat - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.3 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.4 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3 Coolant pipes, coolant temperature senders, coolant circulation pump . . . . . . . . . . . . . . . . 175
3.1 Coolant pipes, coolant temperature senders, coolant circulation pump - exploded view . . 175
ii Contents
Audi TT 2007 ➤

3.4 Removing and installing pump for exhaust gas recirculation cooler V400 . . . . . . . . . . . . 178
3.5 Removing and installing coolant pipe (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3.6 Removing and installing coolant pipe (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3.7 Removing and installing coolant pipe (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4.4 Copying
Protected by copyright. Removing
for private orand installing
commercial radiator
purposes, fans
in part or in V7
whole, / V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
is not 194
with respect to4.5 Checking
the correctness cooling
of information system Copyright
in this document. for leaks by AUDI. .AG.
.......................................... 194
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.2 Turbocharger - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
1.4 Renewing vacuum unit with position sender for charge pressure positioner G581 . . . . . . 202
2 Charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.2 Removing and installing charge pressure sender G31 / intake air temperature sender G42
........................................................................ 210
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

1 Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1.2 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
2 Exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
2.1 Exhaust gas temperature control - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3.2 Exhaust gas recirculation with exhaust gas recirculation cooler - exploded view . . . . . . . . 227
3.3 Removing and installing exhaust gas recirculation valve N18 with exhaust gas recirculation
potentiometer G212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3.4 Checking exhaust gas recirculation cooler change-over . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3.5 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Contents iii
Audi TT 2007 ➤
iv Contents
Audi TT 2007 ➤
1 Engine number
♦ The engine number (“Engine code” and “Serial number”)
-arrow- can be found at the front of the joint between engine
and gearbox.
♦ There is also a sticker on the toothed belt cover showing the
“Engine code” and “Serial number”.
♦ Starting with the letterby“C”,
Protected the Copying
copyright. engineforcodes
private or consist
commercialof 4 let‐in part or in whole, is not
purposes,
ters. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
number.
Note

1. Engine number 1
Audi TT 2007 ➤
2 Engine data
Code letters CBBB
Capacity ltr. 1.968
Power output kW at rpm 125/4200
Torque Nm at rpm 350/1750 … 2500
Bore ∅ in mm 81.0
Stroke mm 95.5
Compression ra‐ 16.5
tio
CN not less than 51
Emission standards EU4 plus
Exhaust gas recirculation yes
Exhaust gas temperature control yes
Turbocharging/supercharging Turbocharger
Glow plugs Steel glow plugs
Charge air cooling yes
Lambda control 1 Lambda probe
Particulate filter yes
Valves per cylinder 4
Note

Audi TT 2007 ➤
WARNING


glow plug system.
– “Interrogate fault memory” in “Vehicle self-diagnosis”.
Caution

battery.
Audi TT 2007 ➤
When working on the cooling system note the following warnings:
WARNING

hot.
♦ To allow pressure to dissipate, cover filler cap coolant on
Caution
Overheating can occur if the filler cap is not fitted properly.

♦ Firmly close filler cap on coolant expansion tank.

WARNING

erly secured.
• There is an increased
Protected by risk of injury
copyright. Copyingiffortest equipment
private or commercial is not in part or in whole, is not
purposes,
secured. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
TT Coupé:
TT Roadster:
the passenger.

Audi TT 2007 ➤

turbocharger
opening.
♦ Seal off open pipes/lines and connections using engine bung
set -VAS 6122- .
that have not been stored in the proper packaging (e.g. in tool
boxes etc.).
♦ When the system is open:
permitted unless Do not work
authorised by AUDIwith compressed
AG. AUDI air. or accept any liability
AG does not guarantee
Do not move the with
vehicle unless absolutely necessary.

4.2 Checking for leaks in the fuel system

Procedure
– Allow engine to run for several minutes at moderate rpm.
renewed.
– Then inspect high-pressure section of fuel system again for
leaks.

used.
Note the following:

Audi TT 2007 ➤

warranty.

Procedure
♦ Cracks
– If Protected
a fault byis copyright.
stored Copying
in theforfault memory, check the vacuum lines
leading to the corresponding component and Copyright

also check
by AUDIthe
with respect to the correctness of information in this document. AG.
remaining vacuum lines in the system.

and wiring
Mark hydraulic lines, vacuum lines and electrical wiring before
removal so they can be re-installed in the original positions and
correctly connected. Make sketches or take photographs if nec‐
essary.

Audi TT 2007 ➤

1 Removing engine

equipment required
♦ Extension -2024 A /1-
V.A.G 1383 A-
♦ Hose clip pliers -
V.A.G 1921-
-VAS 6208-
Audi TT 2007 ➤
♦ Hose clamps for hoses up

to 25 mm -3094-
♦ Puller -T10369-
♦ Engine bung set -VAS
6122-
♦ Safety goggles
Procedure
Note

gearbox.
♦ Collect drained coolant
Protected in a clean
by copyright. Copyingcontainer for re-use
for private or commercial or dis‐
posal. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Fit cable ties in the original positions when installing.
stalling.
Caution


Audi TT 2007 ➤
– Take out luggage compartment floor covering.

– Take out luggage compartment floor mat.
– Remove rear cross panel trim if cover for negative battery ter‐
minal is located behind rear cross panel trim ⇒ Rep. Gr. 70 .
– Release retaining clips -arrows- and detach cover for negative
terminal.
– Loosen nut a few turns and disconnect battery clamp on earth

wire -arrow- from battery terminal.
WARNING

hot.
Audi TT 2007 ➤
bottom -2-.
– Unplug with
electrical
respect toconnector
the correctness-1- from air
of information mass
in this meter
document. -G70-
Copyright . AG.
by AUDI

rier.

Audi TT 2007 ➤
Note

– Release fasteners -1 ... 4- and remove centre noise insulation.
– Only on TT Roadster: Remove noise insulation frame

-arrow- ⇒ Rep. Gr. 50 .
– Release fasteners -arrows- and remove wheel housing liner

(bottom section) on both sides.
Audi TT 2007 ➤
Note
To prevent coolant from entering, seal off connection on charge

air cooler with a clean plug from engine bung set -VAS 6122- .

– Remove bolts -bottom arrows- and take out air cowl down‐
wards.
– Lift retaining clip -arrow-, disconnect coolant hose (bottom
right) from radiator and drain off coolant.

Audi TT 2007 ➤

– Remove bolts -bottom arrows- on rear side of radiator.
Note
The bolts -top arrows- are removed at a later stage.
– As an additional step, open hose clip -arrow-, disconnect cool‐

ant hose at top of engine oil cooler and drain off remaining
coolant.
housing.
Audi TT 2007 ➤

– Loosen hose clip -2- and detach air pipe.

Note
Disregard -item 1-.
– Detach vacuum hose -arrow- from brake servo.
Note
Place a cloth underneath heat exchanger to catch escaping cool‐

ant.

heat exchanger.

Audi TT 2007 ➤
– Detach electrical connector -1- from bracket and unplug.

– Move clear electrical wiring.
Note
Disregard -items 2, 3 and 4-.
Note
– Unplug electrical connector -2- on exhaust gas pressure sen‐

sor 1 -G450- .
Note
Disregard -arrows-.
Audi TT 2007 ➤
– Unplug electrical connector -4- on fuel temperature sender -

G81- .
WARNING
– Release hose clips -2- and -3- and disconnect fuel supply hose
and fuel return hose.
Note
Disregard items marked -1- and -arrow-.
– Release hose clip -1- and detach coolant hose.
Note
– Disengage fuel hose -3- at permitted
bracket. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
clear to one side.
V393- .

Audi TT 2007 ➤
– Release hose clip -1-, detach coolant hose from coolant ex‐
pansion tank and move coolant hose clear -arrow-.
from radiator.

-item B-.
Note
Disregard -item C-.
– Remove bolts -top arrows- at rear and lift out radiator.
Audi TT 2007 ➤

– Slacken nuts -arrows- one turn.
– Apply puller -T10369/1- to wiper arm -1- as shown in illustra‐

tion.
– Apply thrust piece -2- onto wiper shaft.
– Turn bolt -3- in clockwise direction until wiper arm is pulled off
wiper shaft.
– Remove nuts and detach windscreen wiper arms.
Caution

♦ Apply a small quantity of soap solution to transition be‐
tween windscreen and plenum chamber cover -2-. Then,
starting at edge of windscreen, carefully pull plenum
chamber cover upwards off retainer at windscreen
-arrows-.
– Detach plenum chamber cover by pulling it carefully off re‐

tainer at windscreen.
partition panel. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove engine control unit ⇒ Rep. Gr. 23 .

– Release electrical connector -1- for engine wiring harness
-arrow- and detach.

Audi TT 2007 ➤

– Move clear and unplug electrical connector -1-.

– Open wiring duct bracket -arrows-, use removal lever -80 -
200- to unclip wiring and press wiring to side.
– Unclip wiring duct.

– Unclip wiring harness for engine control unit from wiring duct.
– Place engine wiring harness with engine control unit on top of
engine.
– unless
permitted Slideauthorised
the twobyclips
AUDI AG. in AUDI
the direction of the -arrows-
AG does not guarantee or accept anyand remove
liability
Audi TT 2007 ➤
– Remove nut -arrow-, detach terminal 30 wire from electronics

box in engine compartment and move it clear.
Note
Disregard -arrows-.
– Unplug electrical connector -7- (push retainer to the rear and

press down release catch).
– Push back protective sleeve -6-.
– Remove nut -1- and detach B+ wire -item 2- from starter sol‐
enoid switch.
– Remove nut -5- and detach earth wire -4-.
– Remove top starter bolt -3-.
– Detach securing clip -3- for gear selector cable from gearbox
selector lever -1- and pull cable off pin -arrow-.
Metal selector relay lever:
– Detach securing clip -4- for gate selector cable from selector
relay lever -2- and pull cable off pin -arrow-.

Audi TT 2007 ➤
Plastic selector relay lever:


– Remove cable support bracket -arrows- from gearbox and
place to one side (selector cables remain fitted).
– If a plastic pipe is installed between clutch master cylinder and

slave cylinder, clamp off supply hose to clutch master cylinder
using hose clamp -3094- .
Note
♦ Make sure brake fluid does not come into contact with starter
or gearbox when performing the following operations. If it
does, clean affected area thoroughly.
♦ Seal off open pipes/lines and connections with clean plugs
from engine bung set -VAS 6122- to prevent dirt from entering.
– If a pipe/hose assembly is installed between clutch master

cylinder and slave cylinder, clamp off hose -A- using hose
clamp for hoses up to 25 mm -3094- .
Note
Disregard -arrow-.
Audi TT 2007 ➤
– Pull out clip -arrow- as far as stop.

– Pull plastic pipe or pipe/hose assembly -A- out of clutch slave
cylinder and seal end of pipe.
Note
Disregard -item B-.
Caution

♦ Do not operate clutch pedal after detaching pipe from
bleeder screw on clutch slave cylinder.
– Unplug electrical connector -2- for reversing light switch -F4- .

– Remove nut -1- and press bracket to side.
– Remove bottom starter bolt and detach starter.
– Loosen bolts -arrows- for assembly mounting (engine end)

approx. 2 turns.
– Loosen bolts -arrows- for assembly mounting (gearbox end)

approx. 2 turns.

Audi TT 2007 ➤
Caution


-arrow-.
– Unplug electrical connector -2- on air conditioner compressor

regulating valve -N280- .
Caution
Make sure that air conditioner compressor and refrigerant

pipes and hoses are not damaged.
– Remove bolts -arrow-, detach air conditioner compressor -1-

with refrigerant lines connected and tie up to front.

sender -G266- .
– Remove bolts -arrows- and detach heat shield for drive shaft
(right-side).
– Detach drive shaft (left-side) from flange shaft of gearbox and
tie up.
– Detach drive shaft (right-side) from flange shaft of bevel box.
Audi TT 2007 ➤
– Mark position of nuts -arrows- securing swivel joint.

– Remove nuts for swivel joint (right-side).
– If fitted, remove nut on bracket for front right vehicle level
sender -G289- .
– Detach swivel joint from wishbone.
– Swing suspension strut (right-side) outwards and support with

extension -2024 A /1- as shown in illustration.
WARNING

♦ Secure retaining pin and swivel joint with locking pin
-arrow- and nut -1-.
Note
The illustration shows the installation position on front suspension

(left-side).

relation to each other.

Audi TT 2007 ➤
– Push engine/gearbox assembly forward slightly (towards front

end) and pull propshaft off bevel box.
Caution

flange.
Note
The propshaft must be renewed if oil seal is damaged.
– Unfasten nuts -arrows- for clamp.
ticulate filter.
– Tie up particulate filter to rear.
Audi TT 2007 ➤

G31- and detach air pipe.
Note

for sump.

Audi TT 2007 ➤

Note

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

engine, gearbox and body have been detached.
♦ Carefully guide engine/gearbox assembly when lowering to
avoid damage.
♦ Make sure there is sufficient clearance at air conditioner com‐
pressor and at left-side drive shaft.
– First lower engine/gearbox assembly only slightly.

– Then swing gearbox end of engine/gearbox assembly for‐
wards and only then lower further.
Audi TT 2007 ➤
2 Separating engine from manual gear‐

box
♦ Hooks -10 - 222 A /2-

Audi TT 2007 ➤
Procedure
bracket -T10012- .
– Remove bolts -arrows 2, 3- securing bracket for bevel box.
Note
Disregard -arrows 1-.
– Remove bolts -1, 3, 4, 5- securing gearbox to engine.

– Detach gearbox from engine.
Note
Disregard -items 2, A-.
2. Separating engine from manual gearbox 29

Audi TT 2007 ➤

equipment required
port -VW 540-
port -VAS 6095-
VAS 6100-
Procedure
• Gearbox detached from engine ⇒ page 28 .
-VAS 6100- .

Audi TT 2007 ➤

ing engine and gearbox support -VW 540- .

Audi TT 2007 ➤
4 Installing engine
Tightening torques
Note

♦ Additional lubricants such as engine or gearbox oil may be
used, but do not use lubricants containing graphite.
♦ Tolerance for tightening torques ± 15 %.

Further tightening torques
Component Nm
Bolts/nuts M6 10
M7 15
M8 20
M10 40
M12 65

Audi TT 2007 ➤

Item Bolt 1 Nm
1 2) M12x55 80
2 2) M12x165 80
3 M10x105 40
4 M10x50 40
5 3) M12x65 80
• 1) Renew bolts.
• 2) Bolt with M8 threaded pin
• 3) Screwed intowith
gearbox
respect tofrom engineof side

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

♦ Renew self-locking nuts and bolts as well as seals, gaskets
and O-rings.
♦ To secure the air hoses at their connections, spray rust re‐
mover onto the worm thread of the used hose clips before
installing.

– Ensure that intermediate plate is engaged on sealing flange
and pushed onto dowel sleeves -arrows-.
– Renew clutch release bearing if worn ⇒ Rep. Gr. 30 .
Audi TT 2007 ➤
– Initially hand-tighten bolts -arrows- for assembly mounting

(engine end) as far as stop.
.

Audi TT 2007 ➤

(gearbox end) as far as stop.
Note

– Install pump for exhaust gas recirculation cooler -V400-
⇒ page 175 .
– Secure propshaft with flexible coupling to bevel box flange ⇒
Rear final drive 02D/0AV; Rep. Gr. 39 .
– Install wishbone ⇒ Rep. Gr. 40 .
– Install pendulum support ⇒ Rep. Gr. 34 .
– Install drive shafts ⇒ Rep. Gr. 40 .
– Install starter ⇒ Rep. Gr. 27
– Install air hose with plug-in connector ⇒ page 209 .
– Connect clutch slave cylinder ⇒ Rep. Gr. 30 .
34 .
Gr. 27 .
– Install and adjust wiper arms ⇒ Rep. Gr. 92 .
Caution

Audi TT 2007 ➤
Note
♦ Do not use drained coolant again if:

♦ the cylinder head or cylinder block have been renewed.
♦ the coolant is contaminated or dirty.

– Install wheel housing liners (bottom section) and noise insu‐
lation ⇒ Rep. Gr. 66 .

Audi TT 2007 ➤
1 - Bolt
gearbox
Rep. Gr. 34 ⇒ Rep. Gr.
37
2 - Bolts
❑ Pendulum support to
gearbox
Rep. Gr. 34 ⇒ Rep. Gr.
37
3 - Engine support
tion
4 - Bolt
gine
❑ Observe correct tighten‐
ing sequence
⇒ page 38
❑ 40 Nm + 180°
5 - Engine mounting
6 - Bolt
body
❑ Renew
❑ 40 Nm + 90°
8 - Bolt
❑ Connecting bracket to engine mounting Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 20 Nm + 90°
9 - Bolt
❑ Renew
❑ 20 Nm + 90°
10 - Bolt
❑ Renew
❑ 40 Nm + 90°
11 - Bolts
Audi TT 2007 ➤
❑ Renew
❑ 60 Nm + 90°
13 - Bolt
❑ Tightening torque ⇒ Rep. Gr. 34 ⇒ Rep. Gr. 37
14 - Bolt
15 - Bolt
17 - Bolt
18 - Gearbox bracket
Tightening sequence for gearbox support

1- Screw in bolts in the sequence -1, 2, 3- hand-tight.
2- Tighten bolts in the sequence -1, 2, 3- to 40 Nm.
3- Turn bolts in the sequence -1, 2, 3- 180° further.

Procedure

Audi TT 2007 ➤

clear to one side.
V393- .

The following specifications must be obtained:



Assembling
Gr. 20 .

Audi TT 2007 ➤
Procedure

clear to one side.
V393- .


Audi TT 2007 ➤

housing.
– Position support bracket -10 - 222 A- with spindles -10 - 222

A /11- on bolted flanges of wing panels as shown in illustration.
– Attach hooks of spindles to engine lifting eyes.
– Take up weight of engine/gearbox assembly evenly with both
spindles (do not raise assembly).
– Remove bolts -arrows- for assembly mounting (engine end)

one by one and renew (if they were not renewed when instal‐
ling engine).
– Remove bolts -arrows- for assembly mounting (gearbox end)

one by one and renew (if they were not renewed when instal‐
ling engine).
Audi TT 2007 ➤
– Using assembly lever, adjust engine/gearbox assembly be‐

tween engine mounting and support arm -1- until specifica‐
tions listed below are attained:
– Tighten bolts for assembly mounting (engine end).
• Dimension -x- = dimension -x-.
– Tighten bolts for assembly mounting (gearbox end).
Gr. 20 .

Audi TT 2007 ➤
1.1 Poly V-belt drive with tensioner and air conditioner compressor - exploded
view
1 - Poly V-belt
❑ Check for wear
⇒ page 44
❑ Do not kink
on pulleys.
⇒ page 47
shaft sprocket
⇒ page 49
4 - Bolt
❑ Renew
logue
❑ 10 Nm + 90°
5 - Bolt
Rep. Gr. 27
6 - Dowel sleeve Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Ensure correct seatingwithinrespect
bracketto thefor ancillaries
7 - Bolt
8 - Bolt
9 - Idler roller
10 - Bolt

Audi TT 2007 ➤
11 - Idler roller
14 - Bolt
❑ 23 Nm
15 - Bolt
16 - Alternator
17 - Bolt
19 - Bolt
20 - Dowel sleeve

– Renew bolts for bracket for ancillaries and fit as follows:
♦ Bolts -1- and -2- M10x52.
♦ Bolts -3- and -6- M10x30.
♦ Bolts -4- and -5- M10x60.
– Tighten bolts for bracket for ancillaries in the sequence
-1 ... 6- in 4 stages as follows:
1. Screw in all bolts by hand until theyunless
permitted make contact.
2. Tighten all bolts to 40 Nm.
3. Turn bolts -3- and -6- 45° further.
4. Turn bolts -1, 2, 4, 5- 90° further.

hicles with tensioner and air conditioner
compressor

Audi TT 2007 ➤
Removing
– Release fasteners -arrows- and remove right wheel housing

liner (bottom section).

Audi TT 2007 ➤
Caution


-arrow-.
Installing
Note
Before fitting poly V-belt, make sure all mechanical units (e.g. al‐
ternator and air conditioner compressor) are firmly in position.

1- Crankshaft
2- Tensioner
3- Alternator

T10060 A- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Slacken tensioner. with respect to the correctness of information in this document. Copyright by AUDI AG.


Audi TT 2007 ➤

poly V-belt
Removing
– Detach poly V-belt from tensioner
⇒ “1.2 Removing and installing poly V-belt - vehicles with ten‐
sioner and air conditioner compressor”, page 44 .
– Release hose clip -2-, lift retaining clip -1- slightly and remove
air hose.

– Remove bolt -2- and take off tensioner -1- for poly-V-belt.
Installing
Installation is carried out in the reverse order; note
Protected the following:
– Install air pipe ⇒ page 208 . with respect to the correctness of information in this document. Copyright by AUDI AG.


Audi TT 2007 ➤
1.4 Poly V-belt drive without air conditioner compressor - exploded view
shaft sprocket
⇒ page 49
2 - Bolt
Electrical system; Rep.
Gr. 27
3 - Alternator
⇒ Electrical system;
Rep. Gr. 27
⇒ page 50
5 - Poly V-belt
❑ Renew.
⇒ page 48

hicles without air conditioner compres‐
sor
The poly V-belt tensioner is not installed on vehicles without air

conditioner (equipment version).

♦ Poly V-belt repair set with assembly tool ⇒ Electronic parts
catalogue

Audi TT 2007 ➤
Procedure
Note
The poly V-belt repair set with assembly tool contains the assem‐
bly tool -T10367- and illustrated instructions.

– Follow procedure specified in illustrated instructions.
– Install front section of wheel housing liner (front section) ⇒
Rep. Gr. 66 .
– Install front wheel ⇒ Rep. Gr. 44 .

er
Removing
– Removing poly V-belt
♦ ⇒ “1.2 Removing and installing poly V-belt - vehicles with ten‐
sioner and air conditioner compressor”, page 44
♦ ⇒ “1.5 Removing and installing poly V-belt - vehicles without
air conditioner compressor”, page 48
– Counterhold by applying ring spanner to bolt for crankshaft
sprocket and slacken bolts for vibration damper.
– Remove bolts and take off vibration damper.

Audi TT 2007 ➤
Installing
⇒ “1.1 Poly V-belt drive with tensioner and air conditioner
compressor - exploded view”, page 43 .
⇒ “1.4 Poly V-belt drive without air conditioner compressor -
exploded view”, page 48 .
Installation is carried out in the
Protected reverseCopying
by copyright. order; note orthe
for private following:
commercial purposes, in part or in whole, is not
Note
• Installation position: hole -arrow- in vibration damper must be

positioned over raised section of crankshaft sprocket.
– Install poly V-belt.
♦ ⇒ “1.2 Removing and installing poly V-belt - vehicles with ten‐
sioner and air conditioner compressor”, page 44
♦ ⇒ “1.5 Removing and installing poly V-belt - vehicles without
air conditioner compressor”, page 48

cillaries
♦ Eye-head bolt -3368-

Audi TT 2007 ➤
♦ Engine support bracket (supplementary set) -T40093-
♦ Flange nut M10 or nut M10 with washer

Removing
– Remove alternator ⇒ Rep. Gr. 27 .
– Position support bracket -10 - 222 A- with adapters and spin‐
dles on bolted flanges of wing panels as shown in illustration.
– Attach hook of spindle to engine lifting eye (left-side).
WARNING
Risk of accident because of loose bolt connections.

♦ Screw on flange nut or nut with washer -arrow- at least 6
turns to ensure that eye-head bolt -3368- is properly se‐
cured.
– Secure eye-head bolt -3368- with flange nut M10 or nut with
washer to engine support as shown in illustration.
– Attach spindle -10 - 222 A /11- (right-side) to eye-head bolt
-3368- .
– Take up weight of engine evenly with both spindles (but do not
raise engine).

Audi TT 2007 ➤

– Detach electrical connector at coolant shortage indicator

– Remove bolt -3- on engine support.
Note

– Remove bolts -1- and -2- and remove idler rollers for toothed
belt.

Audi TT 2007 ➤

Installing
Note
Renew bolts securing bracket for ancillaries.
– Check that dowel sleeve at top right between bracket for an‐
cillaries and cylinder block is fitted; insert dowel sleeve if
necessary.
– Install engine support and engine mounting ⇒ page 37 .
– Install alternator ⇒ Rep. Gr. 27 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1 - Bolt
tween sprocket and
of oil
one position
3 - Oil seal for crankshaft (pul‐
ley end)
❑ Do not lubricate with oil
dowel pins
⇒ page 56
5 - Cylinder block
6 - Dowel pin
❑ 2x
7 - Bolt

Audi TT 2007 ➤

– Tighten bolts for sealing flange on pulley end -1 ... 10- in three
stages as follows:
1. Screw in bolts -1 ... 10- by hand until they make contact.
2. Tighten bolts -1 ... 6- in diagonal sequence and in stages

to 15 Nm.
3. Tighten bolts -7 ... 10- to 15 Nm.

end)

Audi TT 2007 ➤
Procedure
-3415- .
– Adjust inner section of oil seal extractor -3203- so it is flush

with the outer section and lock in position with knurled screw.
pressure).
– Clamp flats of oil seal extractor in vice and use by
Protected pliers to remove
oil seal. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
ing in.

– Press in oil seal using bolt for crankshaft sprocket and thrust
sleeve of assembly tool -T10053- until flush.

Audi TT 2007 ➤

(pulley end)

♦ Safety goggles
Removing
-3415- .
– Remove bolts -1 ... 10- and carefully release sealing flange

from bonded joint.
– Drive out oil seal with sealing flange removed.
Installing
Caution


Audi TT 2007 ➤
WARNING


sealing flange.
Note

mm).

Caution



Audi TT 2007 ➤

Note

ing the sealant.
– Tighten sealing flange bolts ⇒ page 54 .to the correctness of information in this document. Copyright by AUDI AG.
with respect

Audi TT 2007 ➤
Note
Servicing clutch ⇒ Rep. Gr. 30
1 - Bolt
❑ Renew
❑ 60 Nm + 90°
⇒ page 60
one position
3 - Sender wheel
er -G28-
ing flange (gearbox
end)”, page 61
ing flange (gearbox
end)”, page 61
5 - Bolt
❑ 4.5 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - Dowel pin permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 2x
dowel pins
❑ Do not damage or bend
when assembling
❑ Engaging on sealing
flange ⇒ page 60
end)
❑ With oil seal
9 - Bolt

Audi TT 2007 ➤

– Engage intermediate plate on sealing flange -top arrow- and
push onto dowel sleeves -bottom arrows-.

– Renew sealing flange bolts (gearbox end).
– Tighten bolts -1 … 6- in 2 stages as follows:
1. Screw in bolts by hand until they make contact.
2. Tighten in stages and in diagonal sequence; final torque 15

Nm.

wheel
♦ Counterhold tool -3067- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Removing
Caution


Audi TT 2007 ➤

-item B-, slacken bolts for dual-mass flywheel.
– Remove bolts and take off dual-mass flywheel.
Installing
Note
Renew bolts for dual-mass flywheel.


Audi TT 2007 ➤
♦ Hexagon screwdriver insert with ball head 4 mm for hexagon

socket head bolts (commercially available)
♦ 3x M6x35 bolt
♦ 2x M7x35 bolt
Pressing out sealing flange with sender wheel
– Detach intermediate plate from sealing flange and dowel pins
-arrows-.

crankshaft is positioned at “TDC”, as shown in illustration.
Note
For illustration purposes, the following procedure is shown with

the engine removed.
– Use hexagon screwdriver insert with ball head 4 mm for hex‐

agon socket head bolts to remove engine speed sender -G28-
-item 1-.
Note
Disregard -item 2-.

Audi TT 2007 ➤
– Remove bolts -1 ... 6- for sealing flange.
Note
The sealing flange is pressed off the crankshaft together with the
sender wheel.
– To press off, screw 3 bolts M6x35 -arrows- alternately into

sealing flange not more than 1/2 turn at a time.
– Take off sealing flange with sender wheel.
Pressing in sealing flange with sender wheel
Note
♦ The sealing flange with PTFE oil seal is fitted with a sealing lip
support ring. This support ring acts as an assembly sleeve and
must not be removed before installation.
♦ Sealing flange and sender wheel 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 must always
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 - Hexagon nut
C - Assembly housing
D - Locating pin
E - Hexagon socket-head bolt
F - Guide pin for diesel engines (black handle)
G - Guide pin for petrol engines (red handle)

Audi TT 2007 ➤
A - Fitting sealing flange with sender wheel onto assembly tool -

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

-A- of threaded spindle.
– Press assembly housing -C- downwards so that it lies on hex‐
agon nut -arrow-.
• Protected
Innerbypart of assembly
copyright. device
Copying for private and assembly
or commercial housing
purposes, in part must
or in whole, is not
align unless
permitted (be level) with
authorised each
by AUDI AG.other.
– Remove the securing clip -arrow- from new sealing flange.
Note
The sender wheel must not be taken out of the sealing flange or
rotated out of position.
• The locating hole -A- on the sender wheel -C- must align with
the marking -B- on the sealing flange.
– Place the sealing flange (with the front side downwards) on a
clean flat surface.

Audi TT 2007 ➤
– Press the sealing lip support ring -A- downwards in direction

of -arrows- until it lies against the flat surface.
• The upper edge of the sender wheel and the front edge of the
sealing flange must align -arrows-.
– Place front side of sealing flange on assembly tool -T10134- ,

so that locating pin -B- can be inserted in hole -A- in sender
wheel.
• Ensure the sealing flange lies flat on the assembly tool.
– Press the sealing flange and sealing lip support ring -B- onto
the surface of the assembly tool -T10134- while tightening the
3 knurled screws -A- so that the locating pin will not slip out of
the hole in the sender wheel.
• Ensure that the sender wheel remains fixed on the assembly
tool when installing the sealing flange.

Audi TT 2007 ➤
B - Installing assembly tool -T10134- with sealing flange on crank‐

shaft flange:
• Crankshaft flange must be free of oil or grease.
• Engine is at “TDC” position.
– Screw hexagon nut -B- to end of threaded spindle.
– Press the threaded spindle of assembly tool -T10134- in di‐
rection of -arrow- until the hexagon nut -B- lies on the assem‐
bly housing -A-.
– Position flat edge of assembly housing towards sealing sur‐

face for sump on cylinder block.
– Secure assembly tool -T10134- to crankshaft flange by screw‐
ing hexagon socket head bolts -A- approx. 5 threads into
crankshaft flange.
– Screw two bolts M7×35 mm -item A- into cylinder block to

guide sealing flange.
C - Securing assembly tool -T10134- onto crankshaft flange:

– Press the assembly housing -C- by hand in the direction of the
-arrow- until the sealing lip support ring -B- lies on the surface
of the crankshaft flange -A-.
Caution
Do not interchange components.

♦ The guide pin for PETROL engines (red handle) -F- MUST
NOT be inserted into the threaded hole in the crankshaft.
– Push guide pin for diesel engine (black handle) -D- into hole
in crankshaft. This brings the sender wheel into its final instal‐
lation position.
– Tighten the two hexagon socket head bolts on assembly tool
hand-tight.

Audi TT 2007 ➤
D - Pressing sender wheel onto crankshaft flange with assembly

tool -T10134- :
• A small air gap must be present between cylinder block and
sealing flange after tightening hexagon nut to 35 Nm.
E - Checking installation position of sender wheel on crankshaft:

– Screw hexagon nut -E- to end of threaded spindle.
– Remove bolts -A- from cylinder block.
– Unscrew knurled screws -B- from sealing flange.
– Detach assembly tool -T10134- .
– Detach sealing lip support ring.
– Apply depth gauge -VAS 6082- to crankshaft flange.
– Measure distance between crankshaft flange -A- and sender

wheel -B-.
• Specification: Distance -a- = 0.5 mm.
– Press sender wheel in further if distance -a- is too small
⇒ page 68 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– If reading matches specification, continue with

with assembly
⇒ page 68 .

Audi TT 2007 ➤
F - Pressing sender wheel in further:

– Secure assembly tool -T10134- -item A- to crankshaft flange
by tightening hexagon socket head bolts hand-tight.
– Press assembly tool onto sealing flange by hand.


again ⇒ page 67 .
– If distance “a” is still to small, tighten hexagon nut on assembly
tool -T10134- to 45 Nm.
– Check installation position of sender wheel
Protected on crankshaft
again ⇒ page 67 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Assembling:

Audi TT 2007 ➤
– Install engine speed sender -G28- -item 1-.
Note
Disregard -item 2-.


Audi TT 2007 ➤
3 Crankshaft
Note
When carrying out repairs, secure engine with engine and gear‐
box support -VW 540- to engine and gearbox support
⇒ page 30 .
1 - Bearing shell
❑ For cylinder block (with
oil groove)
❑ Mark used bearing
shells for re-installation
but not on bearing sur‐
face
2 - Drive chain sprocket
3 - Bearing shell
❑ For bearing cap (without
oil groove)
face
4 - Thrust washers
❑ Different types for cylin‐
der block and bearing
cap
❑ Note location
5 - Bolts
❑ Renew
❑ 65 Nm + 90°
❑ For measuring radial
clearance of crankshaft
tighten to 65 Nm, but not
further
6 - Bearing cap
end
❑ Bearing cap 3 with re‐
cesses for thrust washers
❑ Installation position: retaining lugs on bearing shells in cylinder block and bearing caps must be on the
same side
7 - Crankshaft
❑ There should be no needle bearing fitted in the crankshaft on vehicles with manual gearbox; remove
needle bearing if necessary ⇒ page 72
❑ Measuring
with respect to theaxial clearance
correctness ⇒ page
of information 71
in this document. Copyright by AUDI AG.


Audi TT 2007 ➤
❑ With drive spur gear for balance shaft assembly

Honing di‐ Main bearing journal ∅ Conrod journal ∅
mension mm mm
Basic dimen‐ 54.00 –0.022 50.90 –0.022
sion –0.042 –0.042

♦ Dial gaugepermitted
-VAS 6079-
Procedure
– Bolt dial gauge -VAS 6079- with universal dial gauge bracket
-VW 387- onto cylinder block (as shown in illustration) and set
it against crank web.
Axial clearance:
• New: 0.07 ... 0.17 mm.

shaft
♦ Plastigage
3. Crankshaft 71
Audi TT 2007 ➤
Procedure
Note
♦ Mark used bearing shells for re-installation (but do not mark

bearing surface).
♦ If bearing shells are worn down to nickel layer they must be
renewed.
– Remove bearing cap and clean bearing journal.

shell.
– Fit bearing cap and tighten to 30 Nm. Do not rotate crankshaft.
Radial clearance:
• New: 0.03 ... 0.08 mm.
3.5 Extracting and driving in needle bearing

for crankshaft
Note
Depending on the version of the gearbox, a needle bearing is fit‐

ted in the crankshaft ⇒ Electronic parts catalogue .

♦ Drift -VW 207 C- or centring mandrel -3176-

Audi TT 2007 ➤
♦ -1- Internal puller Kukko 21/1

Pulling out
Driving in
– Drive in needle bearing with drift -VW 207 C- or centring man‐
drel -3176- .
• Installation position: side with lettering faces outwards.
3. Crankshaft 73
Audi TT 2007 ➤
• Installation depth of -a- = approx. 2 mm.
3.6 Pulling spur gear off crankshaft and

shrink-fitting new spur gear
♦ Hotplate (commercially available)
♦ Puller -T10392-
♦ Thrust piece -T10392/1-
♦ Temperature gauge -VAS 6519-
If the balance shaft assembly does not have to be renewed, it is
sufficient just to remove the idler gear.
– Remove balance shaft assembly ⇒ page 144 .

Audi TT 2007 ➤
Pulling off spur gear

– Insert thrust piece -T10392/1- in end of crankshaft.
– Insert puller -T10392- in holes in spur gear, turn clockwise

-arrow- and screw in locking pins -A-.
– Counterhold crankshaft with ring spanner -A- and pull spur

gear off endbyofcopyright.
Protected crankshaft
Copying by screwing
for private in spindle
or commercial with
purposes, ring
spanner -B-.unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
Shrink-fitting spur gear
Note
♦ While heating up the new spur gear, monitor the temperature

with the temperature gauge -VAS 6519- .
♦ When the temperature reaches 200 °C, you have approx. 4
seconds to fit the spur gear on the crankshaft.
♦ A higher temperature increases the amount of time available
(220 °C = approx. 6 seconds).
♦ Make sure the end of the crankshaft is clean.
Caution
Do not exceed a maximum temperature of 240 °C; otherwise

the spur gear can become discoloured and distorted.
3. Crankshaft 75
Audi TT 2007 ➤
– Place the new spur gear flat on a hotplate (commercially avail‐

able) and heat it to at least 200 °C, but not more than 240 °C.
The lettering must face upwards.
– Set temperature gauge -VAS 6519- to measuring range 2.
– Position temperature sensor -VAS 6519/1- on collar of spur
gear (as shown) and read off temperature at temperature
gauge.
WARNING
Risk of burns. Use suitable protective gloves for the following

steps.
– When the required temperature has been reached, pick up the

spur gear with pliers as illustrated.
Note
Take care not to damage the teeth of the spur gear.
– With the aid of fitting tool -10 - 203- , slide spur gear by hand
onto end of crankshaft as far as stop. This must be done with‐
out delay, taking care to keep the gear straight.
– Wait a few minutes to allow the spur gear to cool down, and
then install the balance shaft assembly.
⇒ “1.6 Installing a new balance shaft assembly”, page 146
⇒ “1.7 Re-installing a used balance shaft assembly”, page 149

Audi TT 2007 ➤
Note
Oil spray jet and pressure relief valve ⇒ page 80
1 - Bolt
❑ Renew
contact surface
❑ 30 Nm + 90°
❑ When measuring radial
clearance, tighten used
bolt to 30 Nm but not fur‐
ther
only on the appropriate
conrod
in colour -B-
wards pulley end Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Bearing shell
⇒ page 80
face
❑ Note version: Upper
bearing shell (closest to
piston) is constructed
from a more wear-re‐
sistant material. Distin‐
guishing feature on new
bearing shells: black marking on bearing surface near joint
❑ Check that it is securely seated
❑ Axial clearance: wear limit: 0.37 mm
4 - Conrod
❑ With industrially cracked conrod bearing cap
❑ Separating parts of new conrod ⇒ page 80
❑ Mark cylinder allocation in colour -B-

Audi TT 2007 ➤
5 - Circlip
❑ Renew
6 - Piston pin
7 - Piston
❑ With combustion chamber
❑ Version fitted in vehicle may differ from illustration
❑ Mark installation position and cylinder number ⇒ page 79
❑ Measuring cylinder bore ⇒ page 79
❑ Checking piston projection at “TDC” ⇒ page 81
8 - Piston rings
9 - Piston ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

❑ Offset gap 120° from bottom compression ring
Measuring piston ring gap

of cylinder.
mm mm

Audi TT 2007 ➤
Measuring ring-to-groove clearance

mm mm
Checking piston
Nominal dimension
Note
Renew piston if cracking is visible on piston skirt.
Installation position of pistons and allocation of piston/cylinder

• Arrow on piston crown points to pulley end -arrows-.
Measuring cylinder bore

– Use a cylinder gauge -VAS 6078- to take measurements at 3
points in transverse direction -A- and in longitudinal direction
-B-.
Nominal dimension

Audi TT 2007 ➤

1- Bearing shell with oil drilling -arrow- for conrod.
2- Bearing shell without oil drilling for conrod bearing cap.
– Position bearing shells in centre of conrod and conrod bearing
cap when fitting.
• Distance -a- is the same on both sides.
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 theProtected
conrod by copyright. Copying for private or commercial purposes, in part or in whole, is not
bearing cap by hand, proceed as follows: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– 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-.

Note


Audi TT 2007 ➤
4.2 Measuring piston projection at “TDC”
Note
♦ Piston projection at “TDC” must be measured when installing

new pistons or a short engine.
♦ If the measured values for piston projection are not the same
for all pistons, use the highest value to determine the correct
gasket size.
♦ Depending upon piston projection, install the corresponding
cylinder head gasket according to the table below.

equipment required
♦ Measuring bridge -
VW 382/7- from measuring
tool -VW 382-
♦ Measuring plate -
VW 385/17- from universal
measuring tool -VW 385-

Audi TT 2007 ➤
Procedure
– Secure dial gauge -VAS 6079- with measuring bridge -
VW 382/7- and measuring plate -VW 385/17- to cylinder block
– Measure piston projection at two points marked with
-arrows- for each piston.
Piston projection above top sur‐ Identification
face of cylinder block (No. of holes)
mm
0.91 … 1.00 1
1.01 … 1.10 2
1.11 … 1.20 3

1- Part number
2- Holes
3- Ignore
Note
all pistons, use the highest value to determine the correct gasket
size.

Honing dimension Piston ∅ Cylinder bore ∅
mm mm
• 1)Dimensions including coating (thickness 0.02 mm). The
coating will wear down in service.
4.4 Measuring radial clearance of conrods with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Plastigage
Procedure
journal.

Audi TT 2007 ➤
– Fit conrod bearing caps and tighten to 30 Nm without rotating

crankshaft.
Radial clearance:

Audi TT 2007 ➤

1.1 Toothed belt - exploded view
1 - Toothed belt
❑ Check for wear
❑ Installing (adjusting
valve timing)
⇒ page 91
2 - Idler roller
3 - Nut
❑ 20 Nm
5 - Nut
❑ 20 Nm + 45°
6 - Bolt
❑ 20 Nm
7 - Idler roller
8 - Bolt
❑ 20 Nm + 45°
❑ Renew
10 - Bolt
counterhold tool -
T10051-
❑ 100 Nm
11 - Camshaft hub
⇒ “3.5 Removing and installing camshafts”, page 121
12 - Plug
13 - Cover (rear) for toothed belt
14 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 10 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
15 - High-pressure pump hub
16 - Nut

Audi TT 2007 ➤

18 - Bolt
19 - Idler roller
20 - Bolt
❑ Renew
❑ 50 Nm + 90°
21 - O-ring
❑ Renew
22 - Coolant pump
23 - Bolt
25 - Bolt
❑ Renew
❑ Slacken and tighten with counterhold tool -3415-
❑ Do not additionally oil threads and shoulder
❑ 120 Nm + 90°
Cover for toothed belt (bottom and centre) - tightening torque


Audi TT 2007 ➤

equipment required
♦ 2x Diesel injection pump
locking pin -3359-
-T10264-
♦ Locking
withtool -T10265-
♦ Bit XZN 10 -T10385-
Removing

Audi TT 2007 ➤



sor 1 -G450- .
Note

clear to one side.
V393- .

Audi TT 2007 ➤


– Move coolant pipe (right-side) -arrows- to side (coolant hoses
remain connected).
– Release retaining clips -arrows- and detach cover (top) for

toothed belt.

Note
The poly V-belt tensioner does not have to be locked.

Audi TT 2007 ➤

– Detach toothed belt cover (bottom and centre).
Caution

– Rotate crankshaft by turning bolt on crankshaft sprocket until

• The toothed segment -arrow- must face upwards.
-3359- .
Note
♦ Camshaft sprocket is shown in illustration with toothed belt

removed.
♦ Disregard -item 1-.
– Lock crankshaft sprocket in position with crankshaft stop -

T10050- .
Note

Audi TT 2007 ➤
– Slacken bolts -1- for camshaft sprocket approx. 90°.
Note
Disregard -arrow-.
– Remove bolt -1- for coolant pipe.

– Using bit XZN 10 -T10385- , loosen bolts -2- for high-pressure
pump sprocket approx. 90°.
– Loosen nut -1- for tensioning roller.

– Turn eccentric adjuster of tensioning roller with special
wrench, long reach -T10264-
Protected byanti-clockwise
copyright. Copying for-arrow- until ten‐purposes, in part or in whole, is not
private or commercial
sioning roller can be secured withauthorised
permitted unless lockingbytool
AUDI-T10265-
AG. AUDI AG .does not guarantee or accept any liability

Audi TT 2007 ➤
– Then use special wrench, long reach -T10264- to turn eccen‐

tric adjuster of tensioning roller clockwise -arrow- as far as stop
and tighten nut -1- by hand.
Caution

– Take off toothed belt first from idler roller and then from re‐
maining sprockets.
Note
Perform adjustments on toothed belt only when engine is cold.
Caution Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not


Requirements:
• Tensioning roller is locked with locking tool -T10265- and se‐
cured at right stop with nut.
• Camshaft hub locked with diesel injection pump locking pin

-3359- .
• It should just be possible to turn the sprocket on the camshaft
without axial movement.
Note
Disregard -arrow-.

Audi TT 2007 ➤
• Crankshaft is locked in position with crankshaft stop -T10050- .
• Hub of high-pressure pump locked with diesel injection pump

locking pin -3359- .
• The high-pressure pump sprocket should still just turn, but
there must be no axial movement.
Note
If necessary, apply a screwdriver to bolt heads -1- and turn the

high-pressure pump hub until it can be locked with the locking pin.

Audi TT 2007 ➤
– Turn the camshaft sprocket and high-pressure pump sprocket

in their elongated holes clockwise as far as the stop.
– Install toothed belt in the specified sequence:
1- Crankshaft sprocket
3- Camshaft sprocket
4- Coolant pump sprocket
5- High-pressure pump sprocket
6- Idler roller permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Loosen nut -1- for tensioning roller and detach locking tool -
T10265- .
Note
Disregard -arrow-.
Note
Ensure that tensioning roller is seated properly in toothed belt

cover (rear) -arrow-.
– Position counterhold tool -T10172- on camshaft sprocket as

– Apply force to counterhold tool in anti-clockwise direction
-arrow- and maintain tension.
– Tighten bolts -1- for camshaft sprocket and bolts -2- for high-
pressure pump sprocket in this position.
• Tightening torque: 20 Nm.

Audi TT 2007 ➤
– Carefully turn eccentric adjuster of tensioning roller clockwise

-arrow- using special wrench, long reach -T10264- until point‐
er -2- aligns with the centre of the slot on the base plate.
• Nut -1- must not turn.
– Hold tensioning roller in this position and tighten nut.
– Remove locking pins -3359- and crankshaft stop -T10050- .
Checking valve timing:
Caution


fore “TDC”.
– Fit crankshaft stop -T10050- to crankshaft sprocket again.

• It should now be possible to lock camshaft hub with diesel in‐

jection pump locking pin -3359- .
Note
• It is very difficult to reproduce the locking position of the high-

pressure pump hub. However, a slight deviation -arrow- does
not influence engine operation.

Audi TT 2007 ➤
• Pointer -2- on tensioner roller must be centred between tabs

-1- and -3- on base plate.
Note
The maximum permissible sideways deviation from the specified

position is 5 mm.
♦ Re-adjust valve timing if requirements are not met

⇒ page 95 .
♦ If requirements are met, continue with procedure after adjust‐
ing valve timing correctly as described below ⇒ page 95 .
Re-adjusting valve timing:
– If camshaft hub cannot be locked, withdraw crankshaft stop -
T10050- until pin is clear of bore.
– Turn crankshaft in opposite direction of engine rotation slightly
past “TDC”.
– Now turn crankshaft slowly in direction of engine rotation until
it is possible to lock camshaft hub.
– Loosen bolts for camshaft sprocket after locking hub.
A - If pin of crankshaft stop -T10050- is on left side of bore:

B - If pin of crankshaft stop -T10050- is on right side of bore:
– Turn crankshaft slightly in opposite direction to engine rota‐
tion.
– Turn crankshaft in direction of engine rotation again until pin
of crankshaft stop engages in sealing flange as crankshaft ro‐
tates.
Procedure after adjusting valve timing correctly:
– Remove diesel injection pump locking pin -3359- and crank‐
shaft stop -T10050- .
fore “TDC”.

Audi TT 2007 ➤
– If camshaft hub can now be locked, tighten camshaft sprocket

bolts -1- to final torque ⇒ Item 8 (page 84) .
– Tighten bolts -2- for high-pressure pump sprocket to final tor‐
que ⇒ Rep. Gr. 23 .
Assembling
Note


– Install right wheel housing liner (bottom section) ⇒ Rep. Gr.
66 .
– Install coolant pipe (right-side) ⇒ page 186 .

Audi TT 2007 ➤
2 Cylinder head
Note
2.1 Cylinder head cover - exploded view
1 - Bolts
❑ 5 Nm
2 - Fuel rail
liness ⇒ page 5
❑ Do not attempt to bend
high-pressure pipes to a
different shape
❑ Installing high-pressure
pipes ⇒ Rep. Gr. 23
3 - Bolt
Rep. Gr. 23
4 - Injector
liness ⇒ page 5
⇒ Rep. Gr. 23
5 - Bolt
Rep. Gr. 23
6 - Cover for injector
7 - Bush for fuel rail
leaking
8 - Nut
Rep. Gr. 23
9 - Clamping piece
10 - Cable guide
12 - Gasket
❑ Renew if damaged or leaking
13 - Bolt
❑ Renew if seal is damaged
14 - Sealing cap
15 - Heat shield
2. Cylinder head 97
Audi TT 2007 ➤

– Tighten bolts for cylinder head cover in the sequence -1 ... 7-
to 9 Nm.

cover
Removing

sor 1 -G450- .
Note

– Unfasten clips -arrows- and press toothed belt cover (top) to

right side.

Audi TT 2007 ➤
– Remove injectors ⇒ Rep. Gr. 23 .

– Disconnect vacuum hose -1- from cylinder head cover.
– Move electrical wiring and remaining vacuum hoses clear
-arrows-.

Note
– Remove bolts -arrows- and detach fuel rail from cylinder head
cover.
– Slackenpermitted
cylinder head
unless cover
authorised bolts
by AUDI AG.inAUDI
theAGsequence -7 ...or1-.
does not guarantee accept any liability
– Remove bolts and take off cylinder head cover.
Installing
Note
♦ Renew gasket for cylinder head cover if damaged.

♦ Renew bolts for cylinder head cover if seals on bolts are dam‐
aged.
2. Cylinder head 99
Audi TT 2007 ➤
– Make sure that cylinder head cover is clipped properly to

toothed belt cover.
Note
For illustration purposes, the installation position is shown with

the camshaft sprocket removed.
– Use screwdriver to press clips -arrows- on toothed belt cover

onto cylinder head cover until they engage with a click.
– Make sure there is a clearance between hub and toothed belt
cover.
– Install fuel rail and injectors ⇒ Rep. Gr. 23 .
2.3 Cylinder head - exploded

Protected view
1 - Cylinder head
⇒ page 102
❑ After removal, the cylin‐
der head must not be
put down on the gasket
side with the glow plugs
still installed, because
the glow plugs project
slightly beyond the gas‐
ket surface
❑ Checking for distortion
⇒ page 101
❑ Must not be machined
coolant and engine oil
2 - Washer
3 - Bolt
❑ Renew
❑ Correct sequence when
slackening ⇒ page 111
4 - Centre hex stud
❑ Renew
❑ 20 Nm + 90°
6 - Gasket
❑ Renew
7 - Exhauster pump
⇒ Rep. Gr. 47
8 - Bolt

Audi TT 2007 ➤
9 - Connection
10 - Bolts
11 - Gasket
❑ Renew
12 - Bolts
❑ Renew
❑ 20 Nm + 90°
❑ Renewing ⇒ “2.4 Removing and installing cylinder head”, page 102
❑ Identification ⇒ page 101
15 - Hall sender -G40- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For camshaft position
16 - Bolt
❑ Apply locking fluid when installing; refer to ⇒ Electronic parts catalogue
❑ 10 Nm

– Use straight edge and feeler gauge to measure cylinder head
for distortion at several points.
Note
Cylinder heads must not be reworked on TDI engines.

1- Part number
2- Holes
3- Ignore
Note
♦ Cylinder head gaskets of different thicknesses are fitted de‐

pending on the amount of piston projection ⇒ page 81 .
♦ When renewing only the cylinder head gasket, the new gasket
should have the same identification as the old one.

Audi TT 2007 ➤

– Renew cylinder head bolts.
– Tighten bolts in the sequence -1 ... 10- in 4 stages as follows:
1. Tighten to 30 Nm.
3. Turn 90° further.

♦ Guide pins -3070- with -3070/9- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi TT 2007 ➤
♦ Puller -T10052-
Removing
Caution

– Disconnect earth wire at battery with ignition switched off ⇒

Rep. Gr. 27 .
– Drain coolant ⇒ page 163 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not


– Remove flange shaft (right-side) ⇒ Rep. Gr. 39 .

Audi TT 2007 ➤

Note
Disregard -item 4-.
– Remove nuts -2- and bolts -3-, and detach exhaust gas recir‐
culation pipe.
Disregard -item 1-.
– Remove bolt -2- and banjo bolt -3-.

– Detach support for turbocharger from oil return line.
Note
Disregard -item 1-.

Audi TT 2007 ➤
– Remove nuts -2-.
Note
Disregard -item 1-.
housing.


– Remove exhaust gas temperature sender 1 -G235-
⇒ page 223 Protected
. by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi TT 2007 ➤
Note
– Move clear electrical wiring at turbocharger.

sor 1 -G450- .
Note
Disregard -arrows-.
– Remove upper bolt -1- at bracket for particulate filter and tie
particulate filter to rear.
– Unplug electrical connectors -1- at exhaust gas recirculation

valve -N18- and -3- at intake manifold flap motor -V157- .
– Remove bolt -arrow- for dipstick guide tube.
– Remove bolts -2- for exhaust gas recirculation pipe.
Note
Disregard -item 4-.

Audi TT 2007 ➤
Metal selector relay lever:
– Detach securing clip -4- for gate selector cable from selector
relay lever -2- and pull cable off pin -arrow-.
Plastic selector relay lever:



-1- at bracket.

Audi TT 2007 ➤

Note
– Disconnect vacuum hose -1- from vacuum pump.
Note
Disregard -arrows-.

-G62- .
– Slacken hose clips -arrows- and detach coolant hoses from
connection.
Note
Disregard -item 1-.
– Remove nut -1- andpermitted
bolts -2-, detach
unless exhaust
authorised gas
by AUDI AG. recirculation
pipe. with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi TT 2007 ➤
– Disconnect oil supply line from connection on oil filter bracket.

To do so, counterhold at hexagon flats with an open-end span‐
ner and loosen union nut -3-.
Note
– Remove nut -2- at retaining clip for vacuum line.

– Unscrew oil supply line from connection on turbocharger. To
do so, counterhold at hexagon flats with an open-end spanner
and slacken union nut -3-.
– Remove bolt -arrow- securing rear cover for toothed belt.

– Take toothed belt off camshaft sprocket ⇒ page 86 .
– Remove locking tool -T10265- .

– Remove nut -1-.
Note
Disregard -arrow-.

Audi TT 2007 ➤
– Unplug electrical connector -arrow- at Hall sender -G40- .

– Unplug electrical connectors on glow plugs.

– Unscrew bolt approx.Protected
2 turns. by copyright. Copying for private or commercial purposes, in part or in whole, is not

-1- into hub.

Audi TT 2007 ➤
Note
♦ A second mechanic is required for removal of the cylinder

head.
♦ The toothed belt tensioning roller is detached from the stud
when the cylinder head is lifted out.
♦ The oil return line from the turbocharger is pulled out of the
support when the cylinder head is lifted out.
– Lift cylinder head at gearbox end first and guide out of toothed
belt cover. Make sure toothed belt tensioning roller does not
drop out.
– Take care to place cylinder head down without bending oil re‐
turn line. If necessary, place a block of wood below exhaust
manifold.
Caution
Risk of damage to glow plugs when putting down cylinder

head.
♦ After removal, the cylinder head must not be put down on
the gasket side with the glow plugs still installed, because
the glow plugs project slightly beyond the gasket surface.
Installing

Audi TT 2007 ➤
Caution

cylinder block.
surfaces.
♦ Carefully remove any remaining emeryto the and abrasive ma‐ in this document. Copyright by AUDI AG.
with respect correctness of information
terial.
gasket.
protectors fitted to protect the open valves should not be
removed until the cylinder head is ready to be fitted.
valve gear.
operated.
Note

♦ Cylinder heads must not be reworked on TDI engines.
faces between roller rocker fingers and cams must be oiled.
system.

Audi TT 2007 ➤
– Before fitting cylinder head, remove crankshaft stop -T10050-

and turn crankshaft against normal direction of rotation until
all pistons are positioned approximately equally below “TDC”.
– To centralise, screw guide pins -3070/9- into outer holes on

inlet side.
– Note cylinder head gasket identification:

1- Part number
2- Holes
3- Ignore
Note
♦ If the cylinder head gasket or cylinder head have been re‐

placed, select the new cylinder head gasket according to the
number of holes on the old gasket.
♦ If parts of the crankshaft drive have been renewed, the new
cylinder head gasket must be selected by measuring the pis‐
ton projection at “TDC” ⇒ page 81 .
– Place cylinder head gasket in position.

• Note position of dowel sleeves in cylinder block.
• Installation position of cylinder head gasket: the word
“oben” (top) or the part number should face towards the cyl‐
inder head.
Note
Position tensioning roller on stud when fitting cylinder head.
– Screw in 8 cylinder head bolts by hand until they make contact.

– Unscrew guide pins -3070/9- through bolt holes in cylinder
head and screw in remaining cylinder head bolts by hand until
they make contact.

Audi TT 2007 ➤
Note
Cylinder head bolts do not have to be torqued down again.
– Install rear cover for toothed belt, camshaft hub and sprocket
⇒ page 84 .

-3359- .
Note
– Lock high-pressure pump hub with diesel injection pump lock‐

ing pin -3359- .
Note
Disregard -item 1-.

Audi TT 2007 ➤

note the following:
– Install oil supply line ⇒ Item 6 (page 151) .
– Install air pipe (left-side) ⇒ page 208 .
34 .
⇒ page 223 .
– Install support for turbocharger ⇒ page 198 .
– Install flange shaft (right-side) ⇒ Rep. Gr. 39 .
Gr. 27 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Change engine oil ⇒ Maintenance ; Booklet 810to.the correctness of information in this document. Copyright by AUDI AG.
with respect
2.5 Checking compression

To check compression, select function “Self-diagnosis compati‐
ble systems” in “Guided Fault Finding” ⇒ Vehicle diagnosis, test‐
ing and information system VAS 5051.

Audi TT 2007 ➤
3 Valve gear
Caution

valve gear.
operated.
Note
Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
1 - Oil seal
2 - Bolt
3 - Nut
4 - Retaining frame
❑ With integrated cam‐
shaft bearings
page 121
⇒ page 121
❑ Measuring axial clear‐
ance ⇒ page 117
❑ Measuring radial clear‐
ance ⇒ page 118
6 - Inlet camshaft
❑ Removing andProtected
installing
ance ⇒ page 117


Audi TT 2007 ➤
ance ⇒ page 118

7 - Roller rocker finger
❑ Check roller bearings for ease of movement
❑ With retaining clip
9 - Valve
❑ Must not be machined; only grinding-in is permissible
❑ Valve dimensions ⇒ page 134
❑ Checking valve guides ⇒ page 134
10 - Cylinder head
❑ Renewing: with cylinder head installed ⇒ page 127 , with cylinder head removed ⇒ page 130
12 - Valve spring
14 - Valve cotters
15 - Sealing cap
❑ Renew
❑ Removing sealing cap with retaining frame installed: pierce on one side with an awl and pry out
❑ Installing: drive in without sealant using suitable thrust piece
❑ Installation depth 1 ... 2 mm

– Tighten retaining frame bolts and nuts in the sequence
-1 ... 24- in 2 stages as follows:
1. Screw in bolts and nuts evenly by hand until they make con‐
tact.

3. Valve gear 117

Audi TT 2007 ➤
Procedure

– Secure dial gauge -VAS 6079- with universal dial gauge brack‐
et -VW 387- to cylinder head as shown in illustration.
Axial clearance on inlet camshaft and exhaust camshaft

shafts
♦ Plastigage
Procedure
shafts ⇒ page 117 .

Audi TT 2007 ➤
– Remove retaining frame again.

Radial clearance: 0.035 ... 0.085 mm
3.4 Renewing camshaft oil seal

♦ M12x1.5x75
Procedure
– Remove camshaft sprocket and hub
– Insert thrust piece -3240/1- in camshaft.
3. Valve gear 119

Audi TT 2007 ➤
– Screw inner section of oil seal extractor -3240- two turns out
of outer section (approx. 3 mm) and lock with knurled screw.
pressure).
oil seal.
Note
The sealing lip of the oil seal must not be additionally oiled or
greased.
– Apply guide sleeve of fitting tool -10 - 203- to camshaft as

– Carefully push oil seal -1- over guide sleeve and onto cam‐
shaft.
– Press in oil seal onto stop using thrust piece of fitting tool -10
- 203- and bolt M12×1.5×75.
– Install camshaft sprocket and hub

Audi TT 2007 ➤
♦ Diesel injection pump lock‐

ing pin -3359-
♦ Puller -T10052-
T40094-
T40095-
♦ Clamping tool -T40096/1-

♦ Safety goggles
Removing
• Cylinder head installed.
– Take toothed belt off camshaft sprocket and high-pressure
pump sprocket
⇒ “1.2 Removing and installing toothed belt”, page 86 .
3. Valve gear 121

Audi TT 2007 ➤


-1- into hub.
– Remove exhauster pump ⇒ Rep. Gr. 47 .
– Slacken retaining frame bolts and nuts in the sequence

-24 ... 1-.
– Remove bolts and carefully release retaining frame from bon‐
ded joint.
– Mark fitting location of camshafts for re-installation and re‐
move.
Installing
Caution
Make sure axialunless

bearings in by
retaining frame arenot
not damaged.
permitted authorised AUDI AG. AUDI AG does guarantee or accept any liability
♦ The camshafts MUST be installed using the camshaft fit‐
ting tool -T40094- as described in the following.

Audi TT 2007 ➤
Caution

tion.
WARNING
– Remove remaining sealant from cylinder head and retaining

frame using rotating plastic brush or similar.
Set up camshaft fitting tool -T40094- as follows:

– Secure supports -T40094/9- and -T40094/10- (with -
T40094/11- ) to base plate, as shown in illustration. If neces‐
sary, remove any supports already attached at these posi‐
tions.
– Fit support -T40094/1- onto position -F- and support -

T40094/2- onto position -A-.
3. Valve gear 123

Audi TT 2007 ➤
– Place inlet camshaft in supports -T40094/1- and -T40094/2- .

– Turn inlet camshaft in such a way that it can be locked in “TDC”
position using locking device -arrow 1-.
• Recess -arrow 2- for cylinder head bolt must face outwards.
– Place exhaust camshaft in supports -T40094/9- and -

T40094/10- .
– Lock exhaust camshaft with top section -T40094/11- .
• The lug -1- on the top section must engage in the slot -2- in
the camshaft,
– Place clamping tool -T40096/1- on teeth of exhaust camshaft
in such a way that the two arms of the tool engage on the two
halves of the gear (one in each half, as shown in illustration).
• The wider arm must engage in the wider half of the gear.
– Tighten the clamping tool using the knurled wheel so that the
faces of the gear teeth are in alignment.
– Slide inlet camshaft towards exhaust camshaft, until gear
teeth engage -arrows-.
– Fit retaining frame -1- on camshafts.

• All camshaft bearings must be seated on the camshafts.
– Position camshaft fitting tool -T40095- and fix camshafts in
position in retaining frame, as shown in illustration.
– Detach top section -T40094/11- .

Audi TT 2007 ➤
Note

mm).
Caution
Make sure excess sealant does not contaminate camshaft

bearings.
♦ The beads of sealant must not be thicker than specified.
– Apply beads of sealant onto clean sealing surfaces of cylinder

head as shown in illustration.
• Thickness of sealant beads: 2 ... 3 mm.
Note
♦ The retaining frame should be fitted and secured without de‐

lay, as the sealant starts hardening immediately.
♦ After installing the retaining frame, wait about 30 minutes for
the sealant to dry.
– Take camshafts together with retaining frame, camshaft fitting

tool -T40095- and clamping toolProtected
-T40096/1- outCopying
by copyright. of camshaft
fitting tool -T40094- and insert components carefully
permitted unless authorised by into
AUDI AG.cyl‐AUDI AG does not guarantee or accept any liability
inder head. with respect to the correctness of information in this document. Copyright by AUDI AG.
3. Valve gear 125

Audi TT 2007 ➤
– Screw in retaining frame bolts and nuts in the sequence

-1 ... 24- evenly by hand until they make contact.
– Tighten bolts and nuts ⇒ page 117 .
– Remove camshaft fitting tool -T40095- and clamping tool -
T40096/1- .
note the following:
– Drive new sealing cap ⇒ Item 15 (page 117) into cylinder head
to a depth of approx. 1 ... 2 mm using suitable thrust piece.

Caution

valve gear.
operated.
3.6 Checking hydraulic tappets
Note
♦ The hydraulic compensation elements cannot be serviced.

♦ Irregular valve noises when starting engine are normal.

♦ Feeler gauge 0.20 mm
Procedure
– Start engine and run until radiator fan has started up once.
– Increase engine speed to approx. 2500 rpm for 2 minutes
(perform road test if necessary).
Note
If irregular valve noise disappears but repeatedly re-occurs when

travelling short distances, renew oil retention valve. The oil re‐
tention valve is located in the oil filter bracket
⇒ Item 3 (page 151) .
– If the compensation elements are still noisy, locate the defec‐

tive compensation element as follows:

Audi TT 2007 ➤

cam of supporting element to be tested is facing upwards.
– Press roller rocker finger down -arrow- to determine clearance
between cam and roller rocker finger.
– If it is possible to insert a feeler gauge of 0.20 mm between
cam and roller rocker finger, renew hydraulic compensation
element

inder head installed


with knurled spacer ring -VAS 5161/23-1- and guide plate -
VAS 5161/23-
3. Valve gear 127

Audi TT 2007 ➤
Procedure
-VAS 5161/12- and at stud by screwing on 2 M6 nuts without
shoulder by hand until they make contact.
– Screw sealing pin -VAS 5161/10- into guide plate.

– Screw adapter -VAS 5161/11- hand-tight into corresponding
glow plug thread.
ed hammer to release sticking valve cotters.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi TT 2007 ➤

– Slide knurled spacer ring -VAS 5161/23-1- onto assembly car‐
tridge -VAS 5161/8- .
– Connect adapter to compressed air line using a commercially
available connection piece, and apply constant air pressure.
• Air pressure: at least 6 bar
– Move knurled screw
Protected back and
by copyright. forth
Copying slightly;
for private the valve
or commercial cotters
are thus forced apart
permitted and
unless takenbyup
authorised byAG.
AUDI theAUDI
assembly
AG does notcartridge.
Caution
ling.

3. Valve gear 129

Audi TT 2007 ➤


cotters.
sition.
Assembling

inder head removed

Audi TT 2007 ➤

with knurled spacer ring -VAS 5161/23-1- and guide plate -
VAS 5161/23-
♦ Engine
with respectand
to thegearbox support
information-VAS 6095- Copyright by AUDI AG.
correctness of in this document.
♦ Cylinder head tensioning device -VAS 6419-

Procedure
– Insert cylinder head tensioning device -VAS 6419- into engine
and gearbox support -VAS 6095- .
– Secure cylinder head in cylinder head tensioning device, as
– Connect cylinder head tensioning device to compressed air.
3. Valve gear 131

Audi TT 2007 ➤

where valve stem oil seal is to be removed.
with valve heads.

-VAS 5161/12- and at stud by screwing on 2 M6 nuts without
shoulder by hand until they make contact.

– Slide knurled spacer ring -VAS 5161/23-1- onto assembly car‐
tridge -VAS 5161/8- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Attach pressure fork -VAS 5161/2-
with to snap-in
respect device and
to the correctness push in this document. Copyright by AUDI AG.
of information

Audi TT 2007 ➤
Caution
Make sure valve stem oil seals are Protected

not damaged when instal‐
ling.



cotters.
sition.
Assembling
3. Valve gear 133

Audi TT 2007 ➤
Note

is permitted.

∅a mm 28.10 26.00
∅b mm 5.975 5.965
c mm 99.30 99.10
α ∠° 45 45
Note
Valve seats may not be machined due to the very small toleran‐
ces.
3.11 Checking valve
permitted unless guides

Audi TT 2007 ➤
Procedure
Note


• End of valve stem must be flush with guide.
new valves.
Note

faces.
3. Valve gear 135

Audi TT 2007 ➤
17 – Lubrication
1 Oil pump, sump, balance shaft as‐
sembly
Note

oil spray jets, engine oil cooler and oil filter.
1.1 Oil pump, sump, balance shaft assembly - exploded view
1 - Sump
⇒ page 139
2 - Bolt
❑ 20 Nm
3 - Suction pipe
4 - Bolt
❑ 9 NmProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - O-ring with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Renew
6 - Oil pump
⇒ page 144
that the two dowel
pump are fitted onto bal‐
ance shaft assembly
7 - Oil pump drive shaft
8 - Circlip
❑ Must fit securely in
groove
❑ Renew circlip if dam‐
aged or stretched
9 - Spur gear for balance shaft
10 - Bolt
❑ Renew
❑ 20 Nm + 90°
11 - Hub
❑ For idler gear

Audi TT 2007 ➤
❑ Renew
12 - Bolt
❑ Renew
❑ 90 Nm + 90°
13 - Thrust washer
❑ For idler gear
❑ Renew
14 - Idler gear
❑ Renew
❑ To achieve the correct backlash a coating is already applied to the new idler gear. The coating is worn
down rapidly and the backlash is then correct
❑ On idler gears with coating applied to teeth on parts of circumference only, a white dot indicates correct
installation position
❑ If there is no white dot, the complete circumference of the idler gear is coated
❑ Installation position: Part No. must be visible.
❑ Make sure thrust washer is properly seated ⇒ page 138
15 - Thrust washer
❑ For idler gear
❑ Renew
❑ When installing idler gear, apply grease to hold washer on balance shaft assembly
16 - Crankshaft gear permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Re-installing "old" balance shaft assembly ⇒ page 149
❑ Installing new balance shaft assembly ⇒ page 146
❑ Before installing, check that the two dowel sleeves for centring balance shaft assembly are fitted on
cylinder block
18 - Bolt
❑ Renew
19 - Bolt
❑ 9 Nm
21 - Bolt
❑ 9 Nm
22 - Seal
❑ Renew
24 - Bolt
❑ Self-locking
❑ Renew
❑ 9 Nm
25 - Bolt
26 - Seal
❑ Renew

Audi TT 2007 ➤
27 - Oil drain plug

❑ 30 Nm
Guide tube for oil dipstick - tightening torque


– Renew bolts for sump.
– Tighten bolts in 3 stages and in diagonal sequence as follows:
1. Pre-tighten bolts -1 ... 20- in diagonal sequence to 5 Nm.
2. Tighten bolts -arrows- securing sump to gearbox to 40 Nm.

to 15 Nm.
Installation position of thrust washer
Caution

♦ Makepermitted
sure that unlessthrust washer
authorised by AUDI -A- does
AG. AUDI AG not
does slip out oforthe
not guarantee accept any liability
recesseswith in the tobalance
respect shaft
the correctness assembly
of information -arrows-
in this document. when
Copyrightfit‐
by AUDI AG.
ting the idler gear. If this is neglected, the thrust washer
can become trapped. If necessary, apply grease to hold
washer on balance shaft assembly.

Audi TT 2007 ➤
Balance shaft assembly - tightening torque and sequence

– Renew bolts securing balance shaft assembly.
1. Screw in bolts -1 ... 8- by hand until they make contact.
2. Pre-tighten bolts in the sequence -1 ... 8- to 6 Nm.
3. Tighten bolts -5- and -7- to 13 Nm.
4. Tighten bolts -1, 2, 3, 4, 6, 8- to 20 Nm.
5. Turn bolts -1 … 8- 90° further.

Removing
– Drain off engine oil ⇒ Maintenance ; Booklet 810 .
– Remove bolts -1- and detach oil level and oil temperature
sender -G266- -item 4-.
Installing
Note
Renew seal -2- and self-locking bolts -1-.permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
810 .


Audi TT 2007 ➤
♦ Allen key, long reach -T10058-

♦ Safety goggles
Removing

Audi TT 2007 ➤

Note
– Remove bolt -arrow- at air pipe (left-side).


Audi TT 2007 ➤

for sump.
– Remove bolts securing sump to gearbox -arrows-.

– Slacken bolts -1 ... 20- in diagonal sequence and remove.
– Carefully release sump from bonded joint.
Installing
Caution

tion.
WARNING



Audi TT 2007 ➤
Note

mm).
Caution

– Apply bead of sealant onto clean sealing surface of sump as

illustrated.

rear sealing flange -arrows-.
sealant.

• The sump must make flush contact with intermediate plate/
gearbox flange.
Note

sure that sump is positioned flush with cylinder block at gear‐
box end.
oil.

⇒ page 175 .
810 .

Audi TT 2007 ➤
1.4 Removing and installing oil pump

♦ Circlip pliers, commercially available
♦ Bolt M3
Removing
– Remove bolts -arrows- and detach suction pipe from oil pump.
– Remove circlip -1- using circlip pliers.

– Screw in an M3 bolt -2- and pull drive shaft out of oil pump
-arrow-.
– Remove bolts -3, 4, 5- and detach oil pump.
Caution
The bolt on the idler gear must NOT be loosened.
Installing
Note
♦ Fit new O-ring.

♦ Renew circlip if damaged or stretched.
♦ Circlip must fit securely in groove.
– If no dowel sleeves for centring the oil pump are fitted in the
balance shaft assembly, install missing dowel sleeves.
810 .
1.5 Removing balance shaft assembly


Audi TT 2007 ➤
Procedure
Caution


crankshaft is positioned at “TDC”.
– Lock crankshaft in position with crankshaft stop -T10050- .
Note

– Remove bolts and detach balance shaft assembly with oil
pump.
Note
♦ Installing a new balance shaft assembly ⇒ page 146 .

♦ Re-installing a used balance shaft assembly ⇒ page 149 .

Audi TT 2007 ➤
1.6 Installing a new balance shaft assembly

♦ Bits -T10099-
♦ Special tool -T10393-

Procedure
• Crankshaft locked in position with crankshaft stop -T10050- .
Note
♦ The spur gear drive of the balance shaft assembly must be

installed with a backlash of 0.038 ... 0.072 mm.
♦ To achieve the correct backlash, Protected
a suitably thick coating is al‐
ready applied to the new idler gear.
♦ The coating is worn down rapidly and the backlash is then

correct.
♦ On idler gears with coating applied to teeth on parts of cir‐
cumference only, a white dot indicates correct installation
position.
♦ If there is no white dot, the complete circumference of the idler
gear is coated.
♦ A new balance shaft assembly must always be installed in
conjunction with a new idler gear which has the correct coat‐
ing.

Audi TT 2007 ➤
Caution

♦ Before positioning balance shaft assembly, slacken off
bolt for idler gear as specified below, but not further. In‐
stallation position of thrust washer ⇒ page 138
– Slacken bolt -1- for idler gear by approx. 45°.

– Install balance shaft assembly on cylinder block. If the idler

gear is only partially coated it must be installed in the correct
position:
• White dot -arrow- on idler gear must be aligned centrally with
crankshaft.
• Idler gears not marked with a white dot can be installed in any
position.
Note
Due to the gear ratio, the white dot -arrow- will not return to its
original position after the crankshaft has been rotated.

Audi TT 2007 ➤

shaft as required.
balance shaft -arrow-.
– Carefully fit balance shaft gear onto balance shaft; to do so,

push idler gear slightly to one side.
• The threaded holes in the balance shaft should be aligned as
centrally as possible with the elongated holes in the balance
shaft gear.
Note
If it is not possible to align the elongated holes in the balance shaft

gear with the threaded holes, you must turn the gear some teeth
further as required and then fit it again.
– Tighten bolts -arrows- for balance shaft gear.

– Remove locking tool -T10255- .

Audi TT 2007 ➤
Note
The following three steps have to be performed simultaneously

(a second mechanic is therefore required):
– Push idler gear -3- firmly in direction of -arrow- into teeth on

drive gear -2- and balance shaft gear -1-. If necessary use a
suitable wooden tool.
– At the same time, turn balance shaft gear slightly anti-clock‐
wise.
– Tighten bolt securing idler gear.
Note
After installation the idler gear must have no backlash. This can
be checked by exerting light pressure by hand.

note the following:
– Top up engine oil and check oil level ⇒ Maintenance ; Booklet
810 .
1.7 Re-installing a used balance shaft as‐

sembly
Procedure
Note
♦ If re-installing the "old" balance shaft assembly and neither the

drive gear on the crankshaft nor the crankshaft itself have
been renewed, proceed as described in the following. It is also
essential that the idler gear has NOT been slackened.
♦ If the bolt for the idler gear has been slackened or the drive
gear on the crankshaft or the crankshaft itself have been re‐
newed, you must install a new idler gear with the appropriate
coating. Procedure for installation
⇒ “1.6 Installing a new balance shaft assembly”, page 146 .

Audi TT 2007 ➤

shaft as required.
balance shaft -arrow-.
• With the balance shaft locked in position, the idler gear must
engage in the drive gear on the crankshaft.
• Idler gear must have noticeable backlash.
note the following:
810 .

Audi TT 2007 ➤
2 Oil filter bracket and engine oil cooler
2.1 Oil filter bracket and engine oil cooler - exploded view
1 - Gasket
❑ Renew
2 - Bolt
❑ Renew
❑ With oil retention valve
stalling oil filter bracket
with engine oil cooler”,
page 153
4 - Seal
❑ Renew
5 - Connection
❑ 33 Nm
6 - Oil supply pipe
❑ To turbocharger
❑ Installation sequence:
– Screw in union nuts by
hand until they make
contact.
– Tighten union nuts to 22

Nm.
– Secure bracket.

❑ With seal
❑ Renew seal
❑ Opening/closing pressure 0.7 bar
❑ Brown insulation Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing ⇒ pageunless
❑ 20 Nm
8 - Sealing cap
❑ 25 Nm
9 - O-ring
❑ Renew
11 - Seal
❑ Renew

Audi TT 2007 ➤

❑ Diagram of coolant hose connections ⇒ page 161
⇒ “2.2 Removing and installing oil filter bracket with engine oil cooler”, page 153
13 - Seal
❑ Renew
14 - Screw plug
❑ 25 Nm
Oil filter bracket - tightening torque and sequence

– Renew bolts for oil filter bracket.
– Fit bolts at top left and bottom right first.
– Tighten all bolts -arrows- in diagonal sequence and in 2 stages
as follows:
Installation position of seal for engine oil cooler

– Fit seal -2- so it can be attached to all tabs on engine oil cooler
-1-.
• The oil drilling -arrow- must not be covered by the seal.

Audi TT 2007 ➤
2.2 Removing and installing oil filter bracket with engine oil cooler

equipment required
♦ Used oil collection and ex‐
traction unit -V.A.G 1782-
V.A.G 1921-
Removing
– Move wiring harnesses -arrows- and electrical connector -1-
clear at bracket and at air pipe.

Audi TT 2007 ➤
– Clamp off coolant hoses with hose clamps up to 25 mm -3094-

– Disconnect coolant hoses -1-.
– Unscrew bolt -1- and detach bracket for wiring harness.
Note
Disregard -arrows-.

G31- and detach air pipe (front).

Audi TT 2007 ➤

– Press pump for exhaust gas recirculation cooler -V400- to
side.
Note
– Pull oil dipstick out slightly and remove bolts -arrows-.

– unless
permitted Pull guide
authorisedtube forAG.
by AUDI oilAUDI
dipstick
AG doesupwards out
not guarantee of cylinder
or accept any liabilityblock
andtopush
with respect to oneof side.
– Unplug electrical connector -1- at oil pressure switch -F1- us‐

ing assembly tool -T10118- .
– Remove oil pressure switch -F1- -item 2-.
– Disconnect oil supply line from connection on oil filter bracket.
To do so, counterhold at hexagon flats with an open-end span‐
ner and loosen union nut -3-.

Audi TT 2007 ➤
– Place used oil collection and extraction unit -V.A.G 1782- be‐
low engine.
– Unscrew bolts -arrows- and remove oil filter bracket.
Installing
Note

– Install oil filter bracket ⇒ page 152 .

⇒ page 175 .
– Install air pipe (front) ⇒ page 208 .
– Install radiator cowl permitted
⇒ pageunless
192authorised
. by AUDI AG. AUDI AG does not guarantee or accept any liability
810 .

switch -F1-

Audi TT 2007 ➤
Removing

– Remove oil pressure switch -F1- -item 2-.
Note
Disregard -item 3-.
Installing
Installation
permitted is carried
unless authorised by AUDIout
AG. in the
AUDI AGreverse order;ornote
does not guarantee acceptthe following:
any liability
Note
Renew seal.


Audi TT 2007 ➤
Procedure
• Oil level OK
– Connect oil pressure tester -V.A.G 1342- to bore for oil pres‐
sure switch.
– Screw oil pressure switch -F1- -item 2- into threaded hole in
oil pressure tester.
– Connect brown wire -1- of oil pressure tester to earth (–).
– Connect voltage tester -V.A.G 1527B- with adapter leads from
auxiliary
Protected measuring
by copyright. Copying forset -V.A.G
private 1594C-
or commercial to oil
purposes, pressure
in part or in whole,switch
is not
-F1- and battery positive (+).
Note
Renew oil pressure switch -F1- if LED lights up at this stage.
Note

when starting.

– Renew oil pressure switch -F1- if LED does not light up.
– Install oil pressure switch -F1- ⇒ page 156 .

Audi TT 2007 ➤

Procedure
• Oil level OK
– Connect oil pressure tester -V.A.G 1342- to threaded hole for
oil pressure switch -F1- .
– Screw a used oil pressure switch into threaded hole on oil
pressure tester -V.A.G 1342- to seal hole.
– Start engine.
• Oil pressure at idling speed: at least 0.8 bar.
– Install oil pressure switch -F1- ⇒ page 156 .
2.6 Engine oil


⇒ Maintenance ; Booklet 810

Audi TT 2007 ➤
19 – Cooling
1 Cooling system
WARNING

hot.
Note
♦ Secure all hose connections with the correct type ofunless

hoseauthorised
clips by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
(same as original equipment) ⇒ Electronic parts catalogue
with respect .

must align.

Audi TT 2007 ➤

Connection diagram for coolant hoses without 4/2-way valve:
1 - Radiator
with fresh coolant
perature sender
permitted -G83-
⇒ page 178
5 - Thermostat
6 - Coolant pump
block
with fresh coolant
❑ With filler cap
⇒ page 196
cooler
with fresh coolant
sender -G62-
⇒ page 176
with fresh coolant
12 - Gear oil cooler
❑ For dual-clutch gearbox
❑ If renewed, refill system with fresh coolant
Connection diagram for coolant hoses with 4/2-way valve:

Audi TT 2007 ➤
1 - Radiator
with fresh coolant
⇒ page 178
stat
⇒ page 173
6 - Coolant pump
block
with fresh coolant
❑ With filler cap
⇒ page 196
cooler
with fresh coolant
sender -G62-
⇒ page 176
12 - Gear oil cooler
❑ For dual-clutch gearbox

Audi TT 2007 ➤

equipment required
-VAS 6208-
V.A.G 1921-
-VAS 6096-
Draining
Note

Audi TT 2007 ➤
WARNING

hot.

Note
To prevent coolant from entering, seal off connection on charge

air cooler with a clean plug from engine bung set -VAS 6122- .
– Lift retaining clip -arrow-, disconnect coolant hose (bottom)

Audi TT 2007 ➤



Audi TT 2007 ➤
– As an additional step, open hose clip -arrow-, disconnect cool‐

ant hose at top of engine oil cooler and drain off remaining
coolant.
Filling
Note

water and coolant additive. Mixture ratio ⇒ page 166
♦ Use only the coolant additive listed in the ⇒ Electronic parts
catalogue . Other coolant additives could seriously impair in
particular the anti-corrosion properties. The resulting damage
gine damage.
♦ The specified coolant (based on recommended mixture ratio)
⇒ page 166 prevents frost and corrosion damage and stops
year round with the correct coolant additive.
ical climates.
coolant concentration can be increased, but only up to 60%
(this gives frost protection down to about –40 °C). If the con‐
centration exceeds 60%, frost protection decreases again and
cooling efficiency is also impaired.
♦ If radiator, heat exchanger, cylinder head, cylinder head gas‐
ket or cylinder block have been renewed, do not re-use old
coolant.
♦ To check anti-freeze protection in cooling system, use refrac‐
tometer -T10007- .
Recommended mixture ratio for coolant

C
C
C
♦ Coolant ⇒unless
permitted Electronic parts
authorised by AUDI catalogue

Audi TT 2007 ➤
– Connect coolant hose with plug-in connector to radiator (bot‐

tom) ⇒ page 191 .
– Connect coolant hose (bottom) at pump for exhaust gas re‐

circulation cooler -V400- -arrow-.
– Connect coolant hose (top) to enginewith
oil respect
cooler -arrow-.
– Fill reservoir of cooling system charge unit -VAS 6096- with at

least 8 litres of premixed coolant (according to recommended
ratio):
ant expansion tank.
V.A.G 1274/8- .
Note

rection of flow).

Audi TT 2007 ➤

zone.
in the green zone.
sequent filling.
Note
ess.
♦ Check cooling system for leaks if unless
the vacuum isAUDI
notAG.
main‐
permitted authorised by AUDI AG does not guarantee or accept any liability
tained. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Open valve -A-.
is then filled.
expansion tank.

– Install air ducts.
– On vehicles with auxiliary heater, switch heater on (for about
30 seconds) and then off again.
– Set temperature to “HI”.
– Switch off air conditioner compressor (press AC button, LED
in button should not light up
rpm.
running.
– Close filler cap on coolant expansion tank.

Audi TT 2007 ➤

is warm.

Audi TT 2007 ➤
2 Coolant pump and thermostat
2.1 Coolant pump and thermostat - exploded view
1 - Bolt
❑ 15 Nm
2 - Coolant pump
⇒ page 170
3 - O-ring
❑ Renew
4 - O-ring
❑ Renew
stat
❑ Installed according to
version
⇒ page 173
❑ The thermostat is loca‐
ted in the interior of the
4/2-way valve and can‐
not be renewed sepa‐
rately Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 15 Nm
7 - Connection
❑ Installed according to
version
8 - Thermostat
⇒ page 171
❑ Only fitted on version
with connection -7-

Removing

Audi TT 2007 ➤
– Unscrew bolts -1- and remove coolant pump -2-.

Installing
Note
Fit new O-ring.
– Clean and smoothen

Protected by sealing surface
copyright. Copying for O-ring.
– Lightly lubricatewith
O-ring
respect -3-
to thewith coolant.

wards.
2.3 Removing and installing thermostat

Removing

Audi TT 2007 ➤

V157- .
– Release hose clip -4- and disconnect air hose from intake
manifold flap motor -V157- .
Note
Disregard -items
permitted1, 2-. authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
unless

-V157- .
– Release hose clip -1- and detach coolant hose from connec‐
tion.
– Unscrew bolts -arrows- and remove connection.
– Turn thermostat -2- approx. 90° anti-clockwise -arrow- and

take thermostat out of connection.
Installing
Note
Fit new O-ring.

Audi TT 2007 ➤
– Fit thermostat -3- with O-ring -2- into connection -1-.

• Installation position: cross-piece on thermostat must be hori‐
zontal.
– Lubricate O-ring with coolant.
– Install intake manifold flap motor -V157- ⇒ Rep. Gr. 23 .
2.4 Removing and installing 4/2-way valve

with thermostat
Removing
Note
The thermostat is located in the interior of the 4/2-way valve and

cannot be renewed separately.

– Remove alternator ⇒ permitted
Electrical
unlesssystem; Rep.
authorised by AUDI Gr. 27 AG
AG. AUDI . does not guarantee or accept any liability
– Remove throttle valve module -J338- ⇒ Rep. Gr. 23 .
– Detach coolant hoses from connections -A, B and D-.

– Pull valve out of cylinder block and detach connection -C- from
coolant pipe to the left.
Installing
page 170 .
Note
Fit new O-ring.
– Install throttle valve module -J338- ⇒ Rep. Gr. 23 .

– Install alternator ⇒ Electrical system; Rep. Gr. 27 .

Audi TT 2007 ➤

approx. 87 °C approx. 102 °C 1) at least 8 mm
• 1) Cannot be tested.

Audi TT 2007 ➤
3 Coolant pipes, coolant temperature

senders, coolant circulation pump
3.1 Coolant pipes, coolant temperature senders, coolant circulation pump - ex‐
ploded view
1 - Grommet
2 - Sleeve
3 - Bolt
❑ 2.7 Nm
4 - Bolt
❑ 40 Nm
5 - Bracket
❑ For pump for exhaust
gas recirculation cooler
-V400-
6 - Coolant pipe (front)
⇒ page 180
7 - Protected
O-ring by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ withRenew
8 - Coolant pipe (right-side)

⇒ page 186
9 - O-ring
❑ Renew
10 - Radiator outlet coolant
⇒ page 178
11 - Retaining clip
12 - Bolt
❑ 9 Nm
13 - Nut
❑ 9 Nm
14 - Bolt
❑ 9 Nm
15 - Coolant pipe
16 - Bolt
❑ 9 Nm
17 - Gasket
❑ Renew
18 - Connection

Audi TT 2007 ➤
19 - Bolt
❑ 9 Nm
20 - Retaining clip
22 - O-ring
❑ Renew
23 - Centre hex stud
❑ 9 Nm
24 - Bolt
❑ 9 Nm
25 - Coolant pipe (left-side)
26 - Bolt
❑ 9 Nm
27 - Bolt
❑ 40 Nm
28 - Bolt
❑ 13 Nm
3.2 Removing and installing

Protected coolant temper‐
ature sender -G62- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Removing
• Engine cold.

Audi TT 2007 ➤

– Use removal lever -80 - 200- to move electrical wiring and ho‐
ses at air pipe (left-side) clear.
– Release hose clip -3- and push air pipe (left-side) with coolant
pipe towards the left.
Note

-G62- .
Note
Place a cloth underneath the connection to catch escaping cool‐

ant.
– Pull off retaining clip -1- and pull coolant temperature sender
-G62- out of connection.
Note
Disregard -arrows-.
Installing
Note
♦ Fit new O-rings.

♦ To avoid loss of coolant, insert new coolant temperature send‐
er -G62- immediately into connection.


Audi TT 2007 ➤

Removing
• Engine cold.

– Pull off retaining clip -1- and pull radiator outlet coolant tem‐
perature sender -G83- out of connection on coolant pipe.
Installing
Note
♦ Fit new O-ring.

♦ To avoid loss of coolant, fit new radiator outlet coolant tem‐
perature sender -G83- into coolant pipe immediately.
3.4 Removing and installing pump for ex‐

haust gas recirculation cooler -V400-

Audi TT 2007 ➤
Removing
–Protected
Remove bolts
by copyright. -arrows-.
– with
Release
respect to hose clip -2-
the correctness and push
of information front
in this air pipe
document. towards
Copyright by AUDIthe
AG.right.
Note

Audi TT 2007 ➤
Note
Place a cloth underneath pump for exhaust gas recirculation cool‐

er -V400- to catch escaping coolant.

hose clips -3- and disconnect coolant hoses.
– Unscrew bolts -1- and remove pump for exhaust gas recircu‐
lation cooler -V400- .
Note
Disregard -arrow-.
Installing
Note


(front)

Audi TT 2007 ➤
Removing
– Remove oil filter bracket ⇒ page 153 .
housing.
Metal gate relay lever:
– Detach securing clip -4- for gate selector cable from gate relay
lever -2- and pull cable off pin -arrow-.
Plastic gate relay lever:

– Press gate relay lever towards front -arrow 3-.


Audi TT 2007 ➤

V157- .
– Release hose clip -4- and disconnect air hose from intake
manifold flap motor -V157- .
– Remove bolt -2- on exhaust gas recirculation pipe.
Note

-V157- .

– Move vacuum hoses -arrows- on air pipe clear.

Audi TT 2007 ➤

Note
– Remove nut -1- and bolts -2-, detach exhaust gas recirculation
pipe.
– Remove nut -2- at retaining clip for vacuum line.


Audi TT 2007 ➤
– Remove electrical connector -2- for Hall sender -G40- from

bracket and unplug connector.
– Detach bracket from coolant pipe (front).
– Remove bolts -arrows- and detach coolant pipe (front) from
left side of cylinder block.
Installing
• Tightening torques ⇒ page 151 , ⇒ page 175 .
Note
♦ Renew gaskets, seals and O-rings. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Hose connections and air pipes and hoses must
with respect be
to the free ofofoil
correctness information in this document. Copyright by AUDI AG.

– Lightly lubricate O-ring with coolant and slide O-ring onto cool‐
ant pipe (front).
– Push coolant pipe (front) into cylinder block.
– Install oil supply line ⇒ page 151 .
– Install exhaust gas recirculation pipe ⇒ page 227 .
34 .
– Install oil filter bracket ⇒ page 153 .

(left-side)

Audi TT 2007 ➤
♦ Protected
Drip tray for workshop
by copyright. hoistor-VAS
Copying for private 6208-

Audi TT 2007 ➤
Removing

clear at bracket.

hose clips -1- and -4- and disconnect coolant hoses from cool‐
ant pipe (left-side).
– Detach coolant pipe (left-side).
Installing
Note


(right-side)

Audi TT 2007 ➤
Removing

Audi TT 2007 ➤



Audi TT 2007 ➤
hose clips -arrows- and disconnect coolant hoses from coolant
pipe (right-side).
– Remove nut -1- and bolt -2- and take off coolant pipe (right-
side).
Installing
Note
– Check
Protected coolant
by copyright. level
Copying ⇒ page
for private 169 . purposes, in part or in whole, is not
or commercial

Audi TT 2007 ➤
WARNING

4.1 Radiator and radiator fans - exploded view with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ With radiator fan control
unit -J293-
⇒ page 194
2 - Nut
❑ 5 Nm
3 - Radiator cowl
⇒ page 192
⇒ page 191
5 - O-ring
❑ Renew
6 - Radiator
⇒ page 191
with fresh coolant
7 - O-ring
❑ Renew
⇒ page 191
9 - Bolt
❑ 5 Nm
10 - Nut
❑ 5 Nm
11 - Bolt
❑ 5 Nm

Audi TT 2007 ➤
Connecting coolant hose with plug-in connector

– Lightly lubricate new O-ring with coolant and fit O-ring in cool‐
ant hose.
– Press coolant hose onto connection -1- until it engages audi‐
bly.

Removing
Note
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.

from radiator.

Audi TT 2007 ➤

-item B-.
Note
Disregard -item C-.
– Remove bolts -arrows- at rear and lift out radiator.
Installing
Note
♦ Renew seals and O-rings.



Removing

Audi TT 2007 ➤
bottom -2-.
rier.
Note

Audi TT 2007 ➤

– Remove bolts -bottom arrows- and lift out air cowl.
Installing
4.4 Removing and installing radiator fans -

V7- / -V177-
Removing
– Unplug electrical connector -1- and move clear.
Installing
Note



Audi TT 2007 ➤

Audi TT 2007 ➤
Procedure
WARNING

hot.
♦ Cover filler cap on coolant expansion tank with a cloth and
open carefully to dissipate pressure.


1.4 ... 1.6 bar.
scribed.

Audi TT 2007 ➤
1 Turbocharger
1 - Vacuum unit
❑ On turbocharger
❑ With position sender for
charge pressure posi‐
tioner -G581-
3 - Intake silencer
4 - Air cleaner housing
5 - To brake servo
6 - Connection piece
❑ On exhauster pump
tion
N345-
function ⇒ page 230
10 - Vacuum unit
❑ For change-over func‐
tion for exhaust gas re‐
circulation cooler
1. Turbocharger 197
Audi TT 2007 ➤
1 - Banjo bolt
❑ 60 Nm
2 - O-rings
❑ Renew
3 - Bolt
❑ 15 Nm
4 - Oil return pipe
5 - Nuts
❑ 20 Nm
6 - Heat shield
7 - Gasket
❑ Renew
8 - Gasket
❑ Renew
9 - Pulsation damper
10 - Bolt
❑ 10 Nm
11 - Bolt
❑ 8 Nm
12 - Bracket
13 - Heat shield
14 - Turbocharger with position
sender for charge pressure po‐
sitioner -G581-
turbocharger
⇒ page 199
❑ Renewing position sender for charge pressure positioner -G581- ⇒ page 202
15 - Bolt
❑ 9 Nm
16 - Oil supply pipe
❑ Check for obstructions
❑ Before installing, fill turbocharger with engine oil at connection for oil supply pipe
❑ Tightening union nuts ⇒ Item 6 (page 151)
17 - Gasket
❑ Renew
18 - Nut
❑ 20 Nm
19 - Gasket
❑ Renew
20 - Nut permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi TT 2007 ➤
21 - Pipe
❑ To exhaust gas recirculation cooler
23 - Bolt
❑ 20 Nm
24 - Support
❑ For turbocharger
25 - O-rings
❑ Renew

Removing
Caution
If the turbocharger has suffered mechanical damage (e.g.

if necessary.

1. Turbocharger 199
Audi TT 2007 ➤

– Move vacuum hoses -arrows- on air pipe clear.


sender 1 -G235- and move electrical wire clear.
Note


– Release hose clip -3- and push air pipe (left-side) from turbo‐
charger towards the left.
Note

Audi TT 2007 ➤

Note
– Unscrew nuts -1- and detach heat shield (left-side) from ex‐
haust manifold.
– Remove nuts -2- and bolts -3-, and detach exhaust gas recir‐
culation pipe.
– Remove bolts -1- and detach oil return pipe.
Note
– Remove nuts -arrows- and detach turbocharger with exhaust

manifold from cylinder head.
1. Turbocharger 201
Audi TT 2007 ➤
– Move clear electrical wiring for exhaust gas temperature send‐

er 1 -G235- -item 1-.
– Remove bolts -arrows- and detach heat shield.
– Take out turbocharger with exhaust manifold from below, at
the same time pushing engine/gearbox assembly slightly for‐
wards.
Installing
Note

♦ Fill turbocharger with engine oil at connection for oil supply
pipe.
stalling.

1.4 Renewing vacuum unit with position
sender for charge pressure positioner -

G581-
♦ Socket -T10422-
♦ Ring spanner -T10423-
♦ Vehicle diagnostic tester
Caution
The tools listed, in particular the socket -T10422- , are only

intended for use according to the procedure described in the
following; do NOT use the tools for other bolted connections.
There is danger of deformation if the specified torques are ex‐
ceeded.

Audi TT 2007 ➤
Note
A replacement part set is available ⇒ Electronic parts catalogue

for renewing the vacuum unit with position sender for charge
Removing
– Remove air cleaner housing with air mass meter and connect‐
ing pipe ⇒ Rep. Gr. 23 .
– Press release tabs and disconnect crankcase breather con‐
necting pipe -1- from cylinder head cover.
– Unscrew captive bolt -2-, swivel air pipe with connection to rear
and detach from turbocharger.
– Seal opening on turbocharger with sealing cap from replace‐
ment part set.
– Detach heat shield sleeve around electrical connector -1-.

– Depending on version, remove nut -arrow- securing oil supply

line/vacuum line to cylinder head.
1. Turbocharger 203
Audi TT 2007 ➤
Make an improvised tool (14 mm) to counterhold connection for

oil supply line, as shown.
♦ A = 110 mm
♦ B = 25 mm
Caution
It is important that you counterhold connection when loosening

oil supply line. Risk of further damage occurring later.
– Counterhold connection using improvised tool and remove oil

supply line -arrow- from turbocharger.
– Seal opening for oil supply line in turbocharger with plug from
replacement part set.
– Counterhold lock nut -B- with ring spanner -T10423- and re‐
move securing nut -A- from control rod using socket -T10422- .
– Unscrew bolts -arrows- securing vacuum unit and detach vac‐

uum unit -A-.
Installing
Caution
Only use new bolts and nuts from replacement part set.
– If necessary, remove bottom nut securing control rod from new

vacuum unit.
– Screw lock nut on control rod by hand as far as stop towards
vacuum unit.
– Guide control rod through adjusting lever on turbocharger, fit
vacuum unit -A- and secure bolts.

Audi TT 2007 ➤
– Tighten securing bolts -arrows- to 8 Nm.
Note
Please ensure that guide can be moved easily on control rod.
– Remove protective cap, fit oilwithsupply line
respect to -arrow- ofoninformation
the correctness turbo‐ in this document. Copyright by AUDI AG.
charger and tighten to 22 Nm.
– Plug in connector -2- at position sender for charge pressure

positioner -G581- and fasten heat shield sleeve.
– Connect vehicle diagnostic tester .
Selecting operating mode:
– On touch screen, press button for “Vehicle self-diagnosis”.
Selecting vehicle system:
– On touch screen, press button for “01 - Engine electronics”.
The display will show the identification and coding of the engine
control unit.
Selecting diagnostic function:
– On touch screen, press button for “011 - Measured values”.
– On the numeric keypad, enter measured value block “120” and
confirm your entry with “Q” key.
– Connect hand vacuum pump -VAS 6213- to vacuum unit.
– Create voltage of 0.760 V by generating a vacuum (observe
minimum value of measured value block).
Caution
During the following adjustment procedure for the control rod,

the vacuum and the voltage of 0.760 V must be maintained.
1. Turbocharger 205
Audi TT 2007 ➤
– Slowly screw lock nut -B- for control rod downwards by hand.
Adjusting lever is on bottom stop.
– Counterhold lock nut -B- and screw securing nut -A- on control
rod against adjusting lever. Tighten slightly using ring spanner
-T10423- .
– Release vacuum pressure from vacuum unit.
– Observe minimum value of measured value block: value of
3.30 ... 3.90 V should be displayed (unpressurised).
– Apply socket -T10422- , counterhold lock nut -B- using ring
spanner -T10423- and tighten securing nut -A-.
Caution
Create vacuum of 0.75 ± 0.05 bar for vacuum unit to ensure

that adjusting lever is positioned at stop. A voltage of 0.760 V
should build up.
Voltage value OK
– Press locking plate onto control rod by hand and turn by 90°
in direction of -arrow-.
– Seal connection between control rod and securing nut with
sealing paint from replacement part set.
Voltage value not OK
– Counterhold lock nut -B-, loosen securing nut -A- on control

rod and adjust value by turning lock nut -B-.
– Counterhold lock nut -B-, screw securing nut -A- in other di‐
rection and tighten connection using socket -T10422- .
– Press locking plate onto control rod by hand and turn by 90°
in direction of -arrow-.
– Seal connection between control rod and securing nut with
sealing paint from replacement part set.
Continued

Audi TT 2007 ➤
– Depending on version, fit nut -arrow- securing oil supply line/

vacuum line to cylinder head and tighten connection.
– Remove sealing cap from turbocharger.
– Fully assemble engine components.
– Start engine and erase fault memory ⇒ Vehicle diagnosis,
testing and information system VAS 5051.
– Check adjustment as follows:
Selecting diagnostic function:
– On touch screen, press button for “006 - Basic setting”.
– On the numeric keypad, enter measured value block “120” and
confirm your entry with “Q” key.
– On bottom half of touch screen, press button for “Activate”.
– Observe value on bottom part of display: value should fluctu‐
ate between 0.65 ... 0.85 V and 3.30 ... 3.90 V (vacuum unit is
moved to both limit stops
Protected alternately).
Voltage values OK: with respect to the correctness of information in this document. Copyright by AUDI AG.
– Exit basic setting.
1. Turbocharger 207
Audi TT 2007 ➤
2 Charge air cooling
Note
♦ Check that all air pipes and hoses and vacuum lines are cor‐
rectly fitted and that there are no leaks before carrying out tests
or repairs.
1Protected
- Air hose
2 -with
Sleeve
3 - Bolt
❑ 9 Nm
4 - Air pipe (left-side)
5 - Seal
6 - Air hose
❑ Installing ⇒ page 209
⇒ page 211
8 - Seal
9 - Mounting
10 - Bolt
❑ 5 Nm
11 - Mounting
12 - Air hose
13 - Air hose
14 - Air pipe
15 - O-ring
❑ Renew
16 - Charge pressure sender -
sender -G42-
17 - Bolt
❑ 5 Nm

Audi TT 2007 ➤
18 - Bolt
❑ 9 Nm
19 - Sleeve
20 - Grommet
21 - Grommet

-arrow-.
Note

and the seal. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
lock -2-.
– Press air pipe/hose again and pull again to check that plug-in

Audi TT 2007 ➤
2.2 Removing and installing charge pres‐

sure sender -G31- / intake air tempera‐
ture sender -G42-
Removing


Audi TT 2007 ➤
– Remove bolts -arrows- and pull charge pressure sender -

G31- / intake air temperature sender -G42- out of air pipe.
Installing
Note
Fit new O-ring.


er
Removing
–permitted
Remove chargebyair
unless authorised hose
AUDI (left-side)
AG. AUDI AG does not-1-guarantee
from charge airliability
or accept any cooler.
– Push top edge of charge air cooler slightly towards rear.
– Push charge air cooler towards engine.
– Support charge air cooler from below to prevent charge air
cooler from dropping.

Audi TT 2007 ➤
WARNING

Caution
not damaged.
– Remove bolts -arrows- and -1-.

– Detach condenser from charge air cooler and take charge airunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
cooler out from below. with respect to the correctness of information in this document. Copyright by AUDI AG.
Installing
Note


♦ Charge air system tester -V.A.G 1687- with adapter -V.A.G
1687/12-

Audi TT 2007 ➤
Procedure
– Insert adapter -1687/12- into air hose -1- and secure with hose
clip.

valves -3- and -4-.
• Make sure knob is pulled out before turning pressure control
valve -2-.

Audi TT 2007 ➤
– Connect charge air system tester -V.A.G 1687- as shown on

illustration.

Audi TT 2007 ➤

Note
water.
– Open valve -3-.
Caution
Risk of damagepermitted
if pressure is set too
unless authorised high.

Note

retention test.
♦ Release pressure in test circuit by detaching hose coupling
from adapter before removing adapter.

Audi TT 2007 ➤
1 Silencers
Note

♦ Use screwdriver to unfasten and tighten lock washers for heat
shields. Tightening torque: 2 Nm.
1 - Centre silencer
❑ Combined with rear si‐
lencer
⇒ page 221
2 - Rubber mounting
3 - Rubber mountingpermitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4 - Bracket
5 - Bolt
❑ 23 Nm
6 - Mounting
7 - Nut
❑ 23 Nm
8 - Bracket (bottom)
9 - Nut
❑ 23 Nm
10 - Bracket (top)
11 - Bolt
❑ 23 Nm
12 - Nut
❑ 23 Nm
13 - Nuts
❑ 9 Nm

Audi TT 2007 ➤
14 - Heat shield
15 - Clamp
❑ Renew
❑ 7 Nm
16 - Seal
❑ Renew
❑ After renewing, perform “Adaption” in “Guided Functions” ⇒ Vehicle diagnosis, testing and information
system VAS 5051.
18 - Clamp (front)
19 - Nut
❑ 23 Nm
20 - Bolt
❑ 23 Nm
22 - Bracket
23 - Nut
❑ 23 Nm
24 - Bolt
❑ 23 Nm
Installation position of front clamp

• Angle -α- = approx. 20° permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1. Silencers 217
Audi TT 2007 ➤
Installation position of clamp for particulate filter

• Angle -α- = 0 ± 10°
1.2 Removing and installing particulate filter

♦ Engine support -3300 A-
Removing
– Remove Lambda probe ⇒ Rep. Gr. 23 .
– Remove propshaft ⇒ Rear final drive 02D/0AV; Rep. Gr. 39 .
– Remove bevel box ⇒ Rep. Gr. 34 .
sender 2 -G448- and move wiring clear.
Note
Note

Audi TT 2007 ➤

sor 1 -G450- .
– Remove bolt -1- and nuts -arrows- and push exhaust gas
pressure sensor 1 -G450- to side.
– Unscrew
permitted exhaust
unless authorised gas
by AUDI AG. temperature
AUDI AG does not sender 4 accept
guarantee or -G648- -item
any liability 1-
Note
Disregard -item 2-.
ticulate filter.
1. Silencers 219
Audi TT 2007 ➤
– Remove bolts and nuts -arrows-.

– Detach heat shield to rear.
– Using engine support -3300 A- , push engine/gearbox assem‐

bly forwards by distance -a-.
• Distance -a- = 35 mm.
– Remove particulate filter by rotating through 180° and about

its own axis -arrow-.

Note
♦ Renew gaskets, self-locking nuts and clamp for particulate fil‐

ter.
– Install bevel box ⇒ Rep. Gr. 34 .

– Install propshaft ⇒ Rear final drive 02D/0AV; Rep. Gr. 39 .
⇒ page 225 .
– Install Lambda probe -G39- and exhaust gas pressure sensor
1 -G450- ⇒ Rep. Gr. 23 .
– After renewing particulate filter, perform “Adaption” in “Guided
Functions” ⇒ Vehicle diagnosis, testing and information sys‐
tem VAS 5051.

Audi TT 2007 ➤

Procedure
– Loosen bolt connections on front clamp.
– Push exhaust system towards front of vehicle until preloading
at mounting for rear silencer -a- = 11 ... 13 mm.

– Tighten bolt connections on clamp evenly.

Procedure
– Align rear silencer so that there is an equal distance -a- and
-b- between bumper cut-out and tailpipes.

– Listen for noise at the connection points
permitted of authorised
unless cylinderbyhead/ex‐
haust manifold, turbocharger/frontwithexhaust pipe
respect to the etc. tooflocate
correctness information in this document. Copyright by AUDI AG.
any leaks.
1. Silencers 221
Audi TT 2007 ➤
2 Exhaust gas temperature control
2.1 Exhaust gas temperature control - exploded view
1 - Turbocharger
2 - Control pipe
❑ 45 Nm
4 - Nut
❑ 9 Nm
5 - Bracket
❑ Bolted to particulate fil‐
ter
6 - Hose
7 - Bracket
❑ For exhaust gas pres‐
sure sensor 1 -G450-
8 - Exhaust gas pressure sen‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
sor 1 -G450- with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ Rep. Gr. 23
9 - Bolt
❑ 8 Nm
10 - Nut
❑ 9 Nm
sender 3 -G495-
⇒ page 224
❑ Coat with high-tempera‐
ture paste; for high-tem‐
perature paste refer to
logue
❑ 4.5 Nm
12 - Lambda probe -G39- with Lambda probe heater -Z19-
❑ Coat with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts catalogue
❑ 45 Nm
❑ Coat with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts catalogue
❑ 45 Nm

Audi TT 2007 ➤

Removing
– Unplug electrical connector -1- (black) for exhaust gas tem‐
perature sender 1 -G235- and move wiring clear.
Note
Note
The connection can be accessed from below.

from exhaust manifold.
Protected by Note
Disregard -arrows-.
Installing
Note
♦ Coat threads of exhaust gas temperature sender with high-

temperature paste; for high-temperature paste refer to ⇒
Electronic parts catalogue .
Installation position of exhaust gas temperature sender -G235- :
• The angled part of the pipe must have a clearance of -a- = 3

… 5 mm from the bolt on the turbocharger support.

Audi TT 2007 ➤

Removing
– Unplug electrical connector -3- (brown) for exhaust gas tem‐
Note
Disregard -items 1, Protected

2, 4-. by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove exhaust gas temperature sender 3 -G495- -item 1-.
Note
Installing
Note
♦ Coat threads of temperature sender with high-temperature

paste ⇒ Electronic parts catalogue .
Installation position of temperature sender before particulate filter

-G495- :
• Angled section of pipe faces towards left side of vehicle.
• Angle -α- = approx. 7° to left.
Note
Disregard -arrow-.

Audi TT 2007 ➤

Removing
– Unplug electrical connector -2- (orange) for exhaust gas tem‐
Note

Note
Disregard -item 2-.
Installing
Note
Coat threads of temperature sender with high-temperature paste

⇒ Electronic parts catalogue .

Audi TT 2007 ➤
3 Exhaust gas recirculation system

Exhaust gas recirculation system
♦ To improve exhaust emission values, exhaust gas is recircu‐
lated to the combustion chambers, thus reducing the combus‐
tion chamber temperature.
♦ The exhaust gas recirculation system is activated by the en‐
gine control unit -J623- via the exhaust gas recirculation valve
-N18- and the exhaust gas recirculation potentiometer -
G212- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ The exhaust gas recirculation is switched off after
with respect to theapprox.
correctness2of information in this document. Copyright by AUDI AG.
minutes at idling speed.
♦ Restart engine or briefly increase engine speed above 1500
rpm when longer checks are necessary. Then repeat meas‐
urement.
Cooling system for exhaust gas recirculation system
♦ To further improve the exhaust emission values, the exhaust
gas recirculation system is equipped with a cooler that is con‐
nected into the engine cooling system.
♦ Under certain operating conditions, the flow of exhaust gas
that is recirculated to the combustion chamber is routed via
this cooler. The exhaust gas temperature is thereby reduced,
further lowering the combustion temperature and improving
the exhaust emission values.
♦ The engine control unit -J623- determines when the recircu‐
lated exhaust gas is routed via the cooler. The control unit
actuates a vacuum unit via the exhaust gas recirculation cool‐
er change-over valve -N345- , and the vacuum unit in turn
operates the change-over flap for the exhaust gas recircula‐
tion cooler.

⇒ “1.1 Diagram of vacuum connections”, page 197 .

Audi TT 2007 ➤
3.2 Exhaust gas recirculation with exhaust gas recirculation cooler - exploded
view
1 - Vacuum line
❑ Do not alter shape
2 - Nut
❑ 9 Nm
cooler
function ⇒ page 230
⇒ page 231
4 - Gasket
❑ Renew
5 - Bolt
❑ 20 Nm
culation
7 - Clip
8 - Nut
❑ by9 copyright.
Protected Nm Copying for private or commercial purposes, in part or in whole, is not
9with
- Bolt
❑ 20 Nm
10 - Gasket
❑ Renew
11 - Bolt
❑ 9 Nm
valve -N18- with exhaust gas
recirculation potentiometer -
G212-
13 - Pipe for exhaust gas recirculation
14 - Bolt
❑ 20 Nm
15 - Gasket
❑ Renew
16 - Bolt
❑ 9 Nm

Audi TT 2007 ➤
3.3 Removing and installing exhaust gas re‐

circulation valve -N18- with exhaust gas
recirculation potentiometer -G212-
Removing

Audi TT 2007 ➤

Note
Disregard -item 4-.

V157- .
Note
Disregard -items 1, 2, 4- and -arrow-.

-V157- .

Audi TT 2007 ➤
– Unplug electrical connector -1- on exhaust gas recirculation

valve -N18- with exhaust gas recirculation potentiometer -
G212- .
– Remove bolts -2- and -3- and detach exhaust gas recirculation
valve -N18- with exhaust gas recirculation potentiometer -
G212- .
Note
Disregard -item 4-.
Installing
Note
Renew O-ring.

– Install air
permitted hose
unless with by
authorised plug-in connector
AUDI AG. AUDI AG does⇒not
page 209or .accept any liability
guarantee
3.4 Checking exhaust gas recirculation

cooler change-over

Audi TT 2007 ➤
Procedure
– Disconnect vacuum hose from vacuum unit and connect hand
vacuum pump -VAS 6213- in its place.
– Operate hand vacuum pump to produce a vacuum.
• The linkage of the exhaust gas recirculation cooler change-
over should move -arrows-.
If the linkage does not move or only moves jerkily:
♦ The vacuum unit is defective.
♦ The change-over flap for exhaust gas recirculation is sticking.
Note

installing.
3.5 Removing and installing

Protectedexhaust gas forre‐
by copyright. Copying private or commercial purposes, in part or in whole, is not
circulation cooler permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability


Audi TT 2007 ➤
Removing
Metal gate relay lever:
– Detach securing clip -4- for gate selector cable from gate relay
lever -2- and pull cable off pin -arrow-.
Plastic gate relay lever:

– Press gate relay lever towards front -arrow 3-.

Audi TT 2007 ➤

– Remove nuts -2- and bolts -3-.

– Detach exhaust gas recirculation pipe.
Note
Disregard -item 1-.
hose clips -arrows- and disconnect coolant hoses from ex‐
haust gas recirculation cooler.
– Detach heat insulation sleeve from vacuum unit.

Audi TT 2007 ➤
– Remove bolts -1- for exhaust gas recirculation pipe.

– Disconnect vacuum hose -2- from vacuum unit and move
clear.
– Remove bolts -arrows- and detach exhaust gas recirculation
cooler.
Installing
Note
♦ Renew gaskets, seals and self-locking nuts.

♦ Fit heat insulation sleeve in the original position when instal‐
ling.


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

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system
safety. In addition, the bynormal
Protected basicforsafety
copyright. Copying private or precautions
commercial purposes, for working
in part or in whole,on
is notmotor vehicles must, as a
matter of course, permitted
bewithobserved.


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

1 Removing and installing engine, detaching from gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.1 Poly V-belt, bracket for ancillaries - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.5 Front sealing flange - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.6 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.7 Removing and installing sealing flange (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.1 Rear sealing flange and dual-mass flywheel - exploded view . . . . . . . . . . . . . . . . . . . . . . 48
2.3 Removing and installing sealing flange (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.6 Removing and installing chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4 Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

1.1 Toothed belt drive - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.2 Copying
Protected by copyright. Removing
for privateand installing
or commercial inletin camshaft
purposes, control
part or in whole, is not valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . 80
2.3 Removing and installing cylinder head cover
. ................................... 82
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Contents i
Audi TT 2007 ➤

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

. . . . unless
. . . authorised
. . . . .by. AUDI
. . .AG.. .AUDI
. . AG
. .does
. . not
. .guarantee
. . . . or. 190
accept any liability
1 Parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

1.1 Exhaust system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

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

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

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

♦ Protected
Always switch Copying
by copyright. off theforignition before connecting
private or commercial purposes, in partor
or indiscon‐
whole, is not
necting
permitted electrical
unless authorisedwiring for AUDI
by AUDI AG. the AG injection or ignition
does not guarantee system
or accept or
any liability
tester cables.
♦ Certain tests may lead to a fault being detected by the engine

control unit and stored in the memory. You must therefore in‐
terrogate the fault memory and erase it if necessary after
completion of all tests and repair work. If you erase the fault
memory, you must then generate the readiness code in the
engine control unit in “Guided Fault Finding” mode ⇒ Vehicle
Caution
♦ Observe notes on procedure for disconnecting the battery

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

opened; cover filler cap with cloth and open carefully.

WARNING

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

Injection system/fuel system
Even small amounts of dirt can cause faults in the injection sys‐
tem. When working on the fuel supply/injection system, please
pay careful attention to the following basic rules:
opening.
♦ Plug open lines and connections with suitable protective caps
immediately.
♦ Unplugged electrical connectors must be kept clean and dry.
Make sure connections are dry when attaching.
Turbocharger
When working on the turbocharger, pay careful attention to the
following “5 rules”:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
that have been stored loose (e.g. in tool boxes etc.).
♦ When the system is open: Do not work with compressed air if
this can be avoided. Do not move the vehicle unless absolutely
necessary.

Audi TT 2007 ➤

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

equipment required
-VAS 6208-
V.A.G 1383 A-
♦ Hose clip pliers -V.A.G
1921-
1. Removing and installing engine, detaching from gearbox 5

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

Engine bung set -VAS 6122-
Note

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

Electrical system; Rep. Gr. 27
– Remove luggage compartment floor covering.

terminal.
Note
Remove rear cross panel trim if cover for negative terminal of

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

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

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


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

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

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

fore catalytic converter) from bracket, unplug and move clear.
– Unscrew Lambda probe -G39- -arrow- using tool from Lambda

– Use screwdriver to pry off cover caps on wiper arms and un‐
screw hexagon nuts.
– Pull wiper arms off wiper shafts and remove.
– Pull off rubber seal -1- on plenum chamber cover.

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

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

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

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

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

– Disconnect earth cable -2-.
– Slide cover -4- to rear.
– Detach wire -arrow- at starter and move clear.


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

– Unscrew bolts -1- from above.
– To drain off coolant, detach bottom coolant hose -arrow-.
– Remove air pipe -1 and 2- for charge air cooler.

Audi TT 2007 ➤

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

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


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

– Pull off selector cable end-pieces from gearbox selector lever
and relay lever.
– Detach cable support bracket from gearbox -arrows- and
place to one side.
WARNING
Do not press clutch pedal after disconnecting hose leading to

slave cylinder.
– Pull out clip -2- as far a stop in -direction of arrow- and detach
hose -1-.
WARNING
Fuel supply line is pressurised. Wear safety goggles and pro‐

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

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

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

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

prox. 2 turns.
– Loosen bolts -arrows- of assembly mounting for gearbox ap‐

prox. 2 turns.

Audi TT 2007 ➤
– Remove air pipe -arrows-.
– Unplug electrical connector -1- for high-pressure sender -

G65- .
– Detach air conditioner pipe from condenser -2-.
– Unplug electrical connector at oil level sender -1-.

– Unclip bracket -2-.

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

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

– Unplug connector for Lambda probe after catalytic converter
-G130- .
– Unscrew remaining securing nuts -arrows- for front exhaust

pipe/turbocharger from below.

Audi TT 2007 ➤
– Unbolt bracket for exhaust system and tunnel brace -arrows-.
Note
To avoid any damage, the flexible joint in the front exhaust pipe
must not be bent more than 10°.

– Remove front exhaust pipe with catalytic converter and front
silencer.
– Remove bolts -1 ... 3- and take out pendulum support.
– Unscrew the additional coolant pump -arrows-.

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

5085- .
– Remove bolts -arrows- of assembly mounting on engine.
– Remove bolts -arrows- of assembly mounting for gearbox.
Note

avoid damage.
– Pull engine/gearbox assembly as far forward as possible, and

lower gradually.
1.2 Separating engine and gearbox

• Engine/gearbox permitted
assembly unlessremoved
authorised byand
AUDI attached
AG. AUDI AG to engine
bracket -T10012- with
. respect to the correctness of information in this document. Copyright by AUDI AG.

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

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

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

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

Audi TT 2007 ➤
1.3 Securing engine to assembly stand

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


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

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

rails of the support hooks must be positioned as shown.
WARNING
The support hooks and locating pins on the lifting tackle must
be secured with locking pins (arrows in illustration).
-VAS 6100- .
Secure engine to engine and gearbox support -VAS 6095- when
dismantling/assembling engine.
1.4 Installing engine

• Engine installed on engine bracket -T10012- .
Note
♦ Reinstall all cable ties in the same locations when assembling.

(same as original equipment): ⇒ Parts catalogue
♦ Renew self-locking nuts and bolts when performing assembly
work.
♦ Renew bolts which are tightened to a specified angle as well
as oil seals and gaskets.
♦ Clean input shaft splines and (in the case of used clutch plates)
the hub splines. Remove corrosion and apply only a very thin
coating of grease (⇒ Parts catalogue ) to the splines. Then
move clutch plate back and forth on input shaft until the hub
moves smoothly on the shaft. Remove any excess grease.
– Check whether dowel sleeves for centring the engine/gearbox

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

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

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

♦ Additional lubricant such as engine oil or gearbox oil may be
used, but do not use lubricant containing graphite.
♦ Tolerance for tightening torques: 15%.
Securing engine to gearbox

Item Bolt Nm
1, 2 M12×65 80
3 1), 4 1) M12×135 80
5 ... 7 M10×60 40
8 permitted unless authorised
M12×90
by AUDI AG. AUDI AG does not 65guarantee or accept any liability
• 1) with respect to the correctness of information in this document. Copyright by AUDI AG.
Bolt with M8 stud
A: Centring sleeves
– Push in splash plate -2- in such a way that the lower lug en‐
gages into the cylinder block and secure on top with bolt -1-.
Note
Shown in illustration with gearbox removed.
– Guide engine/gearbox assembly into the body.
– Tighten bolts -arrows- of assembly mounting for engine initially

hand-tight.

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

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

♦ The bolts are tightened to final torque only after adjusting the
engine mountings ⇒ page 25 .
– Remove engine bracket -T10012- from engine.

Audi TT 2007 ➤
– Secure pendulum support to gearbox and subframe -1 ... 3-.

– Install drive shafts ⇒ Running gear, front-wheel drive and four-
wheel drive; Repair group 40
– Install exhaust system and align it free of stress
⇒ page 194 .
– Install Lambda probe -G39- ⇒ Rep. Gr. 24 .
– Charge refrigerant circuit ⇒ Air conditioning system; Repair
group 87
– Attach and adjust selector mechanism at gearbox: ⇒ Rep. Gr.
34 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Adjust engine mountings ⇒ page 27 . with respect to the correctness of information in this document. Copyright by AUDI AG.
– Electrical connections and routing: ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations
– Bleed fuel system ⇒ Motronic direct injection and ignition sys‐
tem (4-cylinder); Repair group 24; Servicing fuel injection sys‐
tem
– Connect battery ⇒ Electrical system; Rep. Gr. 27 .
– Installing air pipes with connectors ⇒ page 164
Note

WARNING
Never use battery charging equipment for boost starting. There

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

Audi TT 2007 ➤
1 - Bolt
gearbox
Rep. Gr. 34
2 - Bolts
gearbox
❑ Renew
❑ 40 Nm + 90° (1/4 turn
further).
3 - Engine support
4 - Bolt
gine
❑ 45 Nm
5 - Engine mounting Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - Bolt
body
❑ Renew
❑ 40 Nm + 90° (1/4 turn
further).
8 - Bolt
❑ Connecting bracket to
engine mounting
❑ Renew
❑ 20 Nm + 90° (1/4 turn
further).
9 - Bolt
❑ Renew
❑ 20 Nm + 90° (1/4 turn further).
10 - Bolt
❑ Renew
❑ 40 Nm + 90° (1/4 turn further).
11 - Bolts
❑ Renew
❑ 60 Nm + 90° (1/4 turn further).
Audi TT 2007 ➤
13 - Bolt
❑ Renew
❑ 100 Nm + 90° (1/4 turn further).
14 - Bolt
❑ Tightening torque ⇒ Rep. Gr. 34 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
15 - Bolt
17 - Bolt
18 - Bolt

Procedure
– Lift out activated charcoal filter from retainer
-in direction of arrow- with pipes connected and lay aside.

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



equipment required
♦ Support bracket -10 - 222
A-
♦ 2x spindle -10 - 222 A /11-
♦ Adapter -10 - 222 A /20-
(2x)
♦ Hooks -10 - 222 A /2-
♦ Engine support bracket
(basic set) -T40091-
(supplementary set) -
T40093- with -T40093/3-2-
and -T40093/3-3-
Proceed as follows:
Audi TT 2007 ➤

air mass meter.
– Pull activated charcoal filter with hoses attached upwards out

of the retainer -arrow- and place to side.
– Remove bracket for activated charcoal filter.
– Disconnect coolant pipe -arrows-.
– Detach gear selector cable -arrow-.

Audi TT 2007 ➤

♦ 2x Rack -10 - 222 A /1-
♦ Spindle -10 - 222 A /11- (spindle faces front)
♦ Hooks -10 - 222 A /2-
♦ Adapter -10 - 222 A /20-
♦ Connecting piece -T40091/3- (2x)
– Attach spindle
permitted -10 - 222
unless authorised A /11-
by AUDI with
AG. AUDI AGhook -10
does not - 222orAaccept
guarantee /2- any
andliability
adapter -10 -to222
with respect A /20- of
the correctness toinformation
gearbox lifting
in this eye.Copyright by AUDI AG.
document.
– Tighten spindle slightly to take up weight of engine/gearbox

assembly.
– Fit adapter -T40092/3-2- (left-side) and -T40093/3-3- (right-

side) to supports -T40093/3- .
– Unbolt earth wire from longitudinal member (left-side).
– Remove connecting bolt for front section of longitudinal mem‐
ber on left and right.
– Secure adapter -T40092/3-2- (left-side) and -T40093/3-3-
(right-side) to longitudinal members using the removed bolts
-arrow-.
Note
The illustration shows the left side of the vehicle.
– Fit square-section pipes -T40091/1- with connecting pieces -

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

the two connecting pieces -T40093/4- .
WARNING

♦ Secure support -T10091/2- with pins and split pins of con‐
necting pieces -T40093/4- .
♦ Secure connecting pieces and supports with clamping
bolts.
– Fit spindle -10 - 222 A /11- with adapter -10 - 222 A /20- onto
sliding support and onto engine lifting eye.

– Take up weight of engine/gearbox assembly by evenly tight‐
ening two spindles.
– Unscrew bolts -arrows- on engine assembly mounting one af‐

ter the other, renew them (if not already renewed when engine
was installed) and screw in loosely.
– Unscrew bolts -arrows- on gearbox assembly mounting one

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

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

engine mounting -1- and engine support -4- until the specifi‐
cations listed below are obtained:
• The two bolt heads -2- must be parallel with the edge of the
support arm -3-.
Note

– Tighten bolts of assembly mounting at gearbox.
• Dimension -x- must be identical on both sides of mounting.
– unless
permitted Tighten boltsbyfor
authorised AUDIassembly
AG. AUDI AGmounting.
note the following:
– Tighten bolts for front section of longitudinal member ⇒ Rep.
Gr. 50 .
Audi TT 2007 ➤
1.1 Poly V-belt, bracket for ancillaries - ex‐

ploded view
Note
Before removing, mark direction of rotation of poly V-belt with

chalk or felt-tipped pen. If the belt runs in the opposite direction
when it is refitted, this can cause breakage. Ensure that the belt
is properly seated in the pulleys when installing.
❑ For poly V-belt
⇒ page 38
2 - Bolt
❑ 10 Nm + 90°
Renew ⇒ Parts catalogue
3 - Bolt
❑ 23 Nm
4 - Tensioner for poly V-belt
❑ Pivot with open-end
spanner to slacken poly
V-belt
❑ Secure tensioner in po‐
sition using locking pin -
T10060A-
⇒ page 35 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Tightening sequence permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
6 - Bolt
❑ 23 Nm
7 - Nut
❑ 23 Nm
8 - Alternator
⇒ Electrical system; Re‐
pair group 27
❑ To facilitate attachment
of alternator, knock
back threaded bushes for alternator securing bolts slightly
9 - Bolt
❑ Apply locking fluid when fitting
❑ Locking fluid ⇒ Parts catalogue

Audi TT 2007 ➤
❑ Tightening sequence ⇒ page 33

10 - Bush
❑ 2x
11 - Bolt
❑ 25 Nm
❑ Removing and installing ⇒ Air conditioning; Repair group 87
13 - Poly V-belt
❑ Routing of poly V-belt ⇒ page 33
❑ Check for wear
❑ Do not kink
Routing of poly V-belt
Tightening sequence on bracket for ancillaries

– Proceed as follows:
1. Screw in bolts -1 ... 6- hand-tight.
1.2 Removing and installing poly V-belt


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

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

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

– Remove poly V-belt.
Installing
Note
Before fitting poly V-belt, make sure all ancillary units (alternator
and air-conditioner compressor) are firmly secured.
– Fit the poly V-belt onto the crankshaft and air conditioner com‐
pressor pulleys.
– Then position poly V-belt on alternator pulley and release ten‐
sioner.

cillaries

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



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

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

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

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

Installing
– Tighten bolts in the sequence -1 ... 6-.

– Install alternator ⇒ Electrical system; Repair group 27 .
– Install air conditioner compressor ⇒ Rep. Gr. 87 ; Heating, air
conditioning system .
– Connect battery. Procedures required ⇒ Electrical system;
Repair group 27 .

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

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

spanner on centre bolt.
Installing
– When installing the vibration damper, use only genuine bolts

(same as original equipment): ⇒ Parts catalogue .
♦ The vibration damper can only be installed in one position. The
hole -arrow- in the crankshaft vibration damper must be loca‐
ted over the projection on the toothed belt sprocket.

Audi TT 2007 ➤
1.5 Front sealing flange - exploded view
1 - Bolt
❑ 90 Nm + 90° (1/4 turn)
further
❑ Renew
❑ Attaching counterhold
tool 3415 ⇒ page 65
tween sprocket and
of oil
one position
3 - Bolt
❑ Tightening sequence
⇒ page 40
4 - Oil seal
5 - Sealing flange (front)
❑ Must be positioned on
dowel pins
⇒ page 44
6 - Dowel pins
7 - Diamond-coated washer for
toothed belt sprocket
❑ Renew washer if tooth‐
ed belt sprocket is re‐
moved
8 - Bolt
9 - Cylinder block
❑ Removing and installing crankshaft ⇒ page 53
❑ Dismantling and assembling pistons and conrods ⇒ page 60
Tightening sequence for front sealing flange

1. Screw in bolts -1 ... 10- hand-tight. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2. Tighten bolts -1 ... 6- in diagonal sequence and in stages to
15 Nm.

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

equipment required
♦ Torque wrench -V.A.G
1331-
1332-
Removing
– Remove poly V-beltProtected
⇒ page 33 .

– Remove crankshaft toothed belt sprocket. To do this, counter-

hold sprocket with special tool -3415- .

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

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

in position and, while exerting firm pressure, screw it into oil
seal as far as possible.
– Clamp flats of oil seal extractor in vice. Remove oil seal with
pliers.
Installing
– Position guide sleeve T10053/1 from assembly tool -T10053-

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

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

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

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

sprocket.
Fit toothed belt (adjust valve timing)
Protected ⇒ page
by copyright. Copying66
– Install poly V-belt ⇒ page 33 . to the correctness of information in this document. Copyright by AUDI AG.
with respect

Audi TT 2007 ➤
1.7 Removing and installing sealing flange (front)

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

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

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

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

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

tic brush or similar.
– Cut off tube nozzle at front marking (nozzle approx. 2 mm ∅).

Audi TT 2007 ➤

– Apply the bead of sealant onto the clean sealing surface of the
sealing flange as illustrated -arrow-.
Caution
Make sure oil strainer is not clogged by excess sealant.

Note
Sealant bead must not be wider than 3 mm, otherwise excess

sealant could ingress into sump and clog strainer in oil intake pipe.
– Coat the lower sealing surface on the sealing flange lightly with
sealant -hatched area-.
Note

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

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

2. Tighten bolts -1 ... 6- in diagonal sequence and in stages.
3. Tighten bolts -7 ... 10-.

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

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

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

sprocket.
note the following:
Installing toothed belt and adjusting valve timing ⇒ page 66 .

Audi TT 2007 ➤
2.1 Rear sealing flange and dual-mass flywheel - exploded view
Note
Servicing clutch:⇒ Rep. Gr. 30
1 - Bolt
❑ For dual-mass flywheel/
drive plate
❑ 60 + 90° (60 Nm + 90°
(1/4 turn) further
❑ Renew
dual-mass flywheel
⇒ page 49
one position. Holes are
off-set
❑ Must be positioned on
dowel sleeves
❑ Do not damage/bend
when assembling
❑ Is fitted on sealing
flange ⇒ page 49
4 - Bolt
⇒ page 49
5 - Sealing flange with oil seal
(rear)
❑ Renew only as com‐
plete unit
❑ Use guide sleeve provi‐
ded when fitting
⇒ page 50
❑ Do not lubricate/grease
sealing lip of oil seal
❑ Before installing, remove oil residue from crankshaft journal with a clean cloth.
❑ Guide sleeve is not to be removed until sealing flange has been slipped onto crankshaft journal
6 - Dowel pin Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7 - Cylinder block
❑ Removing and installing crankshaft ⇒ page 53

❑ Dismantling and assembling pistons and conrods ⇒ page 60
8 - Bolt

Audi TT 2007 ➤
Tightening sequence (gearbox end)

15 Nm.

– Fit intermediate plate on sealing flange and push onto dowel
sleeves -arrows-.

wheel
Removing
Caution
To prevent damage to the dual-mass flywheel when removing,

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

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

– Unbolt dual-mass flywheel.
Installing
– Use new securing bolts.
– Insert counterhold -3067- in hole on cylinder block -A-.

(rear)
♦ Safety goggles

Audi TT 2007 ➤

Removing
– Detach intermediate plate at sealing flange and dowel sleeves
-arrows-.

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

and sump.
– Cut off tube

to thenozzle atoffront marking (nozzleCopyright
approx. 2 mmAG. ∅).
with respect correctness information in this document. by AUDI


Audi TT 2007 ➤
– Coat the lower sealing surface on the sealing flange lightly with
sealant -hatched area-.
Caution

Note

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

-1- (fitted on replacement part) onto crankshaft when instal‐
ling.
– Push the sealing flange carefully onto the dowel sleeves on
the cylinder block.
– Tighten bolts in the specified sequence:

2. Tighten bolts -1 ... 6- in diagonal sequence and in stages.
3. Tighten bolts -7 ... 8-.

note the following:
– Fit intermediate plate on sealing flange and push onto dowel
sleeves -arrows-.
– Protected
Installbydual-mass flywheel
copyright. Copying for private⇒
or page 49 purposes,
commercial . in part or in whole, is not

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

-VAS 6095- when dismantling/assembling engine ⇒ page 20 .
1 - Bolt
❑ 65 Nm + 1/4 turn (90 °)
further permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Renew with respect to the correctness of information in this document. Copyright by AUDI AG.
2 - Bearing cap
end
❑ Bearing shell retaining
lugs (cylinder block/
bearing cap) must be on
the same side
3 - Bolt
❑ 10 Nm + 1/4 turn (90 °)
further
❑ Renew
❑ Sender wheel must be
renewed if bolts are
loosened ⇒ page 54
4 - Needle bearing
❑ For vehicles with man‐
ual gearbox
❑ Extracting and driving in
⇒ page 57
5 - Sender wheel
er -G28-
one position. Holes are
off-set
loosened
⇒ page 54
6 - Crankshaft
❑ After removing, place it down so that the sender wheel -item 5- is not damaged and the crankshaft does
not rest on the sender wheel
❑ Axial clearance ⇒ page 55
❑ Radial clearance ⇒ page 56
❑ Do not rotate the crankshaft when checking the radial clearance
3. Crankshaft 53
Audi TT 2007 ➤
7 - Thrust washers
8 - Bearing shell for cylinder block
❑ With oil groove
❑ Do not interchange used bearing shells (mark positions)
❑ Classification for replacement parts ⇒ page 57
9 - Chain sprocket
❑ For oil pump chain
10 - Bearing shell
❑ Without oil groove
❑ The crankshaft bearing shells in the bearing caps are only supplied as spare parts with “yellow” colour-
coding.
Removing and installing sender wheel

– Sender wheel -2- must always be renewed after slackening off
bolts -1-.
Note
♦ If the countersunk bolts are tightened a second time, the seats

for the bolt heads in the sender wheel will be deformed to such
an extent that the bolt heads make contact with the crankshaft
-3- -arrows- and the sender wheel beneath the bolts will be
loose.
♦ Sender wheel can only be fitted in one position
permitted because
unless holes
are offset. with respect to the correctness of information in this document. Copyright by AUDI AG.

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

cylinder block at the factory. Coloured dots are used to identify
the thickness of the bearing shells.
Letter codes on the lower sealing surface of the cylinder block
indicate the thickness of the bearing shell to be fitted at each lo‐
cation.
G = Yellow
B = Blue
W = White
Note
♦ Use blue bearing shells if the identification is no longer visible.

♦ The bottom crankshaft bearing shells are only supplied as re‐
placement parts with “yellow” marking.

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

3. Crankshaft 55
Audi TT 2007 ➤
Procedure
– Bolt dial gauge -VAS 6079- with dial gauge bracket -VW 387-
onto cylinder block and set it against crank web.
– Push crankshaft against dial gauge by hand and set gauge to
“0”.
Axial clearance:
• New: 0.07 ... 0.23 mm.

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

♦ Bearing shells worn down to nickel layer must be renewed.
– Remove main bearing caps and clean bearing caps and jour‐
nals. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Place Plastigage ontowith
bearing journal or into bearing shells
(length of Plastigage should correspond to width of bearing).

shell.

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

crankshaft.
– Remove main bearing caps once more.
– Compare width of Plastigage with measurement scale:
Radial clearance:
• New: 0.017 ... 0.037 mm.

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

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

3.6 Removing and installing chain sprocket

♦ Drift sleeve -30 - 100-
♦ Thrust plate -40 - 105-
♦ Two-arm puller, commercially available


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

gine,
– Fit chain sprocket on end of crankshaft using pliers, and press

onto crankshaft as far as the stop using drift sleeve -30 - 100- .
– Install sump with oil pump ⇒ page 120 .
3. Crankshaft 59
Audi TT 2007 ➤
4 Pistons and conrods - exploded view
1 - Conrod bolt
❑ 30 Nm + 1/4 turn (90°)
further
❑ Renew
contact surface
❑ Use old bolts when
measuring radial clear‐
ance
❑ To measure radial clear‐
ance, tighten to 30 Nm
but do not turn further
2 - Pressure relief valve
27 Nm
❑ Opening pressure:
1.6 ... 1.9 bar
3 - Oil spray jet
❑ For piston cooling
tion
only on the appropriate
conrod.
❑ Mark cylinder number
-B-
❑ Installation position: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Markings -A- face to‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
wards pulley end with respect to the correctness of information in this document. Copyright by AUDI AG.
5 - Bearing shells
❑ Upper bearing shell with oil hole for piston pin lubrication
❑ Axial clearance when new: 0.10...0.35 mm; wear limit: 0.40 mm
❑ Check radial clearance with Plastigage - (new): 0.02 ... 0.06 mm; wear limit: 0.09 mm. Do not turn crank‐
shaft when measuring radial clearance
6 - Conrod
❑ Mark cylinder number -B-
❑ With oil drilling for piston pin lubrication
7 - Circlip
8 - Piston pin

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

of cylinder. Use a piston without rings to push ring into bore.
Piston ring New Wear limit
Dimensions in mm
Compression ring 0.20...0.40 0.8
Oil scraper ring 0.25...0.50 0.8
Checking ring-to-groove clearance

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

Audi TT 2007 ➤
Checking cylinder bore

♦ Cylinder dial gauge 50...100 mm
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-.
♦ Deviation from nominal dimension: max. 0.08 mm
Installation position of bearing shell
Bearing shell -1- with oil drilling -arrow- for conrod.
Bearing shell -2- without oil drilling for conrod bearing cap.
– Position bearing shells in centre of conrod and conrod bearing
cap when fitting. with respect to the correctness of information in this document. Copyright by AUDI AG.
Dimension -a- must be identical on both sides.

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

Audi TT 2007 ➤

1.1 Toothed belt drive - exploded view

Mark the rotation direction of the toothed belt with chalk or felt-tip
pen before removing. If the belt runs in the opposite direction
1 - Bolt
❑ 10 Nm
fitting
❑ Locking fluid ⇒ Parts
catalogue
2 - Toothed belt cover (top)
3 - Bolt
❑ 50 Nm + turn 180° fur‐
ther
❑ Renew
❑ Use counterhold tool
-3036- when loosening
and tightening
⇒ page 64
❑ Remove toothed belt
prior to removing and in‐
stalling ⇒ page 66
fixed by Woodruff key
❑ Detaching camshaft permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
sprocket ⇒ page 65 with respect to the correctness of information in this document. Copyright by AUDI AG.
5 - Bolt
❑ 10 Nm
fitting
❑ Locking fluid ⇒ Parts
catalogue
7 - Woodruff key
❑ Check for firm attachment
8 - Nut
❑ 25 Nm
9 - Semi-automatic tensioning roller
10 - Coolant pump
11 - O-ring
❑ Renew

Audi TT 2007 ➤
12 - Bolt
❑ 25 Nm
13 - Damper wheel
14 - Bolt
❑ 15 Nm
15 - Bolt
❑ 35 Nm
16 - Damper wheel
17 - Sealing flange
Protected by copyright. ⇒ page
Copying for private 44
18 - Diamond-coated washer offor
with respect to the correctness toothed
information belt
in this sprocket
❑ Renew washer if toothed belt sprocket is removed
20 - Bolt
❑ 90 Nm + 90° (1/4 turn) further
❑ Renew
❑ Attaching counterhold tool 3415 ⇒ page 65
21 - Toothed belt
❑ Before removing, mark direction of rotation with chalk or felt-tipped pen
❑ Check for wear
❑ Installing (adjusting valve timing) ⇒ page 66
22 - Toothed belt cover (bottom)
23 - Engine support
❑ Removing ⇒ Removing and installing toothed belt ⇒ page 66
24 - Bolt
❑ 45 Nm
❑ Observe correct tightening sequence ⇒ page 75
25 - Cap for toothed belt cover
Loosening camshaft sprocket

– Use counterhold -3036- when loosening and tightening central
bolt.

Audi TT 2007 ➤
Detaching camshaft sprocket

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

– Use counterhold -3415- when loosening and tightening central
bolt.
Installing engine support

– Fit bolts -1 ... 3- and tighten hand-tight initially.
– Then tighten bolts, tightening torque ⇒ page 63 .

Audi TT 2007 ➤

equipment required
A-
♦ 2x spindle -10 - 222 A /11-
♦ AdapterProtected
-10 - 222 A /20-Copying for private or commercial purposes, in part or in whole, is not
by copyright.
(2x) permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Hooks -10 - 222 A /2-
T40093- with -T40093/3-2-
and -T40093/3-3-
Pin wrench -T10020-

Audi TT 2007 ➤
Locking pin -T10060A-

Removing

air mass meter.
WARNING


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

with hoses.
– Unscrew bolts -1 ... 3- and remove pendulum support.

–permitted
Drainunless
off authorised
coolantby⇒AUDI page 147
WARNING
Fuel supply line is pressurised. Wear safety goggles and pro‐

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

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

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

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

– Remove retaining clip; to do so, unscrew bolts -2 and 3-.
– Unplug electrical connector -1- from coolant level indicator.

– Detach coolant expansion tank -arrows-.
– Disconnect coolant pipe -arrow-.

– Remove poly-V belt and remove locking pin -T10060A-
⇒ page 33 .

Audi TT 2007 ➤
– Disconnect coolant pipe -arrows-.
– Detach gear selector cable -arrow-.

♦ 2x Rack -10 - 222 A /1-
♦ Hooks -10 - 222 A /2-
♦ Adapter -10 - 222 A /20-
♦ Connecting piece -T40091/3- (2x)
– Attach spindle -10 - 222 A /11- with hook -10 - 222 A /2- and
adapter -10 - 222 A /20- to gearbox lifting eye.
– Tighten spindle slightly to take up weight of engine/gearbox
assembly.

Audi TT 2007 ➤

– Secure adapters to longitudinal members using the removed
bolts -arrow-.
Note
– Fit square-section pipes -T40091/1- with connecting pieces -

T40093/4- into connecting pieces -T40091/3- and supports -
T40093/3-- as shown in illustration.

WARNING

bolts.
– Fit spindle -10 - 222 A /11- with adapter -10 - 222 A /20- onto
sliding support and onto engine lifting eye.
ening two spindles.

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

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

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

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

Audi TT 2007 ➤
– Unscrew bolts from toothed belt cover (bottom) -arrows-.
– Unscrew the bottom bolt -3- and remove engine support from
below.
– Unscrew remaining toothed belt cover bolts -arrows- and re‐

move toothed belt cover from engine.
– Mark direction
Protected of rotation
by copyright. Copying forof toothed
private belt. purposes, in part or in whole, is not
or commercial
– Loosen tensioning
with respect roller and
to the correctness remove
of information toothed
in this belt.
– Turn crankshaft back slightly.

Installing
Note
♦ When turning the camshaft, the crankshaft must not be at

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

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

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

-arrows-.
– Fit toothed belt in the sequence: tensioning roller, camshaft

sprocket,
Protected coolant
by copyright. pump
Copying and or
for private last onto idler
commercial roller
purposes, -arrow-.
Note
Check tensioning roller is seated correctly in cylinder head.
– Tension toothed belt. To do so, turn hexagon key at the ec‐

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

Audi TT 2007 ➤
– Check valve timing again.

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

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

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

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

-arrows-; to do so, bring surfaces into contact using support
bracket -10-222A- .
– Adjust engine mountings ⇒ page 27 .
– Attach fuel hoses onto connections. Make sure plug-in con‐
nectors are properly secured.
– Install coolant expansion tank.
– Fit noise insulation.
– Fit engine cover panel.

Audi TT 2007 ➤
2 Cylinder head
2.1 Cylinder head - exploded view
Note
♦ Renew the cylinder head bolts.

♦ On assembly, renew
Protected oil seals
by copyright. and
Copying gaskets
for private as well
or commercial as self-
locking nuts and bolts
permitted that arebytightened
unless authorised AUDI AG. AUDI byAGturning throughor to
does not guarantee accept any liability
a specified angle.
♦ When installing an exchange cylinder head with fitted cam‐

shafts, oil the contact surfaces between the roller rocker fin‐
gers and cams.
♦ The plastic protectors fitted to protect the open valves must
only be removed immediately before fitting the cylinder head.
♦ When fitting a new cylinder head or cylinder head gasket, drain
off all the old coolant and refill with new coolant.
1 - Bolt
⇒ page 78
⇒ page 82
⇒ page 78
3 - Gasket
leaking
4 - Valve housing
5 - Oil filler cap
6 - Seal
leaking
7 - Bolt
❑ 4 Nm
8 - Gasket for cylinder head
cover
leaking
9 - Exhauster pump
10 - Bolt
❑ 4 Nm
11 - Inlet camshaft control
valve 1 -N205-
12 - Seal
❑ Renew
2. Cylinder head 77
Audi TT 2007 ➤
13 - Bolt
❑ 10 Nm
14 - Cable retainer
15 - Seal
16 - Bolt
❑ 10 Nm
17 - Housing
18 - Gasket
❑ Renew
19 - Transport plate
20 - Bolt
❑ 25 Nm
21 - Stud for intake manifold
❑ 10 Nm
22 - Separating plate
❑ Renew
❑ Check installation position:
Protected by copyright. CopyingPart No.ortowards
for private commercialcylinder
purposes, inhead
part or in whole, is not

24 - Bolt
❑ 10 Nm
26 - Seal
27 - Stud for tensioning roller
❑ 10 Nm
28 - Stud for exhaust manifold
❑ 20 Nm
29 - Cylinder head
❑ Checking for distortion ⇒ page 79
30 - Cylinder head bolt
❑ Renew
❑ Note correct sequence when loosening ⇒ page 79
❑ Observe correct tightening sequence ⇒ page 79
Tightening sequence for cylinder head cover

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

Audi TT 2007 ➤
Loosening cylinder head bolts

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

– Then tighten cylinder head bolts in the sequence -1 ... 10- as
follows:
1. Tighten with torque wrench initially to 40 Nm.
2. Turn 90° (1/4 turn) further using a rigid wrench.
3. Turn 90° (1/4 turn) further using a rigid wrench.

– Use straight edge and feeler gauge to measure for distortion
at several points.
♦ Max. permissible distortion: 0.05 mm
2. Cylinder head 79
Audi TT 2007 ➤
2.2 Removing and installing inlet camshaft control valve 1 -N205-

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

Audi TT 2007 ➤

air mass meter.

– Detach
permitted wiring harness
unless authorised by AUDI AG.-2-AUDIfrom
AG doesbracket.
Note
Do not pull on electrical connector when removing inlet camshaft

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

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

to shock impacts.
– Lubricate the seal with engine oil.

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

cover
Removing
♦ Puller -T40039-

Audi TT 2007 ➤

air mass meter. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Detach air intake connection at lock carrier -4-.to the correctness of information in this document. Copyright by AUDI AG.
with respect
1921- .
– Unscrew bolts -arrows-.

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

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

charger -1-.
– Disconnect ACF line going to turbocharger from cylinder
unlesshead
permitted authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
cover -2-. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Loosen cylinder head cover working from outside to inside.

– Remove cylinder head cover.
Installing
Note
♦ Renew cylinder head cover gaskets if damaged.

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

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

Audi TT 2007 ➤

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

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

tion system (RNS).

air mass meter.
1921- .
WARNING


Audi TT 2007 ➤

– Drain off coolant ⇒ page 147
– Remove electrical connector -arrow- for Lambda probe (be‐

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

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

– Disconnect earth cable -1-.

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

Audi TT 2007 ➤
clear.

-G130- .

2. Cylinder head 89
Audi TT 2007 ➤
Note

silencer.
– Remove drive shaft (right-side) ⇒ Rep. Gr. 40
– Detach air pipe -arrow- from charge air cooler.
– Unbolt air pipe from turbocharger -arrows-.

– Detach electrical connectors -1 and 2- and move wire clear.
– Unscrew bolts -arrows- and remove air pipe.
Note

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

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

Protected turbocharger
by copyright. Copying forat cylinder
private blockpurposes, in part or in whole, is not
or commercial
-1- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Unscrew coolant supply pipe at turbocharger -2-.
– Detach coolant supply pipe for turbocharger -3- from cylinder
block.
– Remove oil return pipe -arrows- at turbocharger.
– Remove bolts -1- and -2- and remove support for turbocharg‐
er.
2. Cylinder head 91
Audi TT 2007 ➤
– Loosen the camshaft sprocket bolt using counterhold -3036- .
– Detach camshaft sprocket using two-arm puller -T40001- with

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


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

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

♦ On assembly, renew oil seals and gaskets as well as self-
locking nuts and bolts that are tightened by turning through to
a specified angle.
(same as original equipment) ⇒ Parts catalogue.
♦ If repairing, carefully remove any remaining gasket material
from the cylinder head and cylinder block. Ensure that no long
scores or scratches are made on the surfaces.
♦ Carefully remove any remaining emery and abrasive material.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
♦ No oil or coolant must be allowed to remain in the blind holes
for the cylinder head bolts in the cylinder block.
♦ High-temperature paste ⇒ Parts catalogue
The engine must only be turned at the crankshaft, in the direc‐
tion of normal engine rotation (clockwise).
Note
Apply spanner to central bolt of crankshaft for turning engine.
2. Cylinder head 93
Audi TT 2007 ➤
– Align mark on camshaft sprocket with mark on toothed belt

cover. The indentations on the camshafts -arrows- face each
other.
– If crankshaft has been rotated: set No. 1 cylinder piston to top
dead centre and then turn crankshaft back slightly.

Audi TT 2007 ➤

♦ Note position of centralising pins in cylinder block -arrows-.
♦ Note installation position of cylinder head gasket. The Part No.
should be legible from inlet side.
– Insert and hand-tighten cylinder head bolts.
– Tightening sequence for cylinder head ⇒ page 79 :
Note

after repair work.

– Install wiper arms ⇒ Electrical system; Repair group 92 .
– Install toothed belt ⇒ page 66 .
Electrical fault finding and Fitting locations
– Install intake manifold ⇒ Motronic direct injection and ignition
system (4-cylinder); Repair group 24; Servicing injection sys‐
tem
– Connect battery ⇒ Electrical system; Repair group 27
– Bleed fuel system ⇒ Motronic direct injection and ignition sys‐
tem (4-cylinder); Repair group 24; Servicing fuel injection sys‐
tem with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

WARNING
Never use battery charging equipment for boost starting. There

is danger of damaging the vehicle's control units.

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

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

♦ Battery voltage at least 12.7 V

Audi TT 2007 ➤

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

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

have been unplugged. Interrogate and, if necessary, erase fault in this document. Copyright by AUDI AG.
with respect to the correctness of information
memory after completing the check.
– Read out fault memory of engine control unit. ⇒ VAS 5051

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

♦ After installing camshafts, wait for approx. 30 minutes before
starting engine. Hydraulic valve compensation elements have
to settle (otherwise valves will strike pistons).
♦ After working on the valve gear, turn the engine carefully at
least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.
♦ Always fit new seals and gaskets.
1 - Bolt
❑ 50 Nm + turn 180° fur‐
ther
❑ Renew
❑ Use counterhold tool
-3036- when loosening
and tightening
⇒ page 64
3 - Oil seal
4 - Cylinder head
❑ Machining limit
⇒ page 100
5 - Valve guide
6 - Valve stem Protected
oil sealby copyright. Copying for private or commercial purposes, in part or in whole, is not
7 - Valve spring with respect to the correctness of information in this document. Copyright by AUDI AG.
8 - Upper valve spring plate

9 - Cotters
10 - Hydraulic valve clearance
compensation element
❑ Lubricate contact sur‐
face
11 - Parallel key
❑ Check for firm attach‐
ment
❑ Checking axial clear‐
ance ⇒ page 107
❑ Check radial clearance with Plastigage (roller rocker fingers removed)
❑ Radial clearance when bearing ∅ is 24 mm: 0.024 ... 0.066 mm

Audi TT 2007 ➤
❑ Runout: max. 0.04 mm

❑ Clean sealing surface; machining not permitted
❑ Remove old sealant residues
14 - Bolt
❑ Renew
16 - Bolt
❑ 20 Nm + turn 45° further
❑ Renew
17 - Inlet camshaft
❑ Checking axial clearance ⇒ page 107
❑ Check radial clearance with Plastigage (roller rocker fingers removed)
18 - Chain tensioner
❑ Remove ⇒ page 101 Removing and installing camshaft adjuster
❑ Before removing, lock in place using locking pin -T10115-
19 - Drive chain
20 - Bolt
❑ 10 Nm
21 - Bolt
❑ 10 Nm
22 - Phase sensorpermitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
23 - Exhaust valve
❑ Do not machine, only grinding-in is permitted
24 - Inlet valve
25 - Sealing cap
❑ Renew
❑ Installing: press in 1 ... 2 mm deep without sealant using thrust piece -3334-
3. Valve gear 99
Audi TT 2007 ➤
Cylinder head machining limit

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

1. Fit bolts in the sequence -1 ... 6- and hand-tighten in several
stages.
2. Tighten bolts in the sequence -1 ... 6- to 8 Nm using torque
wrench.
3. Turn 90° (1/4 turn) further in the sequence -1 ... 6- using a
rigid wrench.
Note
Take care to keep retaining frame straight.
Valve dimensions
Note

is permitted.

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

Audi TT 2007 ➤
3.2 Removing and installing camshaft adjuster

equipment required
-T40080-
♦ Camshaft clamp -T10252-
♦ Pin wrench -T10020-
♦ Locking pin -T10115-
Removing
– Remove exhauster pump.
– Remove housing for camshaft adjuster -arrows-.
3. Valve gear 101

Audi TT 2007 ➤

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

– Loosen securing bolt from camshaft adjuster using special
wrench -T40080- .
– Compress chain tensioner -arrow A- and lock with locking pin

-T10115- -arrow B-.
– Remove securing bolt from camshaft adjuster and remove
camshaft adjuster together with chain.
Installing
• The camshafts are located with the camshaft clamp -T10252- .

– Fit chain onto camshaft adjuster.

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

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

without changing its position.
– Turn inlet camshaft slowly in direction of arrow -A- using pin

wrench -T10020- until the camshaft adjuster fits onto the cam‐
shaft.
Note
If it is not possible to fit the pin into the notch: remove chain and
fit chain again.
– Renew securing bolt for camshaft adjuster.

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

mantling.
– Install cylinder head cover ⇒ page 82

3. Valve gear 103

Audi TT 2007 ➤
Removing
Note
♦ Sealing surfaces at bottom of retaining frame and top of cyl‐

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

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

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

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

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

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

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

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

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

• The side surfaces of the recesses should be positioned in ex‐
actly vertical line to the cylinder head.
– Lubricate running surfaces of camshafts.
– Apply an even, slightly projecting sealant bead into the clean

groove of the retaining frame.
Sealant ⇒ Parts catalogue
Note
♦ Do not apply the sealant thicker than prescribed.

♦ No time should be allowed to elapse when fitting and securing
retaining frame, as sealant starts to harden as soon as sealing
surfaces make contact.
♦ Note the use-by date of the sealant.
– Fit retaining frame so that it goes past the exhaust gas recir‐
culation valve -N18- -arrow-.
– Renew bolts for retaining frame.
Note
Camshafts must be in correct position in axial bearings in retain‐

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

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


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

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

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

ing frame must be removed and camshafts installed for a
second time ⇒ page 105 .
– Detach camshaft clamp -T10252- .
– Drive in cap ⇒ Item 25 (page 99) approx. 1...2 mm deep using
thrust piece -3334- .
– Install camshaft oil seal ⇒ page 114
– Install toothed belt cover (rear).
– Insert parallel key into camshaft.
– Install camshaft sprocket. To tighten bolt, hold camshaft

sprocket in position using counterhold tool -3036- .
Note
♦ When turning the camshaft, the pistons must not be at TDC.

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

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

3. Valve gear 107

Audi TT 2007 ➤
Test sequence
– Perform measurement with retaining frame removed.
– Fit camshaft to be tested in retaining frame.
• Axial clearance: 0.05 ... 0.17 mm
3.5 Renewing valve stem oil seals

(with cylinder head installed)

Audi TT 2007 ➤

equipment required
♦ Spark plug socket and ex‐
tension -3122 B-
-3364-
-3365-
♦ Adapter -T40012-
1331-
♦ Removal / installing device
for valve cotters -VAS
5161- with guide plate for
2.0 ltr. and 3.0 ltr. FSI en‐
gine -VAS 5161/19A-
Removing valve stem oil seals

– Remove the camshafts. ⇒ page 103
Note
In order to renew the valve stem oil seals of exhaust valves of

cylinder 3 and cylinder 4, the exhaust gas recirculation valve -
N18- must alsoProtected
be removed.
– Remove roller rocker fingers and place onto a clean surface.
When doing so, make sure that roller rocker fingers are not
interchanged.
– Remove spark plugs with spark plug socket -3122 B- .
3. Valve gear 109

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

and a plastic-headed hammer.
– Screw snap-in device -VAS 5161/6- with engaging fork -VAS

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

time, turn knurled screw of assembly cartridge -VAS 5161/8-
clockwise until ends engage in valve cotters.
– Release the pressure fork -VAS 5161/2- .
– Remove assembly cartridge -VAS 5161/8- .

Audi TT 2007 ➤
– If valve stem seal puller -3364- cannot be used on account of

restricted space, knock out pin -arrow- with a punch and re‐
move the impact extractor attachment.
– Position lower part of valve stem sealpermitted
puller unless
-3364- on valve
stem oil seal. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Insert a punch -1- through hole in lower section of puller.

– Apply assembly lever to puller and pull out valve stem oil seal
-arrow-.
Installing valve stem oil seals
– To prevent damage to the new valve stem seals -B-, attach

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

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

they need to be put into insertion device -VAS 5161/18- first.
♦ Press assembly cartridge -VAS 5161/8- onto insertion device
from above and pick up valve cotters.
– Press down
permitted assembly
unless authorised bycartridge
AUDI AG. AUDI -VAS 5161/8-
AG does withorpressure
not guarantee accept any liability
fork -VAS 5161/2-
with respect and pull
to the correctness knurledinscrew
of information of assembly
this document. Copyright bycar‐
AUDI AG.
tridge up, at the same time turning it in both directions.
– Release the pressure fork -VAS 5161/2- with knurled screw
still in pulled-out position.
– Remove disassembly and assembly tool -VAS 5161- .
mantling.
– Installing camshafts ⇒ page 103 .


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

new valves. Renew cylinder head if wear limit is still exceeded.
3. Valve gear 113

Audi TT 2007 ➤
3.7 Renewing exhaust camshaft oil seal

equipment required
♦ Assembly tool -3066-
♦ Puller -T40001-
Pin wrench -T10020-

Audi TT 2007 ➤

Removing

air mass meter.
WARNING

3. Valve gear 115

Audi TT 2007 ➤

– Loosen camshaft sprocket (apply counterhold tool -3036- ).
– Detach the camshaft sprocket using puller -T40001- and claws

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

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

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

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

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

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

-3036- ).
Note
If a piston is at TDC the valves could strike the piston when turning
the camshaft. Pistons must therefore not be at TDC This could
otherwise result in damage to valves and pistons.

Audi TT 2007 ➤
17 – Lubrication
1 Oil pump and sump
Note
If large quantities of metal shavings or other particles are found

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

Viscosity grades
Protected by copyright.and oil for
Copying specifications: ⇒purposes,
private or commercial Maintenance
in part or in; whole,
Bookletis not
810permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Oil capacities: ⇒ Exhaust emissions test
1.1 Sump - exploded view

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

Audi TT 2007 ➤
9 - Sump
❑ Clean sealing surface
before installing
10 - Bolt
11 - Seal
❑ Attached to ⇒ Item 12 (page 120) .
12 - Oil drain plug
❑ 30 Nm
❑ With captive seal
❑ Renew
13 - Chain sprocket
14 - Bolt
❑ 10 Nm
15 - Protective cap
16 - With oil level/oil temperature sender -G266-
17 - Seal
❑ Renew
❑ Lubricate before installing
18 - Bolt
❑ Renew
19 - Chain guard
20 - Chain
21 - Sealing flange (front)
❑ Must be positioned on dowel pins
Tightening sequence for sump with respect to the correctness of information in this document. Copyright by AUDI AG.
1. Tighten bolts -1...20- securing sump to cylinder block in di‐
agonal sequence initially to 5 Nm.
2. Tighten sump/gearbox bolts -arrows- to 40 Nm.
3. Tighten bolts securing sump to cylinder block in diagonal
sequence to 15 Nm.


Audi TT 2007 ➤
♦ Allen key (long reach) -T10058-

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

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

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

– Unplug connector from charge air pressure sender -G31- ⇒
Rep. Gr. 24 ; Overview of fitting locations .
– Remove air pipe.

sender -G266- .
– Unbolt oil return pipe from turbocharger -arrows-.
– Drain off engine oil.

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

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

silicone sealant.
– Remove sealant residue from cylinder block using a flat scra‐

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

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

mm).

Audi TT 2007 ➤
– Apply the bead of silicone sealant onto the clean sealing sur‐
face of the sump, as illustrated.
♦ Thickness of sealant bead: 2 ... 3 mm
Note

silicone sealant.
♦ The bead of sealant must not be thicker than specified, other‐
wise excess sealant can enter the sump and obstruct the
strainer in the oil intake pipe.
♦ Be particularly careful when applying the bead of sealant
around the rear sealing flange (arrows in illustration).
– Fit sump immediately and tighten bolts as follows; tightening

Note

sure that sump is positioned flush with cylinder block at fly‐
wheel end.
oil.
– Fill up with engine oil and check oil level.

quence. Note the following points:
1.3 Balance shaft assembly with oil pump -

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

Audi TT 2007 ➤
1 - Chain guard
2 - Chain
running direction (fitting
position) with paint
3 - Dowel sleeves
4 - Spacer plate
with oil pump
that the two dowel
pump/cylinder block are
fitted
⇒ page 127
6 - Bolt
❑ 9 Nm
7 - Cover
❑ Prevents foam build-up
in engine oil
8 - Bolt
❑ 40 Nm
9 - Bolt
❑ 8 Nm
11 - O-ring
❑ Renew
12 - Bolt
❑ Renew
❑ Note different bolt lengths ⇒ page 127
13 - Bolt
❑ Renew
❑ Note different bolt lengths ⇒ page 127
14 - Outer rotor
❑ Check contact surfaces for scores
❑ Marking must
permitted unlessbe visible
15 - Inner rotor
16 - Oil pump cover
17 - Chain sprocket
18 - Bolt
❑ Renew

Audi TT 2007 ➤
19 - Chain tensioner with tensioning rail

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

A - Hexagon collared bolt M7x40
B - Hexagon collared bolt M7x70
C - Hexagon collared bolt M7x90
D - Hexagon collared bolt M7x55
E - Screw plug with O-ring
Tightening sequence for balance shaft housing

1. Screw in bolts -arrows- hand-tight.
2. Tighten bolts -arrows- to 15 Nm in diagonal sequence start‐
ing from inside and working outwards.
3. Turn bolts -arrows- 90° further (1/4 turn) in diagonal se‐
quence starting from inside and working outwards using a
rigid wrench.
1.4 Removing and installing balance shaft

assembly with oil pump
Removing
WARNING
The engine must only be turned at the crankshaft, in the direc‐

tion of normal engine rotation (clockwise).

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

Marking on camshaft sprocket must align with arrow on tooth‐
ed belt cover.
– Pull off chain guard. Retaining tabs can be released with a

small screwdriver (insert in openings -arrows-).
– Loosen bolt on oil pump chain sprocket. Counterhold on cen‐

tral bolt of vibration damper.

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

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

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

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

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

as shown -arrows-.
– Install balance shaft
permitted assembly
unless authorised bywith
AUDI AG.oil pump
AUDI AGand spacer
does not plate.
Tighten securing bolts
with respect -arrows-,
to the correctnessworking from
of information inside
in this outwards.
Note
♦ Note different bolt lengths. ⇒ page 127

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

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

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

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

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

– Pre-tension the piston by hand -arrow-.
– Press chain rail in direction of arrow and lock in position using

a 3 mm Allen key -1-.

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

Sump with balance shaft assembly ⇒ page 119
Balance shaft assembly with oil pump ⇒ page 125
1 - Pipe
❑ 1.4 bar - black
❑ 21 Nm
3 - Bolt
❑ 15 Nm
❑ With earth wire for oil
pressure switch
4 - Bracket
5 - Bolt
❑ 15 Nm
6 - Oil cooler
❑ Ensure clearance from
surrounding compo‐
nents
connections
⇒ page 146
⇒ page 134
7 - Gasket
❑ Renew
8 - Oil filter housing
❑ RemoveProtected and install us‐ Copying for private or commercial purposes, in part or in whole, is not
by copyright.
ing oil filter tool unless
permitted -3417- or by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
36 mm socket, e.g.to the correctness of information in this document. Copyright by AUDI AG.
with respect
socket, 36 mm -T10125-
❑ Draining ⇒ page 133
9 - Screw plug
10 - Seal
❑ Renew
❑ Lubricate lightly with oil
12 - Bolt
❑ 15 Nm
13 - Baffle plate

Audi TT 2007 ➤
14 - Gasket
❑ Renew
Installation position of baffle plate
Installation position of seal

– Note position of service tab on seal -arrow-.
– Flat side of seal must face outwards.
2.2 Draining oil filter housing
Note
A valve in the oil filter housing will be opened when the oil drain
adapter -T40057- is screwed in. The valve will be closed again as
soon as the oil drain adapter -T40057- is unscrewed.
2. Oil filter bracket and oil cooler 133

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


Audi TT 2007 ➤
Removing
WARNING


air mass meter.

Audi TT 2007 ➤

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

– Detach coolant hoses -arrows- from coolant pipe.

– Unscrew bolt -1- and detach coolant pipe.

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

Installing
Note
♦ Renew gaskets and seals.



Audi TT 2007 ➤
Removing
WARNING


Removing
air mass meter.


Audi TT 2007 ➤

– Take off poly V-belt. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove tensioner for poly V-belt -arrows-.

– Remove alternator ⇒ Electrical system; Repair group 27 .
– Remove intake manifold and fuel rail ⇒ Motronic direct injec‐
tion and ignition system (4-cylinder); Repair group 24; Servic‐
ing injection system

Audi TT 2007 ➤

– Detach coolant hoses -arrows- from coolant pipe.

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

– Unscrew earth cable -2- for oil pressure switch.
Installing
Note

– Install baffle plate ⇒ Item 13 (page 132) with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi TT 2007 ➤
2.5 Checking oil pressure and oil pressure switch

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

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

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

Note
♦ The cooling Protected

systembyiscopyright.
underCopying
pressure when the engine is hot.
If necessary,permitted
relieveunless
pressure before
authorised by AUDIcommencing
AG. AUDI AG doesrepair work.

♦ Hose clip pliers -V.A.G 1921- or spring-type clip pliers -VAS
5024 A- are recommended for use in installing spring-type
clips.
must align.
1. Removing and installing parts of cooling system 143

Audi TT 2007 ➤
1.1 Cooling system components (on engine) - exploded view
1 - Bolt
❑ 40 Nm
2 - Bolt
❑ 30 Nm
3 - Coolant pipe
4 - Connecting hose
5 - O-ring
❑ Renew
6 - Connection
7 - Bolt
❑ 10 Nm
8 - Retaining clip
9 - O-ring
❑ Renew
sender -G62-
❑
12 - Connecting piece Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
13 - Connecting hose with respect to the correctness of information in this document. Copyright by AUDI AG.
16 - Coolant pipe
17 - Bolt
❑ 5 Nm
19 - Coolant pipe
20 - Bolt
❑ 5 Nm
21 - Coolant distributor housing
❑ With thermostat
❑ Starts to open at 87°C
22 - Bolt
❑ 15 Nm
23 - Coolant pump
24 - Bolt
❑ 15 Nm

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

Audi TT 2007 ➤
1 - Radiator
⇒ page 158
with fresh coolant
tion pump -V51-
3 - Map-controlled engine cool‐
ing thermostat -F265-
⇒ page 155
4 - Coolant pump
⇒ page 155
5 - Cylinder head/cylinder
block
with fresh coolant
6 - Turbocharger
⇒ page 164
7 - Expansion tank
❑ With filler cap
❑ Testing pressure relief
valve in filler cap
⇒ page 151
8 - Heat exchanger
permitted (for
unlessheating
system) with respect to the correctness of information in this document. Copyright by AUDI AG.

with fresh coolant
9 - Coolant connecting pipe
11 - Intake manifold

Audi TT 2007 ➤

equipment required
-VAS 6208-
V.A.G 1921-
-VAS 6096- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Refractometer -T10007- with respect to the correctness of information in this document. Copyright by AUDI AG.
Draining
Note
WARNING


Audi TT 2007 ➤


Audi TT 2007 ➤

Filling
Note

water and radiator antifreeze/anti-corrosion agent.
♦ Only use coolant additive G 12+ in accordance with TL -
VW 774 F- . Other coolant additives could seriously impair in
particular the anticorrosion properties. The resulting damage
gine damage.
♦ Coolant additive G12+ can be mixed with additives G11 and
G12.
♦ G 12+ and coolant additives marked "meeting specification TL
-VW 774- F" prevent frost and corrosion damage as well as
year round with the correct antifreeze and anticorrosion addi‐
tive.
ical climates.
antifreeze concentration must be at least 40 %.
amount of G 12+ can be increased, but only up to 60 % (this
gives frost protection to about -40 °C), as otherwise frost pro‐
tection is reduced again, as is cooling effectiveness.
ket or cylinder block are renewed, do not reuse old coolant.
♦ For checking anti-freeze protection in cooling system, use re‐
fractometer -T10007- for coolant additive G12+.
– Connect bottom coolant hose to radiator -arrow-.


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

least 8 litres of premixed coolant (based on recommended ra‐
tio):
♦ G12+ (40%) and water (60%) for frost protection to -25 °C
– Screw adapter for cooling system tester -V.A.G 1274/8- onto
coolant expansion tank.
– Fit cooling system charge unit -VAS 6096- onto adapter for
cooling system tester -V.A.G 1274/8- .
– Run vent hose -1- into a small container -2-. (The vented air
draws along a small amount of coolant, which should be col‐
lected.)
– Close the two valves -A- and -B- (levers at right angles to di‐
rection of flow).
• Pressure: 6 ... 10 bar
– Open valve -B- (lever in direction of flow).

The suction jet pump generates a partial vacuum in the cooling
system.
• The needle on the gauge should move into the green zone.
– Additionally open valve -A- briefly (lever in direction of flow) so
that thewith
hose oftocooling
respect system
the correctness chargein unit
of information -VAS 6096-
this document. Copyrightis byfilled
AUDI AG.
with coolant.
The suction jet pump will continue generating a vacuum in the
cooling system.
• The needle on the gauge should remain in the green zone.
sequent filling.
If the needle does not reach the green area, repeat the process.
If the vacuum level drops, there is a leak in the cooling system.
– Open valve -A-.
The vacuum in the cooling system causes the coolant to be drawn
out of the cooling system charge unit -VAS 6096- ; the cooling
system is then filled.

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

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

is at normal operating temperature, the coolant level must be
on the MAX mark; when the engine is cold, between the MIN
and MAX marks.
– Switch off engine.

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

Audi TT 2007 ➤
Test condition
Test sequence
WARNING


– Fit cooling system tester -V.A.G 1274- with adapter for cooling
system tester -V.A.G 1274/8- on coolant expansion tank.
– Using hand pump on tester, build up a pressure of approx. 1.0
bar.
Checking pressure relief valve in cap.
– Fit cooling system tester -V.A.G 1274- with adapter for cooling
system tester -V.A.G 1274/9- on filler cap.
– Operate hand pump.
♦ The pressure relief valve should open at a pressure of
1.4 ... 1.6 bar.
1.6 Removing and installing coolant pipes


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

– Take out intake connecting pipe downwards.
– Drain off coolant ⇒ page 147 .

Audi TT 2007 ➤
– Unplug electrical connectors -arrows-.
– Detach coolant hoses from coolant pipes -arrows-.
– Detach hose -A- and unscrewwith
bolt -B-.to Remove
respect front
the correctness coolant
pipe.
– Release connectors -A- from bracket, detach hose -B- and

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


Audi TT 2007 ➤
1.7 Removing and installing coolant distrib‐

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

ing with map-controlled engine cooling thermostat -F265- from
engine.
Installing
Note

– Clean sealing surface for O-ring.

– Renew O-ring and lubricate with coolant.
– Install alternator ⇒ Electrical system; Rep. Gr. 27 ; Alternator .
– Fill up with coolant ⇒ page 147Protected


Audi TT 2007 ➤
Removing
WARNING


air mass meter.

Audi TT 2007 ➤

– Unscrew coolant pump securing bolts -1- and remove coolant

pump -2-.
– Remove O-ring -3-.
Installing
– Coat new O-ring -3- with coolant G12+.

wards.
– Tighten coolant pump bolts -1-.
– Fit toothed belt ⇒ page 66 .

Audi TT 2007 ➤

⇒ page 163
2 - Nut
❑ 10 Nm
3 - Radiator cowl
❑ To connection at cylin‐
der head
5 - O-ring
6 - Radiator
⇒ page 158
coolant in entire system
7 - O-ring
❑ To connection for ther‐
mostat
9 - Bolt
❑ 5 Nm
❑ To charge air cooler
10 - Nut
❑ 10 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 5 Nm
❑ To radiator


Audi TT 2007 ➤
Removing
WARNING


– Disconnect intake connecting pipe -arrow- with hose clip pliers
-V.A.G 1921- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unbolt air intake connection at front of lock carrier -1- and re‐
move air intake connection.

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


Audi TT 2007 ➤
– Detach top coolant hose from radiator -arrow-.
– Unscrew bolts -arrows- on backside of radiator.

– Lift up radiator slightly and remove from below.

Installing


Audi TT 2007 ➤
Removing

Installing

Audi TT 2007 ➤
1.12 Removing and installing radiator fan -

V7- and radiator fan 2 -V177-
Removing
– Move wiring clear.
– Unscrew nuts -arrows- and remove fans.
Installing

Audi TT 2007 ➤
1 Turbocharger
Note
♦ Observe the rules for cleanliness ⇒ page 4

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

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

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

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

– Push charge air hose into connector as far as stop.
– Move securing clip to locked position -2- and press charge air
hose in once again.
– Then pull hose to check that it is fitted correctly and that plug-
in connector is locked.

Part I permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Part II ⇒ page 167
Part III ⇒ page 168
Part IV ⇒ page 169
1. Turbocharger 165
Audi TT 2007 ➤
1 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold and vacuum
unit as one unit
⇒ page 170
2 - Gasket
❑ Renew
3 - Bolt
❑ 9 Nm
4 - Crankcase breather hose
5 - Heat shield
6 - ACF line
7 - Vacuum unit/pressure ac‐
tuator for turbocharger
⇒ page 179
❑ Adjusting ⇒ page 179
8 - Nipple
9 - Seal
❑ Renew
10 - Hose
11 - Hose
12 - Bolt
❑ 3 Nm
14 - Bolt
❑ 8 Nm
15 - Seal
❑ Renew
16 - Connection
17 - Securing clip
18 - Bolt
❑ 9 Nm
19 - Hose
20 - Bolt
❑ 7 Nm
21 - Mounting bracket
22 - Bolt
❑ 7 Nm
23 - Turbocharger air recirculation valve -N249-
❑ Note installation position ⇒ page 167

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

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

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

Audi TT 2007 ➤
11 - Bracket
12 - Bolt
❑ 23 Nm
13 - Nut
❑ 30 Nm
❑ Do not open when removing turbocharger
❑ Renew
❑ Coat studs of exhaust manifold with high-temperature paste
14 - Fastening strip
Part IV
Part I ⇒ page 165
1 - Turbocharger
gether withProtected
exhaust by copyright. Copying for private or commercial purposes, in part or in whole, is not
manifold and vacuum
unit as one unit

⇒ page 170
2 - Vacuum unit for turbocharg‐
er
⇒ page 179
3 - Bolt
❑ 10 Nm
4 - Locking plate
5 - Nut
❑ 9 Nm
❑ Secure with sealing
paint
❑ Sealing paint ⇒ Parts
catalogue
6 - Knurled nut
1. Turbocharger 169
Audi TT 2007 ➤

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

♦ Tensioning strap -T10038-

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


– Disconnect coolant pipe going to coolant expansion tank

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

– Unscrew coolant line -3-.
Note
– Remove heat shield -arrows-.

– Unscrew crankcase breather line with heat shield from turbo‐

charger -1-.
– Disconnect crankcase breather line from cylinder head cover
-2- and remove.
– Disconnect ACF line going to turbocharger from cylinder head
cover -3-.
– Unscrew oil supply pipe from turbocharger -4-.
– Remove electrical connector -arrow- for Lambda probe -G39-

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

Audi TT 2007 ➤

– Remove catalytic converter with front exhaust pipe
⇒ page 191
– Remove noise insulation frameCopying

Protected by copyright. -arrow-.
– Remove drive shaft
with(right-side) ⇒ Rep.
respect to the correctness Gr. 40 in this document. Copyright by AUDI AG.
of information
1. Turbocharger 173
Audi TT 2007 ➤
– Detach air pipe -arrow- frombycharge

Protected copyright. air cooler.

– Detach electrical connectors -1 and 2- and move wire clear.
Note

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

– Use tensioning strap -T10038- to move engine towards the
front.
Note
Make sure there is sufficient clearance around engine and turbo‐

charger.
– Disconnect coolant pipe -arrow-.
Note
♦ Shown in illustration from rear with engine removed.

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

– Lift out turbocharger/exhaust manifold.
Installing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
♦ Renew seals, gaskets and self-locking nuts.

pipe.
free of oil and grease before assembly.

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

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

nute and do not rev up immediately to ensure turbocharger is
supplied with oil.
1.4 Checking vacuum unit for turbocharger

♦ Hand-operated vacuum pump -VAS 6213-
Test condition:
♦ Hose from turbocharger via charge pressure solenoid valve -
N75- to vacuum unit must not be blocked.
♦ Charge pressure control solenoid valve -N75- OK.
1. Turbocharger 177
Audi TT 2007 ➤
Procedure:
air mass meter.

unit -arrow-.
– Move adjuster ring -1- on hand-operated vacuum pump -VAS

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

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

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

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

turbocharger
Removing
– Remove turbocharger ⇒ page 170
– Detach locking plate -1- on turbocharger linkage.
– Loosen lock nut -2-.

– Detach linkage from turbocharger -3-.
– Remove bolts -4- and take out vacuum unit -1-.
Installing
– Adjust vacuum unit for turbocharger ⇒ page 179 .
– Install turbocharger ⇒ page 170
1.6 Adjusting vacuum unit for turbocharger

Turbocharger removed
1. Turbocharger 179
Audi TT 2007 ➤

equipment required
♦ Universal dial gauge brack‐
et -VW 387-
♦ Hand-operated vacuum
pump -VAS 6213-
♦ Pressure control valve -
VAS 6342-
♦ Turbocharger tester -V.A.G
1397A-
♦ Dial gauge set, 4 pieces -
VAS 6341-
1783-
♦ Open-end spanner insert AF 10 -V.A.G 1783/1-
Adjusting
• Tightening torques ⇒ page 169 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

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

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

bocharger tester -V.A.G 1397A- (connection II) and pressure
control valve -VAS 6342- as shown in illustration.
– Close pressure control valve -VAS 6342- at lever -1-.
– Move adjuster ring -1- on hand-operated vacuum pump -VAS

6213- to position -B- to select “pressure”.
– Switch on turbocharger tester -V.A.G 1397A- and set sliding
switch to position II.

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

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

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

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

bocharger tester -V.A.G 1397A- indicates 350 +/- 5 mbar.
– Read off and note value indicated on dial gauge -VAS 6341/1- .
bocharger tester -V.A.G 1397A- indicates 650 to 700 mbar.
pressure reading drops to 350 +/- 5 mbar.
– Add values 1 and 2 together and divide by 2.
– The result (mean value) should be 5 +/- 0.25 mm.
– If the result (mean value) is not 5 +/- 0.25 mm, correct the
setting accordingly, tighten the lock nut hand-tight and repeat
the measurement.
– If the result (mean value) is 5 +/- 0.25 mm, tighten the lock nut
and secure withProtected
sealing paint. For
by copyright. sealing
Copying paint
for private refer to
or commercial ⇒ in part or in whole, is not
purposes,
Parts cataloguepermitted
. with respect
1. Turbocharger 183
Audi TT 2007 ➤
– Secure locking plate -1- on linkage of vacuum unit.

Audi TT 2007 ➤
2 Charge air system

Charge air cooler - exploded view of components ⇒ page 185
Turbocharging diagram ⇒ page 186
Checking charge air system for leaks ⇒ page 187
2.1 Charge air cooler - exploded view of components
1 - Bolt
❑ 5 Nm
2 - Mounting
❑ For charge air cooler
4 - Charge air pipe
❑ Fitting hose connec‐
tions with plug-in con‐
nectors ⇒ page 164
5 - Bolt
❑ 10 Nm
6 - Charge air hose
❑ Fitting hose connec‐
tions with plug-in con‐
7 - Hose clip
8 - Charge air hose
❑ To throttle valve module
-J338-
9 - Hose clip
10 - Bolt
❑ 10 Nm
11 - Charge air pipe
12 - Hose clip
13 - Charge air hose
❑ Fitting hose connec‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
tions with plug-in con‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
14 - Seal
❑ Renew
16 - Bolt
❑ 5 Nm
17 - Bolts
❑ 10 Nm
2. Charge air system 185

Audi TT 2007 ➤
2.2 Turbocharging diagram
1 - Vacuum unit
2 - Solenoid valve for charge
pressure control -N75-
3 - Turbocharger air recircula‐
tion valve -N249-
4 - Turbocharger
5 - Brake servo
7 - Coolant hose/pipe connec‐
tion
8 - Vacuum pump
11 - Activated charcoal filter
solenoid valve 1 -N80-
12 - Dual non-return valve
J338-
15 - Pressure control valve
16 - To activated charcoal filter
17 - Air mass meter -G70- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

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

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

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

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

– Detach charge air cooler upwards and remove from below.
Installing
– Install front bumper cover ⇒ General body repairs, exterior;
Rep. Gr. 63


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

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

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

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

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

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

retention test.
♦ Operation of ultrasonic tester -V.A.G 1842- ⇒ Operating in‐
structions .
♦ Release pressure by detaching coupling from adapter -V.A.G
1687/5- before removing adapter.

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

pipe must not be bent more than 10°.
♦ Renew gaskets and self-locking nuts.
♦ The exhaust manifold and the turbocharger are one compo‐
nent; removing and installing ⇒ page 164
1.1 Exhaust system - exploded view
1 - Bolt
❑ 23 Nm
2 - Bracket for exhaust system
3 - Clamp
it is free of stress before
tightening clamp
⇒ page 194
⇒ page 191
❑ Tighten bolt connec‐
tions evenly.
4 - Nut
❑ 23 Nm
6 - Rubber mounting
7 - Rubber mounting
8 - Mounting
❑ 23 Nm
10 - Tunnel brace
11 - Gasket
❑ Renew
12 - Nut
❑ 40 Nm
❑ Renew

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

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

– Position clamp at angle shown when installing. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Bolt connections face to right. with respect to the correctness of information in this document. Copyright by AUDI AG.
• Nuts face upwards.

• α = approx. 20°
1.2 Removing and installing front exhaust

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

Audi TT 2007 ➤
Removing
air mass meter.
– Unplug electrical connector -arrow- for Lambda probe -G39-

and Lambda probe heater -Z19- and move wiring clear.


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

charger accessible from above.
clear.

-G130- .


Audi TT 2007 ➤
Note

silencer.
Installing
Note
Renew gaskets and self-locking nuts.
1.3 Aligning exhaust system

– Loosen bolt connections of front clamp ⇒ Item 3 (page 190) .
– Push rear silencer towards front of vehicle -arrow-, so that
rubber mounting (left-side) is preloaded by dimension -a- =
11 ... 13 mm.

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

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

– At the same time, distance -b- must be obtained between
bumper cut-out and top of tailpipes.
♦ Dimension b = min. 21 mm
– If necessary, unfasten rear silencer mounting to align tailpipes.

– Start engine and run at idling speed.
– Plug the tailpipe (e. g. with rags or stopper) and leave plugged
until the check is complete.
– Listen for noise at connection points (cylinder head/exhaust
manifold, exhaust manifold/front exhaust pipe, etc.) to locate
any leaks.

Service
Workshop Manual
Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve

turbo TTS), mechanics
Engine ID
CDL CDL CDM
A B A
Edition 01.2008

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system


Audi TT 2007 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo TTS), mechanics - Edition 01.2008
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1 Procedure before opening high-pressure section of injection system . . . . . . . . . . . . . . . . 5
turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Separating engine from manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Separating engine and S tronic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.1 Poly V-belt drive, bracket for ancillaries - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.8 Removing andbyinstalling
Protected sealing
copyright. Copying flange
for private (pulleypurposes,
or commercial end) in. part
. . or
. .in.whole,
. . . .is.not. . . . . . . . . . . . . . . . . . . 59
2 Cylinder block (gearbox
with respect end) of.information
to the correctness . . . . . .in. this
. . document.
. . . . . .by. AUDI
. . . AG.
...................... 63
2.1 Dual-mass flywheel and sealing flange (gearbox end) - exploded view . . . . . . . . . . . . . . . . 63
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.6 Removing and installing drive chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.3 Measuring axial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Contents i
Audi TT 2007 ➤

1.1 Toothed belt drive - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.1 Cylinder head cover and cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.2 Removing and installing inlet camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . 92
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.4 Renewing exhaust camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.5 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.11 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1 Oil pump and sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.1 Sump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.4 Balance shaft assembly with oil pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.5 Removing and installing balance shaft assembly with oil pump . . . . . . . . . . . . . . . . . . . . . . 136
2 Oil filter bracket and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.1 Oil filter bracket and oil cooler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.2 Draining oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.3 Removing and installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
2.4 Removing and installing oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.8 Engine oil . . . . . . . . . . . . . . . . . . Protected
. . . . . by
. .copyright.
. . . . . Copying
. . . . .for. private
. . . . or. .commercial
. . . . . .purposes,
. . . . . in. part
. . .or. in. whole,
. . . is151
not
2.9 Checking engine oil level . . . . . . . .with . . respect

. . . . to. .the. .correctness
. . . . . .of. information
. . . . . . in. this
. . document.
. . . . . by . .AUDI
. . .AG.151
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2 Coolant pump and coolant thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.1 Coolant pump and thermostat with housing - exploded view . . . . . . . . . . . . . . . . . . . . . . . . 160
2.4 Removing and installing thermostat with housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3 Coolant pipes and continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . . . . . . . 164
3.1 Coolant pipes - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3.3 Removing and installing coolant pipes 1 and 2 (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.4 Removing and installing coolant pipe (front right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.5 Continued coolant circulation pump V51 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 170
ii Contents
Audi TT 2007 ➤
3.6 Removing and installing continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . 171
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.1 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.2 Removing and installing air pipes and hoses with plug-in connectors . . . . . . . . . . . . . . . . 178
1.5 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.6 Removing and installing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.7 Adjusting vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2 Charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.2 Removing and installing charge air pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . 195
2.3 Removing and installing turbocharger air recirculation valve N249 . . . . . . . . . . . . . . . . . . 195
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

1 Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.2 Removing and installing front exhaust pipe with catalytic converter and front silencer . . . . 202
2 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3 Exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3.1 Checking vacuum unit for exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Contents iii
Audi TT 2007 ➤
iv Contents
Audi TT 2007 ➤
1 Engine number
♦ The engine number (“Engine code” and “Serial number”) can

be found on the left of the joint between engine and gearbox
-arrow-.
♦ The engine code letters are also stamped on the right of the
cylinder head -2- and on the cylinder block -1-.
♦ Additionally there is a sticker on the toothed belt cover with“En‐
gine code” and “Serial number”.
ters.
number.
Note

1. Engine number 1
Audi TT 2007 ➤
2 Engine data
Code letters CDLA CDLB CDMA
Capacity ltr. 1.984 1.984 1.984
Power output kW at rpm 195/6000 199/6000 195/6000
Torque Nm at rpm 350/2500 … 5250 350/2500 … 5250 350/2500 … 5250
Bore ∅ in mm 82.5 82.5 82.5
Stroke mm 92.8 92.8 92.8
Compression ratio 9.8 9.8 9.8
RON not less than 98 1) 98 1) 98 1)
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Emission standards EU4 EU4 EU4
Exhaust gas recirculation no no no
Turbocharging/supercharging Turbocharger Turbocharger Turbocharger
Knock control yes yes yes
Charge air cooling yes yes yes
Lambda control
Protected by copyright. Copying for private or commercial purposes,2 probes 2 probes
in part or in whole, is not 2 probes
Variable
permitted valve
unless timing
authorised by AUDI AG. AUDI AG does not Inlet
guarantee Inlet
or accept any liability
Inlet
Intake manifold change-over no no no
Secondary air system no no no
Valves per cylinder 4 4 4
• 1) Unleaded premium RON 95 can also be used, but results in reduced power

Audi TT 2007 ➤
WARNING
The fuel system operates at extremely high pressure. This can

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.
♦ Wrap a clean cloth around the connection and carefully
loosen the connection to allow the residual pressure to
dissipate.
– Procedure before opening high-pressure section of injection

system ⇒ page 5 .
WARNING
Escaping fuel can cause a fire risk.

♦ The power supply for the fuel pump control unit -J538-
must be disconnected before opening the fuel system, as
the fuel system pressurisation pump -G6- will be activated
briefly when the driver's door is opened with the battery
still connected.
– Remove luggage compartment side trim (right-side) ⇒ Rep.

Gr. 70 .
Audi TT 2007 ➤
– Remove fuse 6 in fuse holder F -SF6- for fuel pump control

unit -J538- in fuse holder in luggage compartment (right-side).
tester cables.
– Connect vehicle diagnostic, testing and information system -
VAS 5051B- .
Caution

battery.
– Disconnect battery ⇒ Rep. Gr. 27 . with respect to the correctness of information in this document. Copyright by AUDI AG.
WARNING

hot.
♦ Cover filler cap on expansion tank with a cloth and open
carefully to dissipate pressure.

Audi TT 2007 ➤

WARNING

erly secured.
secured.
TT Coupé:
TT Roadster:
the passenger.
3.1 Procedure before opening high-pres‐

sure section of injection system
♦ The injection system consists of a high-pressure section (max‐
imum approx. 120 bar) and a low-pressure section (approx.
6 bar).
♦ Before removing a component in the high-pressure section of
the injection system, the fuel pressure in the high-pressure
section must be reduced to a residual pressure of approx.
6 bar; follow the procedure outlined below.
♦ Vehicle diagnostic, testing and information system -VAS
5051B-
Procedure
Proceed as follows:
and information system -VAS 5051B- with diagnosis lead to
diagnosis connection. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Audi TT 2007 ➤
Display on -VAS 5051B- :

– Select Vehicle self-diagnosis from the list -item 1-.

– From menu -1-, select vehicle system “Engine electronics” and
press → key to continue.

– From menu -1-, select function “Measured values” and press
→ key to continue.

– Press keys 1 4 0 on keypad -1- to select “Display group 140”
and confirm entry by pressing Q key.

Audi TT 2007 ➤

– Check display indicating fuel pressure in fuel rail in display
zone -3-.
• With engine idling the figure displayed will be 35 ... 45 bar. The
display shows the actual pressure in the fuel rail which is being
generated by the high-pressure pump.
Gr. 70 .

Audi TT 2007 ➤

– With engine still running, check display zone -3- for fuel pres‐
sure in fuel system:
• The fuel pressure will decrease very quickly because the me‐
chanical high-pressure pump is no longer being supplied with
fuel from the fuel tank by the electric fuel pump.
– Switch off ignition as soon as fuel pressure has dropped to just
below 8 bar.
Note
Fuel pressure must not fall below 6 bar, otherwise the engine will
stall (this could damage the catalytic converter).
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. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Before opening the high-pressure with
section
respect of thecorrectness
to the fuel sys‐ of information in this document. Copyright by AUDI AG.
tem, place a clean cloth around the connection to catch
escaping fuel.
– Disconnect a fuel line connection without delay.
Note
The pressure will increase again due to the effect of residual heat
if the high-pressure system is not opened immediately.

– Re-fit fuse 6 in fuse holder F -SF6- .
– Generate readiness code in engine control unit ⇒ Vehicle di‐
agnosis, testing and information system VAS 5051.

Audi TT 2007 ➤

turbocharger
opening.
♦ Seal off open lines and connections with clean plugs or sealing
caps immediately.
etc.).

used.
Note the following:
warranty.

and
Protected wiring
Mark hydraulic lines,
with respect vacuum
to the lines
correctness and electrical
of information wiring
in this document. before
removal so they can be re-installed in the original positions and
correctly connected. Make sketches or take photographs if nec‐
essary.

Audi TT 2007 ➤

1 Removing engine

equipment required
-VAS 6208-
V.A.G 1383 A-
1921-

Audi TT 2007 ➤
♦ Tool set for wiper arms -T10369-

Procedure
Proceed as follows:
Note

gearbox.
posal.
WARNING

cause injury.
♦ Do not open the high-pressure section of the injection
system when removing the engine.
♦ However, if the engine has to be removed for repair pro‐
cedures which necessitate opening the high-pressure
section, the fuel pressure in the high-pressure section
must be reduced in a controlled manner to a residual pres‐
sure prior to opening.
– Reduce fuel pressure in high-pressure section of injection sys‐

tem ⇒ page 5 .
Audi TT 2007 ➤
Caution


– Remove rear cross panel trim if cover for negative terminal
Protectedofby copyright. Copying for private or commercial purposes, in part or in whole, is not

terminal.
– Slacken nut a few turns and disconnect battery clamp on earth

cable -arrow- from battery terminal.
WARNING

hot.
– Open filler cap on expansion tank.

– Remove front noise insulation -1- ⇒ Rep. Gr. 66 .

Audi TT 2007 ➤
– Remove noise insulation on left and right sides -arrows-.
– Remove noise insulation frame -arrow- together with rear

noise insulation ⇒ Rep. Gr. 66 .
– Lift retaining clip, disconnect coolant hose (bottom) -arrow-
– Disconnect bottom coolant hose leadingpermitted
to continued coolant
circulation pump -V51- -arrow- and drain with
off respect
coolant.to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤

– Detach coolant hoses -1- and -2-.

Audi TT 2007 ➤
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
Observe rules for cleanliness when working on the fuel supply

system ⇒ page 9 .
– Remove protective sleeve -2- and disconnect fuel hose by

pressing release ring.
– Release activated charcoal filter -arrow B-, lift off -arrow A- and
– Remove bolts -1- and lift out radiator cowl.
Audi TT 2007 ➤
– Lift retaining clip and disconnect coolant hose (top) -arrow-

from radiator.
– Remove bolts -arrows- on reverse side of radiator.

– Remove radiator upwards.
Vehicles with air conditioning:
Caution


-arrow-.


Audi TT 2007 ➤
– Remove bolts -arrows- and detach alternator from bracket for

ancillaries.
Note
♦ If alternator sticks in its bracket, screw bolt back in again down

to the last 2 turns.
♦ Tap carefully on bolt heads with flat side of hammer to release
bushes of alternator mountings.
– Swivel alternator towards right side of vehicle with electrical

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

– Unscrew electrical wiring -1- and clamp -3- and remove from
alternator.
– Lift out alternator.
– Unplug electrical connector -1- for magnetic clutch on air con‐

ditioner compressor.
Caution
Danger of damage to refrigerant lines and hoses.


– Detach air conditioner compressor from bracket for ancillaries
and tie up to the right side.

– Unplug electrical connector -2- for air mass meter -G70- .
– Unscrew top section of air cleaner housing -arrow- and re‐
move air filter element.
Audi TT 2007 ➤
– Remove bolts -arrows- and detach bottom section of air clean‐

er housing.
– Remove bolts -arrows- and detach bracket for air cleaner
housing.
– Take electrical connector -arrow- for Lambda probe -G39- out

of bracket, unplug and move clear.


Audi TT 2007 ➤

– Release hose clip -1- and lay air pipe on engine (hose -2- re‐
mains attached).
Note
Disregard item -3-.
– Unscrew bolts -arrows- and nuts -1- and detach heat shield.
– Working from above, unscrew nuts -arrows- securing front ex‐

haust pipe to turbocharger.
– Detach coolant hoses -arrows- leading to heat exchanger.
Audi TT 2007 ➤
– Disconnect vacuum hose -1- coming from non-return valve.

– Pull non-return valve -arrow- off brake servo.

– Apply puller -T10369/1- to wiper arm -1- as shown in illustra‐

tion.
– Apply thrust piece -2- onto wiper shaft.
– Turn bolt -3- in clockwise direction until wiper arm is pulled off
wiper shaft.
– permitted
Remove unlessnuts andbydetach
authorised AUDI AG.windscreen wiper
AUDI AG does not arms.
Caution

♦ Apply a small quantity of soap solution to transition be‐
tween windscreen and plenum chamber cover -2-. Then,
starting at edge of windscreen, carefully pull plenum
chamber cover upwards off retainer at windscreen.
– Detach plenum chamber cover -2- by pulling it carefully off re‐

– Detach engine wiring harness (rear) at plenum chamber par‐
tition panel.

Audi TT 2007 ➤
– Remove engine control unit ⇒ Rep. Gr. 24 .

– Unplug electrical connector -1- for engine wiring harness
-arrow-.

Audi TT 2007 ➤

engine.
– Unscrew terminal 30 wire -arrow- from electronics box in en‐

gine compartment and move it clear.

– Cut open cable tie -arrow- for protective cover -3-.
– Push back protective cover and unscrew B+ cable at starter
solenoid switch
– Remove nut -1- for earth wire.
– Remove top starter bolt.

Audi TT 2007 ➤
– Detach cable support bracket from gearbox -arrows-.
– Unclip circlip -1- from gear selector cable and circlip -2- from
gate selector cable.
– Pull selector cable end-pieces with selector cables off selector
shaft lever and relay lever.
– Tie selector cables with cable support bracket to one side.
– Clamp off pressure hose to clutch slave cylinder using a hose

clamp -3094- .
– Pull securing clip upwards -arrow- and detach pipe/hose as‐
sembly -1- from bleeder connection on clutch slave cylinder.
Caution

♦ Do not operate clutch pedal after detaching pipe/hose as‐
sembly from bleeder connection on clutch slave cylinder.
Audi TT 2007 ➤
Vehicles with S tronic gearbox:

solenoid switch
– Unscrew earth wire -3-.
Caution
Risk of damage to control unit (mechatronic unit) by static dis‐

charge.
♦ Do NOT touch connector contacts in gearbox connector
with your hands.
– Touch vehicle earth with bare hands to discharge any static

charge.
– Turn retainer catch anti-clockwise and unplug electrical con‐
nector -4- at gearbox.
Note
Disregard -arrows-.

– Loosen bolts -arrows- for assembly mounting (engine end)
approx. 2 turns.
– Loosen bolts -arrows- for assembly mounting (gearbox end)

approx. 2 turns.

Audi TT 2007 ➤

relation to each other for re-installation.
– Remove bolts -arrows- for flexible coupling for propshaft at
bevel box (counterhold using a suitable lever at the triangular
flange).
Caution
Make sure not to damage the oil seal -arrow- in the propshaft
flange.
– Unscrew bolts -1- and -2- at bracket for electrical connector

for Lambda probe (on underbody) and remove cover.
– Remove bolt -3- and move electrical wire to Lambda probe
clear.
– Take plug-in connector -arrow- out of bracket.

– Unplug electrical connector for Lambda probe after catalytic
converter -G130- and move clear.
Audi TT 2007 ➤
– Remove bolts -arrows- and detach bracket for exhaust system

and tunnel brace.
Caution
Avoid damage to flexible joints.

♦ Do not bend flexible joints in front exhaust pipe more than
10°.
– Slacken nuts -arrows- at clamp and disconnect exhaust sys‐

tem.
– Detach front exhaust pipe with catalytic converter and front
silencer.

– Remove bolts -1- for support bracket.
– Pull off securing clip -3- -arrow- and remove selector lever ca‐
ble from gearbox.
Note
Disregard item -2-.
Caution
Make sure not to damage the oil seal in the propshaft flange.
♦ When removing the bolts for the pendulum support/sub‐
frame, the engine/gearbox assembly swings slightly for‐
ward.

Audi TT 2007 ➤

sender -G266- .
– Unbolt heat shield for drive shaft (right-side) from bevel box
-arrows-.
– Unbolt drive shaft (left-side) from gearbox flange and drive
shaft (right-side)
Protected by copyright.from
Copyingbevel box
for private flange. purposes, in part or in whole, is not
or commercial
– Release hose clip -arrow- and detach air hose from charge air
cooler.

– Unscrew bolts -4- and move continued coolant circulation
pump -V51- to one side (coolant hoses -arrows- remain con‐
nected).
Note
Disregard -items 1 and 3-.
Audi TT 2007 ➤

Note

VAS 5085- .
Note

avoid damage.
– Pull engine/gearbox assembly as far forward and to the left as

possible, and lower gradually (pay attention to drive shafts).

Audi TT 2007 ➤
2 Separating engine and gearbox
2.1 Separating engine from manual gear‐

box
♦ Hooks -10 - 222 A /2-

2. Separating engine and gearbox 29

Audi TT 2007 ➤
Procedure
Proceed as follows:
support -T10012- .
– Unscrew bolts -1- and -2- and detach bracket for bevel box.

– Remove bolts -1 ... 5- securing gearbox to engine.

2.2 Separating engine and S tronic gearbox


Audi TT 2007 ➤
♦ Adapter -10 - 222 A /20-
Procedure
Proceed as follows:
support -T10012- .
– Move coolant hose clear -arrow-.

Audi TT 2007 ➤

clear at bracket.
– Unscrew bolts -1- and -2- and remove starter from gearbox.
– Detach coolant hoses -arrows- from ATF cooler.
– Slacken bolts -1- and remove bolts -2-.

Audi TT 2007 ➤
– Engage hook of lifting tackle -2024 A- in gearbox lifting eye

and secure with locking pin -arrow-.
– Attach workshop hoist -VAS 6100- to lifting tackle -2024 A-
with adapter -10 - 222 A /20- .
– Remove bolts -1, 3, 5, 6, 7, 8, 9, 10- securing gearbox to en‐

gine.
Note
Disregard items marked -2, 4 and A-.

Audi TT 2007 ➤

equipment required
VAS 6100- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Engine and gearbox sup‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
port -VAS 6095-

Audi TT 2007 ➤
Procedure
Proceed as follows:
• Gearbox detached from engine.
– Attach lifting tackle -2024 A- to engine and workshop hoist -
Note
To adjust to the centre of gravity of the assembly, the perforated

rails of the support hooks must be positioned as shown.
WARNING
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-.

-VAS 6100- .
– Secure engine to engine and gearbox support -VAS 6095-

(gearbox end) as shown in illustration.

Audi TT 2007 ➤
4 Installing engine
Tightening torques
Note

♦ Tolerance for tightening torques ± 15%.

• Further tightening torques:
Component Nm
Bolts/nuts M6 10
M7 15
M8 22
M10 40
M12 65
Earth cable 22
Item Bolt Nm
1 1) M12x55 80
2 1) M12x165 80
3 M10x105 40
4 M10x50 40
5 2) M12x65 80
• 1) Bolt with M8 stud
• 2) Screwed into gearbox from engine side.

Audi TT 2007 ➤
Securing S tronic gearbox to engine

Item Bolt Nm
1, 3 M12x55 80
5 M12x65 80
6 M12x50 80
7, 8 M10x50 40
9 M12x70 80
10 M12x55 80
2, 4 Securing starter ⇒ Rep. Gr. 27
Procedure
♦ Renew self-locking nuts and bolts.

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

– Install needle bearing if not fitted in crankshaft ⇒ page 72 .
Audi TT 2007 ➤
– Secure bracket for bevel box ⇒ Rep. Gr. 34 or ⇒ Rep. Gr.

39 .

(engine end).

(gearbox end).
Note
– Tighten bolts -2- and -3- securing pendulum support to gear‐

box ⇒ page 42 .
– Install selector lever cable ⇒ Rep. Gr. 34 .

Audi TT 2007 ➤
Caution
flange.
♦ Push engine/gearbox assembly towards bulkhead, guid‐
ing pin on bevel box flange carefully into propshaft flange.
– Tighten bolt -1- securing pendulum support to subframe

⇒ page 42 .
Audi TT 2007 ➤
– Secure propshaft with flexible coupling to bevel box ⇒ Rear

final drive 02D/0AV; Rep. Gr. 39 .
note the following:
– Install front exhaust pipe with catalytic converter and front si‐
lencer ⇒ page 202 .
– Install exhaust system and align free of stress ⇒ page 206 .
– Install heat shield for drive shaft ⇒ Rep. Gr. 39 .
– Installing and adjusting selector mechanism ⇒ Rep. Gr. 34 .
Caution

♦ Do not operate clutch pedal before attaching pipe/hose
assembly to bleeder connection on clutch slave cylinder.
– Connect pipe/hose assembly to bleeder connection on clutch

slave cylinder and bleed clutch system ⇒ Rep. Gr. 30 .
– Install alternator
Protected by⇒ Rep.Copying
copyright. Gr. 27 .
– Install polywith
V-belt ⇒topage 52 . of information in this document. Copyright by AUDI AG.
respect the correctness

– Install starter ⇒ Rep. Gr. 27
– Install noise insulation frame and noise insulation ⇒ Rep. Gr.
66 .
– Install wiper arms ⇒ Rep. Gr. 92 .
Gr. 27 .
– Check engine oil level ⇒ Maintenance ; Booklet 810 .
Caution


Audi TT 2007 ➤
Note

♦ the cylinder head or cylinder block have been renewed.
Audi TT 2007 ➤
1 - Bolt
gearbox
Rep. Gr. 34
2 - Bolts
gearbox
❑ Different lengths
Rep. Gr. 34
3 - Engine support
tion
4 - Bolt
gine
❑ Different lengths
❑ 45 Nm
5 - Engine mounting
6 - Bolt
body
❑ Renew
8 - Bolt
❑ Connecting bracket to engine mounting
❑ Renew
9 - Bolt
❑ Connecting bracket to body permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

10 - Bolt
❑ Renew
11 - Bolts
❑ Renew

Audi TT 2007 ➤

13 - Bolt
14 - Bolt
15 - Bolt
❑ Illustration shows version for S tronic gearbox
17 - Bolt
18 - Bolt

mountings
permitted unless(engine/gearbox mountings)
Procedure
Proceed as follows:
Note
Audi TT 2007 ➤

box:
Note



equipment required
A-
♦ Shackle -10 - 222 A /12-
♦ Adapter -10 - 222 A /20-
♦ Adapter -T40093/6- (2x)

Audi TT 2007 ➤
Procedure
Proceed as follows:


er housing.
Audi TT 2007 ➤
– Remove bolts -arrows- and detach bracket for air cleaner

housing.
– Unscrew bolt and nut -arrows- and press coolant pipe (front
right) to one side (coolant hoses remain attached).
– Position support bracket -10 - 222 A- on top of body flanges

using the following tools:
♦ Rack -10 - 222 A /1- (2x)
♦ Spindle -10 - 222 A /11- (2x)
♦ Shackle -10 - 222 A /12-
♦ Adapter -10 - 222 A /20-
♦ Hook of lifting tackle -2024 A-
♦ Adapter -T40093/6- (2x)
– Hook spindle -10 - 222 A /11- onto gearbox lifting eye (left-
side) with shackle -10 - 222 A /12- .
– Engage spindle -10 - 222 A /11- at gearbox with adapter -10 -
222 A /20- and hook of lifting tackle -2024 A- .
WARNING
Risk of accident.
Illustration shows vehicle with S tronic gearbox.

ening two spindles.

Audi TT 2007 ➤

– Renew each of the 5 bolts in turn (if not already done when
installing engine) and hand-tighten.
– Slacken bolts on left and right-hand support arms by approx.
two turns each.

• The two bolt heads -2-tomust be parallel withinthe edge ofCopyright

the by AUDI AG.
with respect the correctness of information this document.
support arm -3-.
Note

– Tighten bolts for assembly mounting (gearbox end).
Audi TT 2007 ➤
– Tighten bolts for assembly mounting (engine end).
note the following:
Note

Gr. 50 .
– Detach support bracket -10 - 222 A- .
– Install coolant pipe (front right) ⇒ page 168 .
– Install air cleaner housing and air filter element
permitted unless⇒ Rep. by
authorised Gr.
24 . with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi TT 2007 ➤
1.1 Poly V-belt drive, bracket for ancillaries - exploded view
⇒ page 54
one position
2 - Bolt
❑ Renew
3 - Bolt
❑ 23 Nm
❑ Lock with locking pin -
T10060 A-
❑ Protected
Removing and Copying
⇒ pageunless
permitted 52 authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 53
6 - Bolt
Rep. Gr. 27
7 - Sliding bush
8 - Alternator
⇒ Rep. Gr. 27
9 - Bolt
logue
10 - Bush
❑ 2x
11 - Bolt
13 - Poly V-belt
❑ Check for wear

Audi TT 2007 ➤
❑ Do not kink
❑ When installing, make sure it is properly seated on pulleys.


Removing
Proceed as follows:
Note

Audi TT 2007 ➤
Caution


-arrow-.
– Secure tensioner with locking pin -T10060 A-

Installing
– Fit poly V-belt on poly V-belt pulleys (on alternator pulley last).
Vehicles
permittednot equipped
unless authorised bywith
AUDI air
AG. conditioning:
1- Crankshaft
2- Tensioner
3- Alternator

Audi TT 2007 ➤

1- Crankshaft
2- Tensioner
3- Alternator

– Swivel tensioner fractionally clockwise -arrow-, remove lock‐
ing pin -T10060 A- and release tensioner.

poly V-belt
Removing
Proceed as follows:
Note
The tensioner is not locked.
– Remove bolts -arrows- and take off tensioner for poly-V-belt.

Installing

Audi TT 2007 ➤

cillaries
Removing
Proceed as follows:
– Remove poly V-belt tensioner ⇒ page 52 .
– Remove noise insulation (right-side) -arrows-.


Caution
Danger of damage to refrigerant lines and hoses.


– Detach air conditioner compressor from bracket and tie up to
lock carrier.

Audi TT 2007 ➤

Installing
66 .
– Install alternator ⇒ Rep. Gr. 27 .
– Install poly V-belt tensioner ⇒ page 52 .Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

er
Removing
Proceed as follows:

Audi TT 2007 ➤

– Slacken bolts for vibration damper and remove (counterhold

with ring spanner).
Installing
Note

• The vibration damper can only be installed in one position. The

hole -arrow- in the vibration damper must be located over the
projection on the toothed belt sprocket.
66 .

Audi TT 2007 ➤
1 - Bolt
❑ Contact surface to
of oil
one position
3 - Diamond-coated washer
❑ Between toothed belt
sprocket and crankshaft
❑ Renew washer if tooth‐
ed belt sprocket is re‐
moved
4 - Oil seal
❑ For crankshaft (pulley
end)
dowel pins
⇒ page 59
6 - Bolt
7 - Damper wheel
8 - Dowel pin
❑ 2x
9 - Bolt

Audi TT 2007 ➤

1. Hand-tighten bolts -1 ... 11- until they make contact.
15 Nm.

end)
Protected♦by Counterhold tool

copyright. Copying for -3415-

Audi TT 2007 ➤
Procedure
Proceed as follows:
-3415- .
– Unscrew bolt -1- and detach crankshaft sprocket -2- and dia‐
mond-coated washer-3-
– To guide oil seal extractor, screw bolt for crankshaft sprocket

into crankshaft onto stop by hand.

Audi TT 2007 ➤
– Screw inner section of oil seal extractor -3203- nine turns (ap‐
prox. 20 mm) out of outer section and lock with knurled screw.
pressure).
– Unscrew bolt for crankshaft sprocket.
oil seal.

– Press in oil seal using bolt for crankshaft sprocket and thrust
sleeve of assembly tool -T10053- until flush.

(pulley end)

Audi TT 2007 ➤

♦ Safety goggles
Removing
Proceed as follows:
-3415- .
– Unscrew bolt -1- and detach crankshaft sprocket -2- and dia‐
mond-coated washer-3-

Audi TT 2007 ➤

– Carefully lever off sealing flange.
– If necessary, unscrew damper wheel from sealing flange
⇒ page 81 .
Installing
Caution
WARNING


sealing flange.
Note

mm).


Audi TT 2007 ➤
Caution


sealing flange as illustrated.

Note

ing the sealant.
Note
Use guide sleeve -T10053/1- to attach sealing flange with oil seal
fitted.
– Tighten sealing flange ⇒ page 57 .


Audi TT 2007 ➤
Note
♦ When performing assembly work, secure engine to engine

and gearbox support ⇒ page 34 .
♦ Servicing clutch ⇒ Rep. Gr. 30
1 - Bolt
❑ Renew
⇒ page 64
one position (holes are
off-set)
3 - Bolt
dowel pins
❑ Do not damage or bend Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Is fitted onto sealing with respect to the correctness of information in this document. Copyright by AUDI AG.
flange ⇒ page 64
5 - Cylinder block
6 - Dowel pin
end)
❑ With oil seal
❑ Renew only as com‐
plete unit ⇒ page 65
❑ Do not lubricate/grease
sealing lip of oil seal
❑ Use guide sleeve sup‐
plied when fitting
❑ Do not remove guide
sleeve until sealing
flange has been slipped
onto crankshaft journal

Audi TT 2007 ➤

– Tighten sealing flange bolts (gearbox end) in three stages as
follows:
1. Hand-tighten bolts -1 ... 8- until they make contact.
15 Nm.
3. Tighten bolts -7- and -8- to 15 Nm.

– Engage intermediate plate in sealing flange and slide onto
dowel pins -arrows-.

wheel

Audi TT 2007 ➤
Removing
Proceed as follows:
Caution


-item B-, slacken and remove bolts for dual-mass flywheel.
Installing
Note
Renew bolts for dual-mass flywheel.

Procedure
Proceed as follows:
– Remove dual-mass flywheelpermitted
⇒ page 64 .
– Detach intermediate plate from sealing flange and dowel pins

-arrows-.

Audi TT 2007 ➤
– Unscrew bolts -1 ... 8- and remove sealing flange.
Caution

♦ Cover exposed section of oil sump.

Note

mm).


Caution

ing the sealant.

Audi TT 2007 ➤
– Push sealing flange -2- together with guide sleeve -1- (fitted
on replacement part) onto crankshaft.
– Then carefully fit sealing flange onto dowel pins in cylinder
block.
– Tighten sealing flange ⇒ page 64 .

note the following:
– Install intermediate plate ⇒ page 64 .

Audi TT 2007 ➤
3 Crankshaft
Note

oil spray jets, oil cooler and oil filter.
1 - Bolt
❑ Renew
2 - Bearing cap
end
❑ Installation position: re‐
taining lugs on bearing
shells in cylinder block
and bearing caps must
be on the same side
3 - Bolt
❑ Renew
loosened ⇒ page 69
4 - Needle bearing
❑ Only on vehicles with S
tronic gearbox
❑ Extracting and driving in
⇒ page 72
5 - Sender wheel
er -G28-
loosened
⇒ page 69
one position (holes are
off-set)
6 - Crankshaft
❑ Do not place
permitted on authorised
unless sender by wheel
AUDI AG. -item
AUDI 5-
AG after
does notremoving


Audi TT 2007 ➤
7 - Thrust washers
8 - Bearing shell
❑ For cylinder block (with oil groove)
❑ Mark used bearing shells for re-installation but not on bearing surface
❑ Bearing shells worn down to nickel layer must be renewed
❑ Install new bearing shells for the cylinder block with the correct coloured markings ⇒ page 70
❑ For drive chain for oil pump
10 - Bearing shell
❑ For bearing cap (without oil groove)
❑ Mark used bearing shells for re-installation but not on bearing surface
❑ Bearing shells worn down to nickel layer must be renewed
❑ Installing new bearing shells for bearing cap with correct colour-coding ⇒ page 70
Removing and installing sender wheel
Caution
Safety risk from loose sender wheel.

♦ Sender wheel -2- must always be renewed after slacken‐
ing off bolts -1-.
♦ If the countersunk bolts are tightened a second time, the
seats for the bolt heads in the sender wheel will be de‐
formed to such an extent that the bolt heads make contact

with the crankshaft -3- -arrows- and the sender wheel be‐
neath the bolts will be loose.
Note
Sender wheel can only be installed in one position (holes are off-
set).
3. Crankshaft 69
Audi TT 2007 ➤
Allocation of crankshaft bearing shells (top) for cylinder block

♦ Bearing shells of the correct thickness are matched to the
bearings (top) in the cylinder block at the factory. Coloured
dots on the side of the bearing shells are used to identify the
bearing shell thickness.
♦ Letter codes on the lower sealing surface of the cylinder block
indicate the thickness of the bearing shell to be fitted at each
location.
Letter on cylinder block Colour coding of bearing
S= Black
R = Red
G= Yellow
Note
Allocation of crankshaft bearing shells for bearing cap

♦ Bearing shells of the correct thickness are assigned to the
bearing caps at the factory. Coloured dots on the side of the
bearing shells are used to identify the bearing shell thickness.
♦ The correct allocation of bearing shells to bearing cap is indi‐
cated by a sequence of letters on the pulley flange of the
crankshaft. The first letter in the sequence stands for bearing
“1”, the second letter for bearing “2”, etc.
Letter on crankshaft Colour coding of bearing
R = Red
G = Yellow
B = Blue
W = White

Honing di‐ Main bearing journal ∅ Conrod journal ∅
mension
(in mm)
Basic dimen‐ 54.000 – 0.017 47.800 – 0.022

sion – 0.037 – 0.042


Audi TT 2007 ➤
Procedure
Proceed as follows:
Axial clearance: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
• New: 0.07 ... 0.23 mm.

shaft
♦ Plastigage
Procedure
Proceed as follows:
Note

♦ Bearing shells worn down to the nickel layer must be renewed.
– Remove bearing cap.

– Clean bearing cap and bearing journal.
3. Crankshaft 71
Audi TT 2007 ➤

shell.
– Fit bearing cap and tighten bolts to 30 Nm without rotating
crankshaft.
Radial clearance:
• New: 0.017 ... 0.037 mm.

for crankshaft
♦ Drift -VW 207 C-
♦ Puller -T10055- with adapter -T10055/3-
♦ -1- internal puller Kukko 21/2

Audi TT 2007 ➤
Procedure
Proceed as follows:
– Use internal puller Kukko 21/2 -arrow-, adapter -T10055/3-
and puller -T10055- to pull out needle bearing.
– Drive in needle bearing with drift -VW 207 C- .
• Insertion depth: dimension -a- = 2 mm.
3.6 Removing and installing drive chain

sprocket
♦ Drift sleeve -30 - 100-
3. Crankshaft 73
Audi TT 2007 ➤
♦ Thrust plate -40 - 105-
♦ -1- Two-arm puller Kukko 44/1
Removing
Proceed as follows:
– Unscrew bolts -arrows- and remove toothed belt cover (top
section).
Caution

– Rotate crankshaft by turning bolt
with respect forcorrectness
to the toothedofbelt sprocket
information until Copyright by AUDI AG.
in this document.
• Marking on camshaft sprocket must face arrow on toothed belt
cover -top arrow-.
• Notch on vibration damper must face arrow on toothed belt
cover -bottom arrow-.

Audi TT 2007 ➤
– Pull off chain guard; if necessary, retaining tabs can be re‐

leased with a small screwdriver (insert in openings -arrows-).
– Counterhold crankshaft at bolt for toothed belt sprocket and

slacken bolt for chain sprocket for oil pump.

sition with hexagon key (3 mm) -1-.
Caution
If a used drive chain rotates in the opposite direction when it is

refitted, this can cause breakage.
♦ Mark running direction of drive chain with paint for re-in‐
stallation. Do not mark drive chain by means of centre
punch, notch or the like.
– Detach chain sprocket with drive chain for oil pump.
3. Crankshaft 75
Audi TT 2007 ➤
– Pull off drive chain sprocket using two-arm puller Kukko 44/1
-item 2- (protect end of crankshaft with thrust plate -40 - 105-
-item 1-).
Installing
WARNING
Risk of burn injuries.

– Heat drive
with chain
respect tosprocket in oven
the correctness for approx.
of information 15 minutes
in this document. Copyright byto
AUDI AG.
220°C.
• Installation position: wider collar on drive chain sprocket faces
engine.
– Fit drive chain sprocket on end of crankshaft using pliers, and

press onto crankshaft as far as the stop using drift sleeve -30
- 100- .
– Fit drive chain according to marking for direction of rotation
(made during removal).
– Install sealing flange (pulley end) ⇒ page 59 .
– Install balance shaft assembly with oil pump ⇒ page 136 .

Audi TT 2007 ➤
Note
♦ All bearing and running surfaces must be oiled before assem‐

bling.
1 - Bolts
clearance, tighten used Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
bolt to 45 Nm but not fur‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ther
❑ Renew
contact surface
in colour -B-
wards pulley end
3 - Bearing shells
❑ Upper bearing shell with
oil hole for piston pin lu‐
brication
⇒ page 79
face
❑ Bearing shells worn
down to nickel layer
must be renewed
4 - Conrod
❑ With oil drilling for piston
pin lubrication
❑ Only renew as a com‐
plete set
in colour -B-
5 - Circlip
❑ Renew
6 - Piston pin
❑ If difficult to remove, heat piston to approx. 60 °C

Audi TT 2007 ➤
7 - Piston
❑ Mark installation position to conrod and cylinder allocation
❑ Installation position: arrow on piston crown points to pulley end
❑ Checking cylinder bore ⇒ page 79
8 - Piston rings
❑ Inscription “TOP” faces towards piston crown

of cylinder.
– Check gap using feeler gauge.
Dimensions in mm
Compression ring 0.20 … 0.40 0.8
Checking ring-to-groove clearance with respect to the correctness of information in this document. Copyright by AUDI AG.
– Clean annular groove of piston.

Dimensions in mm
Checking piston
Nominal dimension

Audi TT 2007 ➤

– Use an internal dial gauge -VAS 6078- to take measurements
at 3 points in transverse direction -A- and in longitudinal di‐
rection -B-.
Nominal dimension

– Insert bearing shells centrally in conrod/conrod bearing cap.
• Distance -a- = approx. 1.5 mm.

Note


Honing dimension Diameter of piston Diameter of cylinder
(in mm) bore
• 1) Dimension not including coating (thickness 0.02 mm). The
coating wears down in service.
4.3 Measuring axial clearance of conrods

♦ Feeler gauge

Audi TT 2007 ➤
Procedure
Proceed as follows:
Axial clearance:
• New: 0.10 ... 0.30 mm.

♦ Plastigage
Procedure
Proceed as follows:
journal.
shell.
– Fit conrod bearing cap and tighten bolts to 45 Nm without ro‐
tating crankshaft.
Radial clearance:
• New: 0.02 ... 0.06 mm.

Audi TT 2007 ➤

1.1 Toothed belt drive - exploded view
1 - Bolt
❑ 9 Nm
2 - Toothed belt cover (top)
3 - Bolt
❑ Renew
counterhold tool -3036-
❑ 50 Nm + turn 180° fur‐
ther
❑ Located in position by
Woodruff key -item 7-
5 - Bolt
logue Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

7 - Woodruff key
ment
8 - Nut
❑ 23 Nm
10 - Coolant pump
⇒ page 161
11 - O-ring
❑ Renew
12 - Bolt
❑ 23 Nm
13 - Damper wheel
14 - Bolt
15 - Bolt
❑ 33 Nm
16 - Damper wheel
17 - Sealing flange

Audi TT 2007 ➤
18 - Diamond-coated washer
❑ Between toothed belt sprocket and crankshaft
❑ Renew
❑ Contact surfaces between toothed belt sprocket, diamond-coated washer and crankshaft must be free
of oil
20 - Bolt
❑ Renew
❑ 90 Nm + turn with
90°respect
further
21 - Toothed belt
❑ Check for wear
❑ Installing (adjusting valve timing) ⇒ page 87
22 - Toothed belt cover (bottom)
23 - Bolts
❑ 7x
❑ 9 Nm
24 - Engine support
25 - Bolt
Removing and installing crankshaft sprocket

– Use counterhold tool -3415- to slacken and tighten bolt for
crankshaft sprocket.
Note
Contact surfaces between toothed belt sprocket, diamond-coated

washer and crankshaft must be free of oil.
– When installing, fit new diamond-coated washer between

toothed belt sprocket and crankshaft.


Audi TT 2007 ➤
♦ Shackle -10 - 222 A /12-
♦ Adapter -T40093/6- (2x)
Removing
Proceed as follows:

Audi TT 2007 ➤

– Loosen front section of wheel housing liner (right-side) and
press towards rear ⇒ Rep. Gr. 66 .
– Remove poly V-belt tensioner ⇒ page 52 .
– Remove bolts -arrows- and detach bracket for activated char‐

coal filter.
Note
Disregard item -1-.
– Detach coolant hose -arrow-.

Audi TT 2007 ➤
– Move electrical wiring clear at coolant expansion tank.

– Unplug electrical connector -1- at coolant shortage indicator
switch -F66- .
– Remove bolts -arrows- and remove coolant expansion tank.

section).
right) to one side.

♦ Rack -10 - 222 A /1- (2x)
♦ Spindle -10 - 222 A /11-
♦ Shackle -10 - 222 A /12-
♦ Adapter -T40093/6- (2x)
– Hook spindle -10 - 222 A /11- with shackle -10 - 222 A /12-
onto engine lifting eye.
WARNING
Risk of accident.
– Take up weight of engine/gearbox assembly by tightening

spindle.

Audi TT 2007 ➤

– Remove bolts -1, 2, 3-.
Note
Bolt -2- can be accessed from the wheel housing end.
Caution
Danger of damage to components and hoses.

♦ When raising the engine, take care that no components
are damaged and no hoses are stretched.
– Raise engine using support bracket -10 - 222 A- until engine

support can be taken out.
Caution


cover -top arrow-.
Caution
Risk of damage to engine.

♦ The “TDC” markings must align before the vibration damp‐
er is detached.
♦ Do not rotate the crankshaft unless the “TDC” position is
marked by an additional marking.

Audi TT 2007 ➤
– Remove toothed belt cover (bottom section) -arrows-.
– Mark “TDC” position -arrow-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Caution

– Loosen tensioning roller and detach toothed belt.

Caution

– Check whether the camshaft and the crankshaft are posi‐

tioned at “TDC”:
• The markings on the camshaft -top arrow- and the crankshaft
-bottom arrow- must be aligned.

Audi TT 2007 ➤
– Fit toothed belt according to marking for direction of rotation

(made during removal) as follows:
• Crankshaft, tensioning roller, camshaft, coolant pump and id‐
ler roller -arrow-.
– Make sure tensioning roller is positioned correctly in cylinder

head.
• Retaining bracket -arrow- must engage in slot on cylinder
head.
– Tension toothed belt as follows:

1. Using hexagon key, turn eccentric adjuster clockwise
-arrow- until notch -2- is above indicator -3- (toothed belt
over-tensioned).
2. Let eccentric adjuster return to initial position (release tooth‐
ed belt).
3. Using hexagon key, turn eccentric adjuster clockwise
-arrow- until notch -2- is with
aligned with
respect to indicatorof information
the correctness -3-. in this document. Copyright by AUDI AG.
– Tighten nut -1- for tensioning roller.
Caution


turning bolt for toothed belt sprocket until crankshaft is at
“TDC” again.
• It is important that the engine is rotated without stopping during
the final 45° (1/8 turn).
– Check toothed belt tension:
• Notch -2- and indicator -3- must be aligned.
– If necessary, tighten toothed belt further.

Audi TT 2007 ➤
– Check valve timing:

– Repeat adjustment of valve timing if markings are not aligned.
note the following:
– Install toothed belt cover (bottom section) ⇒ page 81 .
– Check valve timing again:

cover -top arrow-.
– Install engine support and engine mounting ⇒ page 42 and
adjust ⇒ page 44 .
– Install poly V-belt tensioner ⇒ page 52 .

Audi TT 2007 ➤
2 Cylinder head
2.1 Cylinder head cover and cylinder head - exploded view
1 - Bolt
❑ Renew if seal is dam‐
aged
⇒ page 91
2 - Cylinder head cover permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
3 - Gasket
leaking
4 - Pressure control valve
5 - Filler cap
6 - Seal
leaking
7 - Bolt
❑ 4 Nm
8 - Gasket for cylinder head
cover
leaking
9 - Exhauster pump
10 - Bolt
❑ 4 Nm
11 - Inlet camshaft control
valve 1 -N205-
⇒ page 92
12 - Seal
❑ Renew
13 - Bolt
❑ 9 Nm
14 - Wiring bracket
15 - Seal
16 - Bolt
❑ 9 Nm
17 - Housing
❑ For drive chain
18 - Gasket
❑ Renew

Audi TT 2007 ➤

20 - Bolt
❑ 23 Nm
21 - Stud
❑ For intake manifold
❑ 9 Nm
22 - Separating plate
❑ Renew
❑ Check installation position: Part No. towards cylinder head
24 - Bolt
❑ 9 Nm
26 - Seal
27 - Stud
❑ For tensioning roller
❑ 15 Nm
28 - Stud
❑ For exhaust manifold
❑ 17 Nm
29 - Cylinder head
❑ ⇒ Fig. “ Checking cylinder head for distortion “ , page 92
❑ ⇒ Fig. “ Cylinder head machining limit “ , page 92
30 - Bolt
❑ Renew
❑ Tightening torque and sequence ⇒ page 92by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected

2. Cylinder head 91
Audi TT 2007 ➤


– Use straight edge and feeler gauge to measure cylinder head
for distortion at several points.
Cylinder head machining limit

Machining of the cylinder head (surface grinding) is only permis‐
sible down to the minimum dimension -a-.
• Minimum dimension: -a- = 139.20 mm
2.2 Removing and installing inlet camshaft

control valve 1 -N205-
Removing
Proceed as follows:

Audi TT 2007 ➤

– Release electrical wiring -2- from bracket.
Caution
Risk of damage to electrical wiring.

♦ Do not pull on electrical connector when removing inlet
camshaft control valve 1 -N205- .
– Remove bolts -arrows- and pull inlet camshaft control valve 1

-N205- out of drive chain housing.
Installing
♦ Renew the seal.
♦ Remove any kind of dirt from inlet camshaft control valve 1 -
N205- .
Caution
♦ Protect inlet camshaft control valve 1 -N205- against dam‐

age by knocks and impact.
♦ Do not remove a new inlet camshaft control valve 1 -N205-
from packaging until you are ready to install it.
– Lubricate seal lightly with engine oil.

– Carefully fit inlet camshaft control valve 1 -N205- into drive
chain housing and press in by hand as far as the stop (exert
pressure in line with axis of valve).
note the following:
– Install coolant bleeder pipe ⇒ page 164 .
2. Cylinder head 93
Audi TT 2007 ➤

cover
Removing
Proceed as follows:
– Unscrew bolts -arrows- and press toothed belt cover (top)

slightly to one side.
– Remove ignition coils ⇒ Rep. Gr. 28 .

– Loosen hose clips -1- and -3- and move air pipe clear to one
side (hose -2- remains connected).
– Disconnect vacuum hose -1- from cylinder head cover.

– Remove bolts -arrows- and detach pressure control valve for
crankcase breather system.

Audi TT 2007 ➤
– Disconnect pipe -2- coming from activated charcoal filter from

cylinder head cover.
– Remove bolts -3-, release hose clip -1- and disconnect crank‐
case breather pipe with heat shield from cylinder head cover.
– Slacken cylinder head cover bolts in the sequence -14 ... 1-.
Installing
Note
♦ Renew gasket for cylinder head cover if damaged.

♦ Renew bolts for cylinder head cover if seals on bolts are dam‐
aged.
♦ Secure all hose connections with the correct
permitted type ofby hose
unless authorised clips
(same as original equipment) ⇒ with
Electronic parts
respect to the catalogue
correctness . in this document. Copyright by AUDI AG.
of information

– Install crankcase breather pipe ⇒ page 179 .
– Secure toothed belt cover (top section) ⇒ page 81 .
– Install ignition coils ⇒ Rep. Gr. 28 .

2. Cylinder head 95
Audi TT 2007 ➤
♦ Special wrench, long reach -T10070-
Removing
Proceed as follows:
– Remove turbocharger ⇒ page 182 .
WARNING
Risk of injury caused by fuel.

♦ To allow the fuel pressure to dissipate, wrap a clean cloth
around the connection and carefully loosen thebyconnec‐
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
tion before opening the fuel system. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Caution
Observe rules for cleanliness when working on the fuel supply

system ⇒ page 9 .
– Remove protective sleeve -2- and disconnect fuel hose by

pressing release ring.

Audi TT 2007 ➤
– Remove centre hex stud -arrow- for dipstick guide tube.

– Loosen hose clip -1-, pull turbocharger air recirculation valve
-N249- off air pipe and move clear (hose -4- remains connec‐
ted).
– Unplug electrical connector -arrow- at charge air pressure

sender -G31- .
Note
Disregard item -3-.
2. Cylinder head 97
Audi TT 2007 ➤
– Unplug electrical connector -1- at intake air temperature send‐

er 2 -G299- .
Note
Disregard -arrow-.

J338- .
– Unscrew nut -2- and bolt -1- and remove support for intake
manifold.
– Unplug electrical connectors at fuel pressure sender for low

pressure -G410- -1- and fuel pressure regulating valve -N276-
-2-.
– Move electrical wiring clear.
Note
Disregard -arrows-.

Audi TT 2007 ➤

-1- from oil separator.
– Unplug electrical connectors:
2 - For injectors (remove electrical connectors from bracket)
3 - For activated charcoal filter solenoid valve 1 -N80-
4 - For intake manifold flap motor -V157-
5 - For fuel pressure sender -G247- and Hall sender -G40- (re‐
move electrical connectors from bracket)

– Release electrical wiring
Protected -2- from
by copyright. bracket.
Note
Disregard item -3-.
– Move electrical wiring clear -arrows- and unscrew bolt -1- for
bracket.

– Disconnect coolant hoses and vacuum hoses -arrows-.
2. Cylinder head 99
Audi TT 2007 ➤

– Remove bolts and detach cylinder head.
Installing
• Tightening torques ⇒ page 90 , ⇒ page 92
Caution

cylinder block.
surfaces.
terial.
gasket.
protectors fitted to protect the open valves should not be
Note

faces between the hydraulic compensation elements, roller
rocker fingers and cams must be oiled before installing the
camshaft housing.
at their connections, spray rust remover ontoProtected
the worm thread
of used hose clips before installing. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
system.

Audi TT 2007 ➤

cover -top arrow-.
• Cams -A- on both camshafts should be symmetrically aligned.

– Check that crankshaft is still positioned at “TDC” and then turn
back in the opposite direction of engine rotation by approx.
45°.

• Installation position: Part No. must be visible.
• Note position of dowel sleeves in cylinder block.
– Tighten bolts for cylinder head ⇒ page 92 .
Note

after repair work.

– Rotate crankshaft in normal direction of rotation back to “TDC”.
– Install support for intake manifold throttle valve module -J338-
⇒ Rep. Gr. 24 .
– Secure dipstick guide tube ⇒ page 131 .

– Install turbocharger ⇒ page 182 .


Audi TT 2007 ➤


Audi TT 2007 ➤
Procedure
Proceed as follows:
• Engine oil temperature min. 30 °C.
– Unplug electrical connector -2- for injectors.
Note
Disregard items -1, 3, 4 and 5-.

– Remove spark plugs with spark plug socket and extension
-3122 B- .
– 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.
When new 10.0 … 14.0
Wear limit 7.0
Assembling
Faults are stored in engine control unit because electrical con‐
nectors have been unplugged.
VAS 5051B- .

Audi TT 2007 ➤
3 Valve gear
Caution

valve gear.
♦ Turn the engine carefully at least 2 rotations to ensure that
none of the valves make contact when the starter is op‐
erated.
1 - Bolt
❑ Renew
counterhold tool -3036-
3 - Oil seal
❑ For exhaust camshaft permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Renewing ⇒ page 108 with respect to the correctness of information in this document. Copyright by AUDI AG.
4 - Cylinder head
5 - Valve guide
❑ Renewing: with cylinder
head installed
⇒ page 120 , with cylin‐
der head removed
⇒ page 123
7 - Valve spring
9 - Valve cotters
10 - Hydraulic valve compen‐
sation element
❑ With roller rocker finger
and securing clip
❑ Mark installation posi‐
tion for re-installation
❑ Lubricate running surfa‐
ces with oil
11 - Parallel key

Audi TT 2007 ➤

❑ Only clean sealing surface (do not machine)
❑ Only renew together with cylinder head
14 - Bolt
❑ Renew
16 - Bolt
❑ Renew
17 - Inlet camshaft with respect to the correctness of information in this document. Copyright by AUDI AG.
18 - Chain tensioner
❑ Removing ⇒ “3.5 Removing and installing camshaft adjuster”, page 111
❑ Before removing, lock in place using locking pin -T10115-
19 - Drive chain
20 - Bolt
❑ Self-locking
❑ Renew
❑ 9 Nm
21 - Bolt
❑ Version fitted in vehicle may differ from illustration
23 - Exhaust valve
24 - Inlet valve
25 - Sealing cap
❑ Renew
❑ Installing: press in 1 ... 2 mm deep without sealant using thrust piece -3334-
3. Valve gear 105

Audi TT 2007 ➤

– Renew bolts for retaining frame.
2. Tighten to 8 Nm.

Procedure with respect to the correctness of information in this document. Copyright by AUDI AG.
Proceed as follows:
– Fit camshaft to be tested in retaining frame.
• Axial clearance: 0.05 ... 0.17 mm

Audi TT 2007 ➤

shafts
Procedure
Proceed as follows:
shafts ⇒ page 106 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove retaining frame again. with respect to the correctness of information in this document. Copyright by AUDI AG.

Radial clearance:
Bearing (∅ 24 mm): 0.024 ... 0.066 mm.
Bearing (∅ 32 mm): 0.030 ... 0.051 mm.
3. Valve gear 107

Audi TT 2007 ➤
3.4 Renewing exhaust camshaft oil seal

equipment required
♦ Puller -T40001-
♦ Nuts M12 (2x)
Procedure
Proceed as follows:
– Loosen bolt for camshaft sprocket using counterhold tool
-3036- .

Audi TT 2007 ➤
– Detach camshaft sprocket using two-arm puller -T40001- and

claws -T40001/6- and -T40001/7-
– To guide oil seal extractor, screw adapter -2085/2- into cam‐

shaft by hand as far as it will go.
– Screw inner section of oil seal extractor -2085- two turns (ap‐
prox. 3 mm) out of outer section and lock with knurled screw.

pressure).
oil seal.
Note
ing in.
– Mask groove at taper of camshaft with adhesive tape

-arrow-.
3. Valve gear 109

Audi TT 2007 ➤
– Place two M12 nuts -item 1- underneath head of bolt -

T10071/4- .
– Press oil seal in onto stop using guide sleeve -T10071/3- and
bolt -T10071/4- .
Note
Make sure parallel key for camshaft sprocket is correctly seated.
Caution

– Tighten bolt for camshaft sprocket using counterhold tool

-3036- .

Audi TT 2007 ➤
3.5 Removing and installing camshaft adjuster

equipment required
-T40080-
♦ Camshaft clamp -T10252-
♦ Pin wrench -T10020-
3. Valve gear 111

Audi TT 2007 ➤
Removing
Proceed as follows:
– Remove exhauster pump
Protected ⇒ Rep.
by copyright. Gr.
Copying 47 . or commercial purposes, in part or in whole, is not
for private
Note
Disregard item -1-.
– Use hose clamps -3094- to clamp off coolant hoses -1- and
-2- and detach.
– Remove bolt -3- and press coolant bleeder pipe slightly to‐
wards rear.

– Release electrical wiring -2- from bracket.
Note
Disregard item -3-.

Audi TT 2007 ➤
– Move electrical wiring clear -arrows- and unscrew bolt -1- for
bracket.
– Remove bolts -arrows- and detach housing for camshaft ad‐

juster.
Caution


cover -top arrow-.
• Cams -A- on both camshafts should be symmetrically aligned.

3. Valve gear 113

Audi TT 2007 ➤
– Fit camshaft clamp -T10252- and tighten -arrows-, as shown

in illustration.
– Additionally, counterhold camshaft sprocket with counterhold
tool -3036- .
– Use special wrench, long reach -T40080- to slacken camshaft

adjuster bolt approx. 1/2 a turn.
– Press chain tensioner down -arrow A- and lock with locking pin
-T10115- -arrow B-.
– Unscrew camshaft adjuster bolt and remove camshaft adjust‐
er together with drive chain.

• Camshafts locked in position with camshaft clamp -T10252- .
Note
Renew camshaft adjuster bolt.
– Fit drive chain on camshaft adjuster.

Audi TT 2007 ➤
– Position camshaft adjuster in front of exhaust camshaft as fol‐

lows:
• Groove -A- and pin -B- must be aligned.
– Lay chain over inlet camshaft sprocket starting at top -arrow-

without changing its position.
– Slowly turn inlet camshaft in clockwise direction -arrow A- us‐

ing 2-hole pin wrench -T10020- until camshaft adjuster fits
onto camshaft.
Note
If it is not possible to fit the pin into the notch: remove chain and
fit chain again.
– Tighten camshaft adjuster bolt using special wrench, long

reach -T40080- .

3. Valve gear 115

Audi TT 2007 ➤
♦ Sealant remover, commercially available

Removing
Proceed as follows: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
♦ Sealing surfaces at bottom of retaining frame and top of cyl‐

inder head may not be machined.
♦ The camshaft bearings are integrated into the cylinder head
and retaining frame. Toothed belt must be slackened before
removing retaining frame.
♦ If the retaining frame has been unfastened, oil seal for cam‐
shaft and sealing cap must be renewed.
– Remove camshaft adjuster ⇒ page 111 .

– Loosen bolt for camshaft sprocket using counterhold tool
-3036- .

Audi TT 2007 ➤
– Detach camshaft sprocket using two-arm puller -T40001- and

claws -T40001/6- and -T40001/7-
– Remove bolts -arrows- for toothed belt cover (rear).

– Swivel toothed belt cover (rear) slightly away from cylinder
head.
– Slacken retaining frame bolts in the sequence -6 ... 1-.

– Unscrew bolts, carefully detach retaining frame and set it down

on a soft surface on workbench.
– Remove camshafts with drive chain from cylinder head and
put down on a clean surface.
Installing
Note
Renew bolts for retaining frame.
Caution

tion.
– Remove sealant residue on cylinder head and retaining frame

using commercially available sealant remover.
– Check whether all roller rocker fingers contact the valve ends
correctly.
3. Valve gear 117

Audi TT 2007 ➤
– Position drive chain as follows on chain sprockets of camshaft

(removed):
• The side surfaces of the recesses should be positioned exactly
vertical.
– Insert camshafts together with drive chain into cylinder head
and chain tensioner.
– Check “TDC” position of camshafts again:

• The side surfaces of the recesses should be positioned in ex‐
actly vertical line to the cylinder head.
Note
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 1.0

mm).
Caution

♦ The sealant beads must not be thicker than specified.
– Apply an even, slightly projecting sealant bead into the clean

groove of the retaining frame.
Note
The retaining frame must be installed within 5 minutes after ap‐

plying the sealant.

Audi TT 2007 ➤
– Tighten bolts for retaining frame ⇒ page 106 .
– Check “TDC” position of camshafts:

• It should be possible to insert camshaft clamp -T10252- as far
as stop.
Note
♦ If necessary, turn camshafts slightly backwards or forwards

when inserting camshaft clamp -T10252- .
♦ Disregard -arrows-.
– Remove camshaft clamp -T10252- .

– Drive sealing cap ⇒ Item 25 (page 105) in approx. 1 ... 2 mm
using thrust piece -3334- .
note the following:
Caution


– Secure toothed belt cover (rear) ⇒ page 81 .
– Insert parallel key into camshaft, ensuring it is correctly seat‐
ed.
– Install camshaft adjuster ⇒ page 111 .
3. Valve gear 119

Audi TT 2007 ➤
3.7 Renewing valve stem oil seals with cylinder head installed

equipment required
tension -3122 B-
-3364-
-3365-
♦ Removal and installation
device for valve cotters -
VAS 5161- with guide plate
for 2.0 ltr. and 3.0 ltr. FSI
engine -VAS 5161/19B-
Procedure
Proceed as follows:
-3122 B- .

Audi TT 2007 ➤
– Fit guide plate -VAS 5161/19B- from removal and installation

device for valve cotters -VAS 5161- on cylinder head.
– Secure guide plate with knurled screws -VAS 5161/12- .
– Screw adapter -T40012- with seal hand-tight into the corre‐

sponding spark plug thread.
– Apply drift -VAS 5161/3- to guide plate and use plastic-headed
hammer to release sticking valve cotters.
– Connect adapter to compressed Protected
air linebyusing a commercially
available connection piece, and apply
permittedconstant air pressure.
• Air pressure: at least 6 bar

– Insert assembly cartridge -VAS 5161/8- in guide plate.
Inlet side:
– Engage pressure fork -VAS 5161/2- at snap-in device, as
Exhaust side:
Continuation for both sides:
– Press down with pressure fork for assembly cartridge.
– Turn knurled screw in both directions.
• The valve cotters are forced apart and are taken up by the
cartridge.
– Take out assembly cartridge.
– Detach guide plate and turn to one side.
• The compressed air hose remains connected.
3. Valve gear 121

Audi TT 2007 ➤
If the puller -3364- cannot be used on some of the valve stem oil
seals due to the confined space, proceed as follows:
– Knock out pin -arrow- of puller using a drift and remove impact
extractor attachment.
– Apply bottom section of puller -3364- to valve stem oil seal.

– Secure puller with a punch -1- or other suitable tool as shown
in the illustration.
– Apply assembly lever to puller and pull out valve stem oil seal
-arrow-.

Audi TT 2007 ➤
Caution
ling.

– Remove plastic sleeve.
If valve cotters had been removed from assembly cartridge they

– Secure guide plate back onto cylinder head.
– Insert assembly cartridge with knurled spacer ring in guide
plate.
while turning screw in both directions.
• The valve cotters are thus inserted.
sition. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Repeat procedure for each with
valve.
Assembling

inder head removed
3. Valve gear 123

Audi TT 2007 ➤
♦ Engine and gearbox support -VAS 6095-
♦ Clamping device -VAS 6419-

Audi TT 2007 ➤
Procedure
Proceed as follows:
– Attach clamping device -VAS 6419- to engine and gearbox
support -VAS 6095- .
– Secure cylinder head in clamping device -VAS 6419- as illus‐
trated.
– Connect compressed air line to clamping device -VAS 6419- .
where valve stem oil seals are to be removed.
with valve heads.
– Fit guide plate -VAS 5161/19B- from removal and installation

device for valve cotters -VAS 5161- on cylinder head.
– Secure guide plate with knurled screws -VAS 5161/12- .
– Apply drift -VAS 5161/3- to guide plate and use plastic-headed

hammer to release sticking valve cotters.

Inlet side:
shownProtected
in illustration.
3. Valve gear 125

Audi TT 2007 ➤
Exhaust side:
Continuation for both sides:
– Press down with pressure fork for assembly cartridge.
– Turn knurled screw in both directions.
cartridge.
Caution
ling.

– Remove plastic sleeve. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi TT 2007 ➤

– Secure guide plate back onto cylinder head.
plate.
sition.
Note

is permitted.

∅a mm 33.85 ± 0.10 Protected by copyright.
28.0 ±Copying
0.1 for private or commercial purposes, in part or in whole, is not
∅b mm 5.98 ± 0.01 with respect5.96 ± 0.01 of information in this document. Copyright by AUDI AG.
to the correctness
c mm 104.0 ± 0.2 101.9 ± 0.2

α ∠° 45 45
WARNING
Care must be taken when disposing of old sodium-cooled ex‐

haust valves - risk of injury.
♦ The valves must be sawn in two with a metal saw between
the centre of the stem and valve head. When doing so, the
valves must not come into contact with water.
♦ Then throw a maximum of ten valves into a bucket of water
and step away immediately.
♦ A sudden chemical reaction will occur upon contact with
water in which the sodium filling burns.
♦ After performing these steps the valves can be disposed
of in the normal way.

3. Valve gear 127

Audi TT 2007 ➤
Procedure
Proceed as follows:
Note


• End of valve stem must be flush with valve guide.
– Determine amount of sideways play.
• Wear limit: 0.8 mm. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
new valves.
Note

faces.

Audi TT 2007 ➤
17 – Lubrication
1 Oil pump and sump
Note

when performing engine repairs, this is an indication of dam‐
age 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, oil cooler and oil filter.
Caution
Risk of damage to catalytic converter.

♦ The oil level must not be above the “max” mark on the
dipstick.

Audi TT 2007 ➤
1.1 Sump - exploded view
1 - Bolt
❑ 9 Nm
2 - Oil level and oil temperature
sender -G266-
⇒ page 131
3 - Seal
❑ Renew
4 - Bolt
5 - Sump
❑ Clean sealing surface
before installing
⇒ page 131
6 - Baffle plate
7 - Bolt
❑ 9 Nm
8 - Oil return pipe
9 - Bolt
10 - Seal
❑ Renew
11 - Bolt
12 - Oil drain plug
❑ 30 Nm
13 - Seal
❑ Renew
14 - Cover

– Tighten bolts securing sump in three stages as follows:
1. Tighten bolts -1 ... 20- securing sump to cylinder block in
diagonal sequence initially to 5 Nm.
2. Tighten bolts securing sump to gearbox -arrows- to 40 Nm.
3. Tighten bolts -1 ... 20- securing sump to cylinder block in
diagonal sequence to 15 Nm.

Audi TT 2007 ➤
Guide tube for oil dipstick - tightening torque

– Tighten centre hex stud -arrow- to 6 Nm.

Removing
Proceed as follows:
– Unscrew three bolts -1- and remove cover -2-.
– Pull oil level and oil temperature sender -G266- -item 3- off
sump and remove together with seal -4-.
Installing
Note
Renew the seal.

–permitted
Fillrespect
with up with
to the engine
correctnessoil and check
of information in thisengine
document.oil levelby⇒AUDI
Copyright Mainte‐
AG.

♦ Allen key (long reach) -T10058-

♦ Safety goggles

Audi TT 2007 ➤
Removing
Proceed as follows:
– On TTS Roadster, remove noise insulation frame -arrow- to‐

gether with rear noise insulation ⇒ Rep. Gr. 66 .
Note
Disregard items marked -2, 3, 4- and -arrow-.

Audi TT 2007 ➤

sender -G266- .
– Remove bolts -arrows- for oil return line for turbocharger.
– Remove bolts -arrows- securing sump to gearbox.

– Unscrew bolts -1 ... 20- securing sump to cylinder block in di‐
agonal sequence.
– Carefully release sump from bonded joint, taking care not to
bend sump.
Installing
Caution

tion.
WARNING



Audi TT 2007 ➤
Note

mm).
Caution

– Apply bead of sealant onto clean sealing surface of sump, as

illustrated.
Note

sealing flange -arrows-.
sealant.
Note
♦ If sump is fitted with engine removed, make sure sump is flush

with cylinder block at gearbox end.
oil.

note the following:
– Fill up with engine oil and check engine oil level ⇒ Mainte‐

Audi TT 2007 ➤
1.4 Balance shaft assembly with oil pump - exploded view
1 - Chain guard
2 - Chain
running direction with
paint
3 - Dowel sleeves
4 - Spacer plate
with oil pump
that the two dowel
sleeves for centralising
oil pump and cylinder
block are fitted
❑ Do not dismantle
❑ Do not unscrew chain
sprocket for balance
shaft assembly
⇒ page 136
6 - Bolt
❑ 9 Nm
7 - Baffle plate
8 - Bolt
❑ 20 Nm
9 - Bolt
❑ 8 Nm
11 - O-ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
12 - Bolt
❑ Renew
❑ Different bolt lengths ⇒ page 136
13 - Bolt
❑ Renew
❑ Different bolt lengths ⇒ page 136
14 - Outer rotor
❑ Marking must be visible
15 - Inner rotor
16 - Oil pump cover
❑ To remove, detach chain tensioner -item 19-

Audi TT 2007 ➤
17 - Chain sprocket
18 - Bolt
❑ Renew
❑ To detach, remove balance shaft assembly ⇒ page 136
❑ Pre-tension before installing ⇒ page 139
20 - Bolt
❑ 15 Nm
Bolts for balance shaft housing

A - Flange bolt M7x40
B - Flange bolt M7x70
C - Flange bolt M7x90
D - Flange bolt M7x55
E - Screw plug with O-ring
Balance shaft housing - tightening torque and sequence

– Renew bolts -arrows- for balance shaft housing.
– Tighten bolts in 3 stages as follows:
2. Tighten bolts to 15 Nm in diagonal sequence starting from
inside and working outwards.
3. Turn bolts 90° further in diagonal sequence starting from
inside and working outwards.
1.5 Removing and installing balance shaft

assembly with oil pump

Audi TT 2007 ➤
Removing
Proceed as follows:
section).
Caution


cover -top arrow-.
– Pull off chain guard; if necessary, retaining tabs can be re‐

leased with a small screwdriver (insert in openings -arrows-).

slacken bolt for chain sprocket for oil pump.

Audi TT 2007 ➤

sition with hexagon key (3 mm) -1-.
– Detach chain sprocket for oil pump and disengage drive chain
at balance shaft drive.
– Remove bolts -1- and -2- and detach baffle plate.
Note
Disregard -arrows-.
– Slacken bolts -arrows-, working from outside inwards.

– Remove bolts and detach balance shaft assembly.
Installing
Note

♦ Renew seal on bolt for balance shaft assembly
⇒ Item 13 (page 135) .

Audi TT 2007 ➤
– If necessary, pre-tension chain tensioner:

– Pre-tension piston by hand -arrow-.
– Press chain rail in direction of -arrow- and lock in place using

hexagon key (3 mm) -item 1-.
– Fit spacer plate onto dowel sleeves on balance shaft assembly

as shown -arrows-.
– Fit balance shaft assembly with oil pump and spacer plate.
– Fit bolts -arrows- with correct length ⇒ page 136 and tighten
⇒ page 136 .

Audi TT 2007 ➤
– To install baffle plate, insert lugs -arrows- into balance shaft

assembly.
– Check whether the camshaft and the crankshaft are posi‐

tioned at “TDC”:
– Align mark -arrow- on balance shaft sprocket with locating

hole.
– Use locking pin -T10027- to lock balance shaft sprocket in this
position.
– Fit drive chain onto balance shaft sprocket.

– Install chain sprocket for oil pump (hand-tighten bolts until they
make contact).
• Chain sprocket for oil pump can only be installed correctly in
one position.
• When installing, you may turn ONLY the oil pump.
– Remove hexagon key (3 mm) -item 1-.

tighten bolt for chain sprocket for oil pump.
note the following:
– Install toothed belt cover (top section) ⇒ page 81 .

Audi TT 2007 ➤
2 Oil filter bracket and oil cooler
2.1 Oil filter bracket and oil cooler - exploded view
1 - Pipe
tion
❑ Black insulation
❑ Opening/closing pres‐
sure 1.2 ... 1.6 bar.
⇒ page 147
❑ 21 Nm
3 - Not fitted
4 - Bracket
5 - Bolt
❑ 15 Nm
6 - Oil cooler
❑ Ensure clearance from
surrounding compo‐
nents
connections
⇒ page 153
⇒ page 143
7 - Gasket
❑ Renew
8Protected
- Oil filter housing
❑ Removing
permitted unless and
authorised installing
❑ Draining ⇒ page 142

9 - Screw plug
10 - Seal
❑ Renew
❑ Lubricate lightly with oil
12 - Bolt
❑ 15 Nm
13 - Baffle plate

Audi TT 2007 ➤
14 - Gasket
❑ Renew
Installation position of baffle plate

– Insert baffle plate -1- into cylinder block, as shown in illustra‐
tion.
Installation position of seal

– Note position of tab on seal -arrow-.
• Flat side of seal must face outwards.
2.2 Draining oil filter housing

Special tools and workshop equipment required permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi TT 2007 ➤
♦ Oil drain adapter -T40057-
– Remove dust cap -arrow- on oil filter housing.

– Hold hose of oil drain adapter -T40057- in used oil collection
and extraction unit -V.A.G 1782- .
– Screw oil drain adapter into oil filter housing.

• A valve in the oil filter housing will be opened when the oil drain
adapter is screwed in.
– Allow engine oil to drain out.
2.3 Removing and installing oil cooler


Audi TT 2007 ➤
Removing
Proceed as follows:

ted).

Audi TT 2007 ➤

sender -G31- .
Note
Disregard item -3-.


er housing.
– Use assembly tool -T10118- to release electrical connector

-arrow- at oil pressure switch -F1- and unplug.

Audi TT 2007 ➤
– Detach coolant hose -1-.
– Unscrew bolts -arrows- and remove oil cooler.
Installing
Note
♦ Renew seals and gaskets.


– Install air cleaner housing and air filter element ⇒ Rep. Gr.
24 .

Audi TT 2007 ➤

Removing
Proceed as follows:
– Remove oil cooler ⇒ page 143 .
– Drain oil filter housing ⇒ page 142 .
– Press release tabs and disconnect crankcase breather pipe
-1-.
Note
Disregard item -2-.
Installing
• respect
with Tightening torques
to the correctness ⇒ pagein141
Note

– Install baffle plate ⇒ page 142 .

– Install oil cooler ⇒ page 143 .

switch -F1-

Audi TT 2007 ➤
♦ U/J extension and socket for oil pressure switch -T40175-
Removing
Proceed as follows:


er housing.

Audi TT 2007 ➤
– Use assembly tool -T10118- to release electrical connector

-arrow- at oil pressure switch -F1- and unplug.
– Unscrew oil pressure switch -F1- using U/J extension and
socket for oil pressure switch -T40175- .
Installing
Note
24 .


Audi TT 2007 ➤
Procedure
Proceed as follows:
• Oil level OK
• Engine oil temperature approx. 80 °C
– Remove oil pressure switch ⇒ page 147 .
– Screw oil pressure switch into oil pressure tester -
V.A.G 1342- .
– Screw oil pressure tester -V.A.G 1342- into bore for oil pres‐
sure switch in oil filter bracket.
auxiliary measuring set -V.A.G 1594C- to positive battery ter‐
minal (“+”) and connect one connection of oil pressure switch.
– Connect second connection of oil pressure switch to earth
(“–”).
– Renew oil pressure switch if LED lights up when engine is not
running.
– Start engine.
Note

when starting.

– Renew oil pressure switch if LED does not light up.
– Install oil pressure switch ⇒ page 147 .


Audi TT 2007 ➤
Procedure
Proceed as follows:
• Oil level OK
V.A.G 1342- .
– Screw oil pressure tester -V.A.G 1342- into bore for oil pres‐
sure switch in oil filter bracket.
– Start engine. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Oil pressure at idling speed:
with respect atcorrectness
to the least 1.2 bar. in this document. Copyright by AUDI AG.
of information

2.8 Engine oil

2.9 Checking engine oil level


Audi TT 2007 ➤
19 – Cooling
1 Cooling system
WARNING

hot.
Note
must align when installing.

Audi TT 2007 ➤
1 - Radiator
with fresh coolant
tion pump -V51-
3 - Thermostat with housing
4 - Coolant pump
block
with fresh coolant
6 - Turbocharger
❑ With filler cap and pres‐
sure relief valve
lief valve ⇒ page 176
with fresh coolant
9 - Coolant hose/pipe connec‐
tion
10 - Oil cooler
with fresh coolant

Audi TT 2007 ➤

equipment required
-VAS 6208-
V.A.G
Protected 1921- Copying for private or commercial purposes, in part or in whole, is not
by copyright.
♦ with
Cooling
respect tosystem charge
the correctness unit in this document. Copyright by AUDI AG.
of information
-VAS 6096-
Draining
Proceed as follows:
Note
WARNING

hot.

Audi TT 2007 ➤
– Disconnect bottom coolant hose from radiator -arrow- and
drain off coolant.

Audi TT 2007 ➤
– Disconnect bottom coolant hose leading to continued coolant

circulation pump -V51- -arrow- and drain off coolant.
Note
Illustration shows coolant hose on vehicle with S tronic gearbox.
Filling
Proceed as follows:
Note

♦ Use only the radiator antifreeze/anti-corrosion agent approved
for this engine ⇒ Electronic parts catalogue . Other coolant
additives could seriously impair in particular the anticorrosion
properties. The resulting damage could lead to loss of coolant
and consequently to serious engine damage.
♦ The specified radiator antifreeze/anti-corrosion agent pre‐
vents frost and corrosion damage and stops scaling. Such
additives also raise the boiling point of the coolant. For these
reasons the cooling system must be filled all year round with
the correct antifreeze and anticorrosion additive.
ical climates.
♦ Frost protection
Protected by is required
copyright. down
Copying to about
for private –25 °C
or commercial (in countries
with arctic climate:
permitted unless down tobyabout
authorised –35
AUDI AG. °C).
concentration of radiator antifreeze/anti-corrosion agent can
be increased, but only up to 60% (this gives frost protection to
about –40 °C). If the concentration exceeds 60%, frost pro‐
tection decreases again and cooling efficiency is also im‐
paired.
coolant.
fractometer -T10007- .

Audi TT 2007 ➤
– Connect coolant hose with plug-in connector to radiator

⇒ page 172 .
– Connect the coolant hose to the continued circulation coolant

pump -V51- -arrow-.

• Radiator antifreeze/anti-corrosion agent (40 %) and water (60
%) for frost protection to –25 °C
ant expansion tank.

V.A.G 1274/8- .
Note

rection of flow).

Audi TT 2007 ➤

zone.
in the green zone.
sequent filling.
Note
ess.
tained.

– Open valve -A-.
is then filled.
expansion tank.
– Top up coolant toProtected

“max”bymark.
– Set temperature to with

“HI”.respect to the correctness of information in this document. Copyright by AUDI AG.
– Switch off air conditioner compressor (press ECON button).

rpm.
running.

Audi TT 2007 ➤

is warm.

Audi TT 2007 ➤
2 Coolant pump and coolant thermo‐

stat
WARNING

hot.
2.1 Coolant pump and thermostat with housing - exploded view
1 - Bolt
❑ 15 Nm
2 - Coolant pump
⇒ page 161
3 - O-ring
❑ Renew
4 - Thermostat with housing
⇒ page 162
5 - O-ring
❑ Renew
6 - Coolant pipe 1 (front)
7 - Bolt
⇒ page 161
9 - O-ring
❑ Renew
10 - Retaining clip
11 - Coolant hose
❑ With mounting for radia‐
tor outlet coolant tem‐
12 - O-ring
❑ Renew
13 - Bolt
❑ 9 Nm
14 - O-ring
❑ Renew

Audi TT 2007 ➤

Removing
Proceed as follows:
• Engine cold.
– Open filler cap on coolant expansion tank briefly to dissipate
residual pressure in cooling system.

Note
– Pull out retaining clip -1- and detach radiator outlet coolant
temperature sender -G83- .
Installing
Note
♦ Fit new O-ring.

♦ Insert new radiator outlet coolant temperature sender -G83-
immediately into connection to avoid loss of coolant.


Removing with respect to the correctness of information in this document. Copyright by AUDI AG.
Proceed as follows:
2. Coolant pump and coolant thermostat 161

Audi TT 2007 ➤

– Unscrew bolts -1- and remove coolant pump -2- with O-ring
-3-.
Installing
Note
Fit new O-ring.

– Lubricate O ring -3- with coolant
permitted additive.
wards.
2.4 Removing and installing thermostat with

housing
Removing
Proceed as follows:
– Remove coolant pipes ⇒ page 165 .
– Unplug electrical connector -2- for radiator outlet coolant tem‐
Note
Disregard item -1-.
– Lift retaining clip and detach coolant hose -arrow- from ther‐
mostat with housing.

Audi TT 2007 ➤
– Unscrew bolts -arrows- and remove thermostat with housing.

Installing
Note

♦ Secure all hose connections with thebycorrect
Protected copyright.type offorhose
Copying privateclips
(same as original equipment)permitted
⇒ Electronic partsbycatalogue
unless authorised . AG does not guarantee or accept any liability
AUDI AG. AUDI

– Lubricate O ring with coolant additive.
– Install coolant pipes ⇒ page 165 .
2. Coolant pump and coolant thermostat 163

Audi TT 2007 ➤
3 Coolant pipes and continued coolant

circulation pump -V51-
3.1 Coolant pipes - exploded view
1 - Coolant pipe (front right)

⇒ page 168
2 - Bolt
❑ 6 Nm
3 - Bolt
❑ 40 Nm
4 - Bolt
❑ 23 Nm
5 - Coolant bleeder pipe
6 - Bolt
❑ 9 Nm
7 - O-ring
❑ Renew
8 - Bolt
❑ 9 Nm
9 - Retaining clip
sender -G62-
⇒ page 165
11 - O-ring
12 - Coolant hose/pipe con‐
nection
⇒ page 165
14 - Bolt
❑ 9 Nm
16 - Bolt
❑ 9 Nm
17 - Bolt
❑ 9 Nm
18 - O-ring
❑ Renew
19 - Nut
❑ 9 Nm

Audi TT 2007 ➤

ature sender -G62-
Removing
Proceed as follows:
• Engine cold.

-G62- .
Note
♦ Place a cloth underneath to catch escaping coolant.

♦ Disregard item -2-.
– Pull off retaining clip and detach coolant temperature sender

-G62- .
Installing
Note
Fit new O-ring.
♦ unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
♦ Insert new coolant temperature sender -G62- immediately into
connection to avoid loss of coolant.
3.3 Removing and installing coolant pipes 1

and 2 (front)
3. Coolant pipes and continued coolant circulation pump V51 165

Audi TT 2007 ➤
Removing
Proceed as follows:
er housing.

Audi TT 2007 ➤

ted).

sender -G31- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Note
Disregard item -3-.
– Detach coolant hoses -arrows- from coolant pipes.
– Detach coolant hose -A-.

– Unscrew bolt -B- and remove coolant pipe 2 (front).

Audi TT 2007 ➤
– Use removal lever -80 - 200- to press bracket with electrical

connectors -A- off coolant pipe.
– Detach coolant hose -B-.
– Unscrew bolts -C- and remove coolant pipe 1 (front).
Installing
Note


– Install radiator cowl ⇒ page 173 . with respect to the correctness of information in this document. Copyright by AUDI AG.

(front right)

Audi TT 2007 ➤
Removing
Proceed as follows:
– Clamp off coolant hose -arrow- with hose clamp -3094- and
detach.
– Clamp off coolant hose -arrow- with hose clamp -3094- and
detach.

Audi TT 2007 ➤
Note
– Unscrew bolt and nut -arrows- and detach coolant pipe (front
right).
Installing
Note
3.5 Continued coolant circulation pump -V51- - exploded view
1 - Bracket
2 - Bolt
3 - Coolant hose with respect to the correctness of information in this document. Copyright by AUDI AG.
4 - Coolant hose
5 - Bolt
❑ 4 Nm
tion pump -V51-
⇒ page 171

Audi TT 2007 ➤
3.6 Removing and installing continued cool‐

ant circulation pump -V51-
Removing
Proceed as follows:
Note
– Clamp off coolant hoses -arrows- with hose clamps -3094- and
detach.
– Remove bolt -3- and detach continued coolant circulation
pump -V51- . with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
Installing

Audi TT 2007 ➤

⇒ page 174
2 - Nut
❑ 10 Nm
3 - Radiator cowl
⇒ page 173
⇒ page 172
5 - O-ring
❑ Renew
6 - Radiator
⇒ page 173
7 - O-ring
❑ Renew
⇒ page 172
9 - Bolt
❑ 5 Nm
10 - Nut
❑ 10 Nm
11 - Bolt
❑ 5 Nm
Connecting coolant hose with plug-in connector to radiator

– Lubricate new O-ring with coolant additive and fit O-ring in

coolant hose.
– Press coolant hose onto radiator -1- until it engages with a
click.

Audi TT 2007 ➤

Removing
Proceed as follows:
Note


– Lift retaining clip and disconnect coolant hose (top) -arrow-
from radiator.
– Remove bolts -arrows- on reverse side of radiator.

– Lift up radiator slightly and remove upwards.
Installing

Removing
Proceed as follows:

Audi TT 2007 ➤
WARNING

♦ Unplug electrical connectors before performing work on
radiator cowl.

– Remove bolts -arrows- and lift out radiator cowl.
Installing

Removing
Proceed as follows:
Installing
• Tightening
respect to thetorque ⇒ofpage 172in this document. Copyright by AUDI AG.
with correctness information



Audi TT 2007 ➤
Procedure
Proceed as follows:
WARNING

hot.
carefully to dissipate pressure. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not


Audi TT 2007 ➤

1.4 ... 1.6 bar.
scribed.

Audi TT 2007 ➤
1 Turbocharger
Note
Check that all air pipes and hoses and vacuum lines are correctly
fitted and that there are no leaks before carrying out tests or re‐
pairs.
1.1 Connection diagram

tion valve -N249-
J338-
3 - Pressure control valve for
crankcase breather system
4 - To activated charcoal filter
5 - Vacuum unit
7 - Turbocharger
8 - Brake servo
11 - Air cleaner
12 - Coolant hose/pipe con‐
nection
13 - Exhauster pump
16 - Activated charcoal filter
solenoid valve 1 -N80-
17 - Dual non-return valve
18 - Charge air pressure send‐
er -G31-
1. Turbocharger 177
Audi TT 2007 ➤
1.2 Removing and installing air pipes and

hoses with plug-in connectors
Removing
Proceed as follows:
– Release tab -A- on plug-in connector by pulling retaining clip
-arrow-.
Installing
Note

and the seal.

lock -2-.
– Press air pipe/hose again and pull again to check that plug-in

Audi TT 2007 ➤

Part 1
1 - Turbocharger
❑ Combined with exhaust
manifold
⇒ page 182
2 - Gasket
❑ Renew
3 - Bolt
❑ 9 Nm
4 - Heat shield
5 - Crankcase breather pipe
6 - Hose leading to activated
charcoal filter
7 - Vacuum unit for turbocharg‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
er permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Checking ⇒ page 187 with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ page 189
8 - Ring connector
9 - Hose
11 - Hose
12 - Bolt
❑ 3 Nm
13 - Banjo bolt
❑ 8 Nm
14 - Hose
15 - Seals
❑ Renew
16 - Securing clip
17 - Bolt
❑ 7 Nm
18 - Connection
19 - Seal
❑ Renew
Part 2
1. Turbocharger 179
Audi TT 2007 ➤
1 - Seal
❑ Renew
2 - Banjo bolt
❑ 30 Nm
3 - Oil supply pipe
4 - Turbocharger
manifold
⇒ page 182
5 - Bolt
❑ 9 Nm
6 - Banjo bolt
❑ 30 Nm
7 - Seal
❑ Renew
8 - Banjo bolt
❑ 35 Nm
9 - Seal
❑ Renew
10 - Coolant supply
Protectedpipe
❑ 23 Nm
12 - Banjo bolt
❑ 35 Nm
13 - Bolt
❑ 9 Nm
14 - Seal
❑ Renew
15 - Gasket
❑ Renew
16 - Oil return pipe
17 - Bolt
❑ 9 Nm
18 - Gasket
❑ Renew
Part 3

Audi TT 2007 ➤
1 - Gasket
❑ Renew
2 - Nut
❑ Renew
❑ Lubricate exhaust mani‐
fold studs with high-tem‐
perature paste. For
refer to ⇒ Electronic
parts catalogue
❑ 21 Nm
3 - Banjo bolt
❑ 35 Nm
4 - Seal
❑ Renew
5 - Bolt
❑ 9 Nm
6 - Coolant return
permitted unlesshose/pipe
7 - Turbocharger
manifold
⇒ page 182
8 - Bracket
9 - Bolt
❑ Coat with high-tempera‐
ture paste when instal‐
ling; for high-tempera‐
ture paste refer to ⇒
logue
❑ 30 Nm
10 - Bolt
❑ Coat with high-temperature paste when installing; for high-temperature paste refer to ⇒ Electronic parts
catalogue
❑ 30 Nm
11 - Bracket
12 - Bolt
❑ 23 Nm
13 - Nut
❑ Do not slacken when removing turbocharger
❑ Renew
❑ Lubricate exhaust manifold studs with high-temperature paste. For high-temperature paste refer to ⇒
Electronic parts catalogue
❑ 30 Nm
14 - Fastening strip
Part 4
1. Turbocharger 181
Audi TT 2007 ➤
1 - Vacuum unit for turbocharg‐

er
⇒ page 189
2 - Pressure hose
3 - Bolts
❑ Self-locking
❑ Renew
❑ 9 Nm
4 - Locking plate
5 - Lock nut
❑ 9 Nm
❑ After tightening, secure
with sealant paint; for
sealing paint refer to ⇒
logue
6 - Adjusting nut
❑ After tightening, secure
with sealant paint; for
sealing paint refer to ⇒
logue


Audi TT 2007 ➤
Removing
Proceed as follows:
Caution
If the turbocharger has suffered mechanical damage (e.g.

if necessary.
– Remove noise insulation at front -1- and rear -2- ⇒ Rep. Gr.
66 .
silencer ⇒ page 202 .

1. Turbocharger 183
Audi TT 2007 ➤
-arrows-.
– Lift retaining clip -3- and remove bolt -4-.

– Remove banjo bolt -1- for coolant supply pipe and -2- for oil
supply pipe and press pipes to the side.
– Remove bolts -arrows- and detach oil return pipe from turbo‐
charger.
– Unscrew bolts -1- and -2- and remove support for turbocharg‐
er.

Audi TT 2007 ➤
– Unplug electrical connector -1- and move electrical wiring har‐

ness clear -arrows-.
– Remove bolts -arrows- and pull air pipe off turbocharger (leave
in installation position).
– Disconnect hose -2- coming from activated charcoal filter from

– Remove bolts -3-, release hose clip -1- and disconnect crank‐
case breather pipe with heat shield from cylinder head cover.
– Unplug electrical connectors -1- at ignition coils.

– Move wiring harness clear to the left.
Note
Disregard items -2, 3 and 4-.
1. Turbocharger 185
Audi TT 2007 ➤
– Disconnect coolant hose -arrow- from coolant expansion tank.

– Unscrew bolt -3- and detach coolant bleeder pipe.
– Detach coolant hose -arrow-.

Audi TT 2007 ➤
– Unscrew nuts -arrows- and lift off turbocharger with exhaust

manifold.
Note
Seal off open pipes/lines and connections on turbocharger with

clean plugs or protective caps to prevent dirt from entering.
Installing
• Tightening torques ⇒ page 179 , ⇒ page Protected
194 . by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note

pipe.

– Observe the instructions for installing air pipes and hoses with
plug-in connectors ⇒ page 178 .
– Install front exhaust pipe with catalytic converter and front si‐
lencer ⇒ page 202 .
– Check engine oil level ⇒ Maintenance ; Booklet 810 .
1.5 Checking vacuum unit for turbocharger

1. Turbocharger 187
Audi TT 2007 ➤
Procedure
Proceed as follows:
♦ Hose from turbocharger via charge pressure solenoid valve -
N75- to vacuum unit must not be blocked.
♦ Charge pressure control solenoid valve -N75- OK.
– Connect hand vacuum pump -VAS 6213- to vacuum unit

-arrow-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Move adjuster ring -1- on hand vacuum pump to position

“pressure” -arrow B-.

Audi TT 2007 ➤
Caution
Risk of damage to vacuum unit.

♦ The pressure must not exceed 850 mbar.
– Operate hand vacuum pump repeatedly and observe linkage

-A-.
• The linkage should move at a pressure of approx. 300 mbar
and above.
• At approx. 800 mbar the linkage should be at its limit stop.
• The linkage should travel approx. 13 mm.
Note
♦ If it is not possible to build up pressure with hand vacuum pump

or if the pressure drops again immediately, check hand vac‐
uum pump and connecting hoses for leaks.
♦ If no fault is found: renew vacuum unit ⇒ page 189 .

turbocharger
Removing
Proceed as follows:
– Remove turbocharger ⇒ page 182 .
– Detach locking plate -2- for linkage.
– Remove nut -3- and bolts -1-.
– Disconnect pressure hose -arrow- and vacuum unit.
Installing
– Adjust vacuum unit for turbocharger ⇒ page 190 .
– Install turbocharger ⇒ page 182 .
1. Turbocharger 189
Audi TT 2007 ➤
1.7 Adjusting vacuum unit for turbocharger

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

Audi TT 2007 ➤
Procedure
Proceed as follows:
• Turbocharger removed ⇒ page 182
– Disconnect pressure hose -arrow-.
– Detach locking plate -2- for turbocharger linkage.
Note
– Slacken nut -2-.

– Adjust bypass flap via nut -3-.
• It must be possible to still just turn the bypass flap by hand.
– Hand-tighten nut -2-.
– Connect hand vacuum pump -VAS 6213- and pressure control

valve -VAS 6342- to vacuum unit and connection “II” of turbo‐
charger tester -V.A.G 1397A- , as shown in illustration.
– Close pressure control
Protected valve -VAS
by copyright. Copying 6342-
for private. or commercial purposes, in part or in whole, is not
• Lever -1- shouldwith
berespect
horizontal.
– Move adjuster ring -1- on hand vacuum pump to position

“pressure” -arrow-.
– Switch on turbocharger tester -V.A.G 1397A- and set sliding
switch to position “II”.
1. Turbocharger 191
Audi TT 2007 ➤
– Secure universal dial gauge bracket -VW 387- to turbocharger

-arrow-.
– Attach dial gauge -VAS 6341/1- with extension, 30 mm -VAS
6341/3- and flat pickup -VAS 6341/4- to universal dial gauge
bracket, as shown in illustration.
– With pressure at 0 bar, set dial gauge to 1 mm preload.
– Set scale of dial gauge to “0”.
– Make sure that dial gauge can move freely.
– Operate hand vacuum pump until turbocharger tester indi‐
cates the following value:
• 500 ± 5 mbar
– Read off value indicated on dial unless
permitted gauge.authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– If specification is not attained or is exceeded, turn nut -3- ac‐

cordingly.
– Lock nut -2- by hand and repeat measurement.

pressure reading drops to 0 mbar.
– Set dial gauge -VAS 6341/1- to “0”.
Note
The following measurements must be performed in the specified

sequence. Do not allow the pressure to drop to 0 mbar between
measurements.
– Operate hand vacuum pump -VAS 6213- until turbocharger

tester -V.A.G 1397A- indicates the following value:
• 500 ± 5 mbar
– Operate hand vacuum pump until turbocharger tester indi‐
cates the following value:
• 650 ... 700 mbar
pressure reading drops to 500 ± 5 mbar.
– Read off and note value indicated on dial gauge.
– Add values “1” and “2” together and divide by 2.
• Specification (mean value): 4 ± 0.25 mm

Audi TT 2007 ➤
– If specification is not attained or is exceeded, turn nut -3- ac‐

cordingly.
– Lock nut -2- by hand and repeat measurement.
– If the specification is attained, lock nuts and secure with seal‐
ing paint; for sealing paint refer to ⇒ Electronic parts cata‐
logue .
– Secure locking plate -2- at linkage for vacuum unit and connect
pressure hose -arrow-.
1. Turbocharger 193
Audi TT 2007 ➤
2 Charge air cooler
Note
♦ Hose connections and air pipes and hoses must be free of oil and grease before assembly.
♦ Secure all hose connections with the correct type of hose clips (same as original equipment) ⇒ Electronic
parts catalogue .
♦ To ensure that the charge air hoses can be properly secured at their connections, spray rust remover onto
the worm thread of used hose clips before installing.
1 - Bolt
❑ 5 Nm
2 - Mounting
❑ For charge air cooler
⇒ page 196
4 - Hose clip
5 - Bolt
❑ 10 Nm
6 - Air pipe
⇒ page 178
7 - Air hose
⇒ page 178
8 - Hose clip
9 - Leading to air hose
10 - Air hose
❑ To throttle valve module
-J338-
11 - Hose clip
12 - Air pipe
13 - Bolt
14 - Hose clip with respect to the correctness of information in this document. Copyright by AUDI AG.
15 - Air hose
16 - Hose clip
17 - O-ring
❑ Renew
18 - Charge air pressure sender -G31-

Audi TT 2007 ➤
19 - Bolts
❑ 5 Nm
20 - Bolt or nut
❑ 10 Nm
21 - Hose clip
22 - Hose
23 - Hose clip
24 - Housing
26 - Bolt
❑ 3x
❑ 7 Nm
27 - O-ring
❑ Renew
28 - Hose clip
29 - Hose
2.2 Removing and installing charge air pres‐

sure sender -G31-
Removing
Proceed as follows:
– Unscrew bolts -1- and remove charge air pressure sender -
G31- .
Installing

air recirculation valve -N249-
Removing
Proceed as follows:
– Unscrew bolts -arrows- and remove turbocharger air recircu‐
lation valve -N249- .
• Tightening torque ⇒ page 179 with respect to the correctness of information in this document. Copyright by AUDI AG.
2. Charge air cooler 195

Audi TT 2007 ➤

• Installation position: Markings must be on same side
-arrows-.

er
Removing
Proceed as follows:
Caution
not damaged.

– Release hose clip -arrow- and detach air hose from charge air
cooler.

Audi TT 2007 ➤
– Unscrew bolts -arrows-; to do so, release air ducts (left and

right) and swivel towards headlights.
– Swivel top edge of charge air cooler slightly towards rear.
– Push charge air cooler towards engine and support from below
to prevent it from dropping.

– Take out charge air cooler from underneath.
Installing
Installing
Note




Audi TT 2007 ➤
♦ Charge air system tester -V.A.G 1687-

Procedure
Proceed as follows:
– Lift retaining clip -A- and detach air hose -B-.
– Fit adapter -V.A.G 1687/5- onto air hose -A- and turn by ap‐
prox. 90° -B-.

Audi TT 2007 ➤

valves -3- and -4-.
Note
Make sure knob is pulled out before turning pressure control valve
-2-.
– Connect charge air system tester -V.A.G 1687- as shown on

illustration.

Audi TT 2007 ➤

Note
water.
– Open valve -3-.
Caution
Risk of damage if pressure is set too high.


Note

retention test.
♦ Release pressure by detaching coupling from adapter -V.A.G
1687/5- before removing adapter.
– Observe the instructions for installing air pipes and hoses with
plug-in connectors ⇒ page 178 .

Audi TT 2007 ➤
1 Silencers
1 - Rubber mounting
2 - Nut
❑ 23 Nm
4 - Bolt
❑ 23 Nm
5 - Bolt
❑ 23 Nm
6 - Mounting
7 - Tunnel brace
8 - Gasket
❑ Renew
9 - Nut
❑ Renew
❑ Coat studs with high-
temperature paste; for
refer to ⇒ Electronic
parts catalogue
❑ 40 Nm
10 - Lambda probe -G39-
⇒ Rep. Gr. 24
11 - Front exhaust pipe with
catalytic converter and front si‐
lencer
bend flexible joint more
than 10° – otherwise it can be damaged
❑ Install flexible joint so that it is not under
permittedtension.
❑ Take care not to damage wire mesh with onrespect
flexible joint.

❑ Do not remove protective packaging from replacement part until you are ready to fit the flexible joint
12 - Lambda probe 2 -G108-
13 - Clamp
1. Silencers 201
Audi TT 2007 ➤

14 - Nut
❑ 23 Nm
15 - Bracket
17 - Bracket
18 - Exhaust flap valve -N220-
❑ With vacuum unit
❑ Checking vacuum unit for exhaust flap ⇒ page 209
19 - Nut
❑ 23 Nm
20 - Bolt
❑ 23 Nm
21 - Rear silencer
❑ Combined with centre silencer
22 - Nut Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 23 Nm
23 - Bolt
❑ 23 Nm


pipe with catalytic converter and front si‐
lencer
Removing
Proceed as follows:

Audi TT 2007 ➤


er housing.

– Loosen hose clip -1- and move air pipe clear to one side (hose
-2- remains connected).
Note
Disregard item -3-.
1. Silencers 203
Audi TT 2007 ➤
– Unscrew bolts -arrows- and nuts -1- and detach heat shield.
– Working from above, unscrew nuts -arrows- securing front ex‐

haust pipe to turbocharger.
Note
The illustration shows the installation position from underneath.

Caution
flange.

Audi TT 2007 ➤
– Remove bolts -1- and -2- on underside of vehicle.

– Detach cover from bracket for electrical connector for Lambda
probe.
– Remove bolt -3- and move electrical wire to Lambda probe
clear.
– Remove electrical connector -arrow- for Lambda probe after

catalytic converter -G130- from bracket and unplug connector.
– Remove bolts -arrows- and detach bracket for exhaust system

and tunnel brace.
1. Silencers 205
Audi TT 2007 ➤
Caution

10°.
– Disconnect exhaust system at clamp -1-.

– Detach front exhaust pipe with catalytic converter and front
silencer.
Installing
Note

Procedure
Proceed as follows:
– Loosen bolt connections for clamp.
– Push rear silencer towards front of vehicle -arrow- so that rub‐
ber mounting (left-side) on rear silencer is preloaded by -a- =
11 ... 13 mm.

Audi TT 2007 ➤


Procedure
Proceed as follows:
– Adjust the rear silencer so that there is an even distance be‐
tween the bumper cut-outs and the tailpipes.
• Distance -a- is the same on both sides.
• Distance -b- = approx. 19 mm.
• Distance -c- = approx. 22.5 mm.

Procedure
Proceed as follows:
– Plug tailpipes during leak test (e.g. with cloth or plugs).
– Listen for leaks at joints between cylinder head and exhaust
manifold with turbocharger, exhaust manifold/turbocharger
and front exhaust pipe, etc. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Rectify any leaks that are found.with respect to the correctness of information in this document. Copyright by AUDI AG.
1. Silencers 207
Audi TT 2007 ➤
2 Exhaust manifold
The exhaust manifold and the turbocharger are combined as one
unit; removing and installing ⇒ page 177 .

Audi TT 2007 ➤
3 Exhaust flap
3.1 Checking vacuum unit for exhaust flap

Procedure
Proceed as follows:
– Detach hose from vacuum unit for exhaust flap on rear silenc‐
er.
– Connect hand vacuum pump -VAS 6213- to vacuum unit.
– Operate hand vacuum pump.

• The linkage should move upwards.
– Vent vacuum pump.
• Linkage should move downwards. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– If linkage does not move, check linkage for
with ease
respect of movement
and check vacuum unit for leaks.
3. Exhaust flap 209

Service
Workshop Manual
Audi TT 2007 ➤
6-cylinder injection engine (3.2 ltr. 4-valve), mechanics
Engine ID BUB CBR
A
Edition 03.2009

Service
Repair Group
00 - Technical data
10 - Removing and installing engineProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
13 - Crankshaft group with respect to the correctness of information in this document. Copyright by AUDI AG.

17 - Lubrication
19 - Cooling
26 - Exhaust system


Audi TT 2007 ➤
6-cylinder injection engine (3.2 ltr. 4-valve), mechanics - Edition 03.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1 Observe the following to prevent injuries to persons and damage to the injection and ignition
system: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Using testers and measuring instruments during a road test . . . . . . . . . . . . . . . . . . . . . . . .
4
3.3 Working
with respect to the correctness on the
of information cooling
in this system
document. . .AUDI
Copyright by . . .AG.
......................................... 4
3.4 Procedure before opening high-pressure section of injection system . . . . . . . . . . . . . . . . 4
turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.7 Installing radiators, condensers and charge air coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 Separating engine from manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Separating engine from direct shift gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.1 Poly V-belt drive - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.6 Removing and installing sealing flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.1 Dual-mass flywheel - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.4 Renewing crankshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Contents i
Audi TT 2007 ➤
4.3 Measuring axial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68


1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.1 Cylinder head and cylinder head cover - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.1 Timing chain covers - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.2 Renewing oil seals in timing chain cover (top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.3 Timing chain - exploded view of components with respect .to.the
. .correctness
. . . . . .of. information
. . . . . .in. this
. . document.
. . . . .by. AUDI
. . AG.
83
2.4 Detaching and re-fitting timing chain on camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.5 Removing and installing camshaft timing chain and drive chain for valve gear . . . . . . . . . . 94
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.8 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.10 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1 Oil pump and sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.1 Oil pump and sump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.3 Oil pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2 Oil cooler and oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.1 Oil cooler, oil filter housing - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.2 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.4 Checking oil pressure and oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.5 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
2 Coolant pump, thermostat, coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.1 Thermostat housing - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.3 Removing and installing continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . 156
2.4 Removing and installing thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.5 Removing and installing hose connection with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.8 Removing and installing coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.9 Removing and installing coolant pipe going to gear oil cooler . . . . . . . . . . . . . . . . . . . . . . 164
ii Contents
Audi TT 2007 ➤

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

1 Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.2 Removing and installing front exhaust pipe with catalytic converter and front silencer . . . . 177
2 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.1 Exhaust manifold - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.2 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3.1 Principle and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3.2 Secondary air system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3.3 Checking combination valve for secondary air system for proper operation and leakage -
engine code BUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3.4 Removing and installing combination valve for secondary air system - engine code BUB
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3.5 Checking combination valves forProtected secondary air system
by copyright. Copying forfor proper
private operation
or commercial purposes,and leakage
in part or in whole,- is not
engine code CBRA . . . . . . . . . .permitted .with
. . respect
. .unless
. . .to.authorised
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 189
3.6 Removing and installing combination valve for secondary air system (left-side) - engine code
CBRA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.7 Removing and installing combination valve for secondary air system (right-side) - engine
code CBRA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.8 Removing and installing secondary air pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.9 Removing and installing sender 1 for secondary air pressure G609 - engine code CBRA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Contents iii
Audi TT 2007 ➤
iv Contents
Audi TT 2007 ➤
1 Engine number
♦ The engine number (“engine code” and “serial number”) can
be found at the front next to the poly V-belt pulley on the
crankshaft -arrow-.
♦ There is also a sticker on the cylinder head cover showing the
“engine code” and “serial number”.
ters.
number.
♦ The 4th character indicates theinpower output and by torque of the

with respect to the correctness of information this document. Copyright AUDI AG.
Note
♦ The engine code is additionally marked at the engine lifting

eye (right-side).
♦ The 3-character engine code also appears on the vehicle data
sticker.
1. Engine number 1
Audi TT 2007 ➤
2 Engine data
Code letters BUB CBRA
Capacity ltr. 3.189 3.189
Power output kW at rpm 184/6300 184/6300
Torque Nm at rpm 320/2500 … 3000 320/2500 … 3000
Bore ∅ in mm 84 84
Stroke mm 95.9 95.9
Compression ratio 10.85 10.85
RON not less than 98 1) 98 1)
Injection/ignition system Motronic
Motronic
Firing order 1-5-3-6-2-4
1-5-3-6-2-4
Emission standards EU4 LEV2
Exhaust gas recirculation no no
Turbocharging/supercharging no no
Lambda control 4 probes 4 probes
Variable valve timing yes yes
Intake manifold change-over yes yes
Secondary air system yes yes
Valves per cylinder 4 4
• 1) Unleaded premium RON 95 can also be used, but results in reduced power

Audi TT 2007 ➤
WARNING

cause injury.
♦ Wrap a clean cloth around the connection and carefully
loosen the connection to allow the residual pressure to
dissipate.
– Procedure before opening high-pressure section of injection

system ⇒ page 4 .
WARNING
Escaping fuel can cause a fire risk.

♦ The power supply for the fuel pump control unit -J538-
must be disconnected before opening the fuel system, as
the fuel system pressurisation pump -G6- will be activated
briefly when the driver's door is opened with the battery
still connected.
Caution

battery.
3.1 Observe the following to prevent injuries

to persons and damage to the injection
and ignition system:
♦ Do not touch or disconnect ignition coils with output stages
when the engine is running or being turned at starter speed.
tester cables.
♦ If you want to crank the engine at starting speed without ac‐

tually starting it (e.g. compression test), first unplug the con‐

nectors from the ignition coils and the injectors. After
completing the work, interrogate and erase the fault memory.
Audi TT 2007 ➤

VAS 5051B- .

WARNING

erly secured.
secured.
TT Coupé:
TT Roadster:
the passenger.
3.3 Working on the cooling system

When working on the cooling system note the following:

hot.
3.4 Procedure before opening high-pres‐

sure section of injection system
♦ The injection system consists of a high-pressure section (max‐
imum approx. 120 bar) and a low-pressure section (approx.
6 bar).

Audi TT 2007 ➤
♦ Before removing a component in the high-pressure section of

the injection system, the fuel pressure in the high-pressure
section must be reduced to a residual pressure of approx.
6 bar; follow the procedure outlined below.
5051B-
Procedure
and information system -VAS 5051B- with diagnosis lead to
diagnosis connection.

– Select Vehicle self-diagnosis from the list -item 1-.

– From menu -1-, select vehicle system “Engine electronics” and
press → key to continue.

– From menu -1-, select function “Measured values” and press
→ key to continue.
Audi TT 2007 ➤

– Press keys 1 4 0 on keypad -1- to select “Display group 140”
and confirm entry by pressing Q key.

– Check display indicating fuel pressure in fuel rail in display
zone -3-.
• With engine idling the figure displayed will be 35 ... 45 bar. The
display shows the actual pressure in the fuel rail which is being
generated by the high-pressure pump.
Gr. 70 .


Audi TT 2007 ➤

– With engine still running, check display zone -3- for fuel pres‐
sure in fuel system:
fuel from the fuel tank by the electric fuel pump.
– Switch off ignition as soon as fuel pressure has dropped to just
below 8 bar.
Note
The fuel rail is still filled with fuel, however it is no longer under
high pressure.
WARNING

♦ 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.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Disconnect a fuel line connection without delay.
Note
The pressure will increase again due to the effect of residual heat
if the high-pressure system is not opened immediately.

– Re-fit fuse 6 in fuse holder F -SF6- .
– Generate readiness code in engine control unit ⇒ Vehicle di‐
agnosis, testing and information system VAS 5051.
Audi TT 2007 ➤

turbocharger
opening.
etc.).

– Allow engine to run for several minutes at moderate
permitted unless authorised byrpm.
renewed.
– Then inspect high-pressure section of fuel system again for
leaks.
4.3 Foreign particles in engine

♦ When performing assembly work on engine, all open passag‐
es in the intake and exhaust systems must be sealed with
suitable plugs (e.g. from engine bung set -VAS 6122- ) to pre‐
vent foreign particles from entering the engine.
♦ In the event of mechanical damage to one of the cylinder
banks, the intake and exhaust systems and combustion cham‐
bers of the opposite cylinder bank must always be examined
to prevent further damage occurring later.

used.

Audi TT 2007 ➤
Note the following:
♦ Damage
permitted caused
unless authorised byAG.
by AUDI contact
AUDI AGcorrosion is not
does not guarantee covered
or accept under
any liability
warranty.

and wiring
♦ Mark fuel lines, hydraulic lines, vacuum lines, lines for activa‐
ted charcoal filter system 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.
♦ 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).

Procedure
♦ Cracks
remaining vacuum lines in the system.
– If it is not possible to build up pressure with hand vacuum pump
-VAS 6213- or if the pressure drops again immediately, check
hand vacuum pump and connecting hoses for leaks.

Audi TT 2007 ➤
4.7 Installing radiators, condensers and

charge air coolers
Even when the radiator, condenser and charge air cooler are cor‐
rectly 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, condenser or charge air cooler.

Audi TT 2007 ➤

1 Removing engine

equipment required
V.A.G 1383 A-
-VAS 6208-
Audi TT 2007 ➤
♦ Engine support -T40074-
♦ Nut M12 (1x)

♦ Bolts M10 (2x)
Procedure
Note

gearbox.
posal.
Caution


– Remove rear cross panel trim if cover for negative terminal of
terminal. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi TT 2007 ➤
– Slacken nut a few turns and disconnect battery clamp on earth

cable -arrow- from battery terminal.
WARNING

hot.

Audi TT 2007 ➤

drain off coolant.

Note
Illustration shows coolant hose on vehicle with direct shift gear‐

box.
– Detach resonance pipe -2- from air intake hose. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
J338- .

Audi TT 2007 ➤
– Remove bottom section of air cleaner housing -arrows-.
– Unbolt bracket for air cleaner housing -arrows-.
– Unplug electrical connector -1- for Lambda probe 2 -G108-

and electrical connector -2- for Lambda probe -G39- .
– Unplug electrical connector -3- for brake fluid level warning
contact -F34- .
– Move electrical wiring to Lambda probes clear.

– Release wiper arms one by one by tilting them slightly on the
wiper shafts.
– Remove nuts and detach windscreen wiper arms.
Note
Use puller (commercially available) to remove wiper arm if nec‐

essary.
Audi TT 2007 ➤
– Pull off rubber seal -1-

tition panel.
– Unscrew bolt -arrow- and detach engine control unit from re‐
tainer.
– Unplug electrical connector -arrow- for body wiring harness

-1-.


Audi TT 2007 ➤

– Cut open cable tie -1-.

engine.
– Unscrew terminal 30 wire from electronics box in engine com‐

partment -arrow- and move it clear.
Audi TT 2007 ➤
Note

solenoid switch
– Remove top starter bolt.
– Detach cable support bracket from gearbox -arrows-.
– Unclip circlip -1- from gear selector cable and circlip -2- from
gate selector cable.
– Pull selector cable end-pieces with selector cables off selector
shaft lever and relay lever.
– Tie selector cables with cable support bracket to one side.

Audi TT 2007 ➤
– Clamp off pressure hose to clutch slave cylinder using a hose

clamp -3094- .
– Pull securing clip upwards -arrow- and detach pipe/hose as‐
sembly -1- from bleeder connection on clutch slave cylinder.
Caution

♦ Do not operate clutch pedal after detaching pipe/hose as‐
sembly from bleeder connection on clutch slave cylinder.
Vehicles with direct shift gearbox:

solenoid switch
Caution
Riskpermitted
of damage to control unit
AG.(mechatronic unit) byorstatic dis‐
unless authorised by AUDI AUDI AG does not guarantee accept any liability
charge.
♦ Do NOT touch connector contacts in gearbox connector

with your hands.
– Touch vehicle earth with bare hands to discharge any static

charge.
– Turn retainer catch anti-clockwise and unplug electrical con‐
nector -4- at gearbox.

– Disconnect coolant hoses going to heat exchanger at bulk‐
head -arrows-.
Audi TT 2007 ➤
– Detach coolant hose at top left of radiator -arrow-.
– On rest-of-world vehicles detach vacuum line -1- from activa‐

ted charcoal filter in engine compartment and move clear.
WARNING


nection.
– Disconnect fuel supply hose -4- by pulling release ring.

– Move fuel supply hose clear.
– Detach vacuum hose going to brake servo -arrow-.

– Detach vacuum hoses from intake manifold and move clear.
2 - To fuel system diagnostic pump -V144-
4 - To activated charcoal filter solenoid valve 1 -N80-
– Detach activated charcoal filter solenoid valve 1 -N80- from
bracket and move it clear to the side.
Note
Items -1, 3- and -arrows- can be disregarded.

Audi TT 2007 ➤

– Unscrew nuts -1- and -2- (accessible from above) securing
front exhaust pipe to exhaust manifold.
Note
Nuts -3 ... 6- are removed at a later stage.
– Remove top bolts -upper arrows- for radiator cowl.
Caution

– To slacken poly V-belt turn tensioner in direction of -arrow-.

– Loosen bolts of assembly mounting at engine -arrows- approx.

2 turns.
Audi TT 2007 ➤
– Loosen bolts of assembly mounting at engine -arrows- approx.

2 turns.

– Unplug electrical connector -2- at reversing light switch -F4- .
– Remove nut -1- and remove bracket with wiring from bottom
starter bolt.

– Detach electrical connector -1- at secondary air pump motor -
V101- and move wire clear.
Note
Disregard items marked -2, 3 and arrow-.
– Move coolant hose at bottom of radiator cowl clear.

– Detach electrical connectors -1- for radiator fans at bottom of
radiator cowl.
– Remove bolts -bottom arrows- at bottom of radiator cowl.
– Remove radiator cowl with both radiator fans from below.

Audi TT 2007 ➤

WARNING

– Remove bolts -arrows- for air conditioner compressor.

– Tie up air conditioner compressor together with refrigerant ho‐
ses at front of longitudinal member (refrigerant hoses remain
connected).

sender -G266- .
-arrows-.
– Remove drive shaft (right-side) ⇒ Rep. Gr. 40 .
– Detach drive shaft (left-side) from flange shaft of gearbox.
– Unscrew nuts -3 ... 6- securing

with front
respect exhaust pipeofto
to the correctness exhaust
information in this document. Copyright by AUDI AG.
manifold.
Note
Nuts -1 and 2- have been removed at an earlier stage.
Audi TT 2007 ➤
– Remove nuts -1- and -2- on underside of vehicle.

– Detach cover from bracket for electrical connectors for Lamb‐
da probes.
– Remove bolt -3- and move electrical wiring to Lambda probes
clear.
– Detach electrical connectors from bracket and unplug.

1- For Lambda probe after catalytic converter -G130-
2- For Lambda probe 2 -G131- (after catalytic converter)
– Unbolt bracket for exhaust system -arrows-.

Caution

10°.

– Detach front exhaust pipes with catalytic converters and front
silencer.

Audi TT 2007 ➤

Caution

flange.

– Remove bolts -1- for support bracket.
– Pull off securing clip -3- -arrow- and remove selector lever ca‐
ble from gearbox.
Note
Disregard item -2-.
Caution
Make sure not to damage the seal in the propshaft flange.

♦ When removing the bolts for the pendulum support/sub‐
frame, the engine/gearbox assembly swings slightly for‐
ward.
– Remove bolts -1, 2, 3- correctness

and remove pendulum support.
with respect to the of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
– Bolt engine support -T40074- with M12 nut (1x) and M10 bolts
(2x) -arrows- to cylinder block (tightening torque: approx. 20
Nm).
Note

VAS 5085- .
– Remove bolts of assembly mounting at engine -arrows-.
– Remove bolts of assembly mounting at gearbox -arrows-.
Note

avoid damage.
– Pull engine/gearbox assembly as far forward as possible, and

lower gradually.

Audi TT 2007 ➤
2 Separating engine and gearbox
2.1 Separating engine from manual gearbox

equipment required
♦ Hooks -10 - 222 A /2-
VAS 6100-
Procedure
support.
– Unscrew bolts -1- and -2- and remove bracket -A- for bevel
box.

Audi TT 2007 ➤

– Remove bolts -1 ... to6-theon
with respect engine/gearbox
correctness of information inflange.

Audi TT 2007 ➤
2.2 Separating engine from direct shift gearbox

equipment required
♦ Hooks -10 - 222 A /2-
VAS 6100-
♦ Retainer -T10013-
♦ Bolt M8x40 with nut and
washer (25 mm outer diam‐
eter)
Procedure
support.
– Unscrew bolts -1- and -2- and remove bracket -A- for bevel
box.

Audi TT 2007 ➤
– Move electrical wiring clear -arrows-.
– Detach coolant hoses from gear oil cooler and from coolant
pipe going to gear oil cooler -arrows-.
– Remove bolts -1- and -2- and take off coolant pipe -A-.
– Disconnect air hose -arrow-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Loosen bolt -2- and remove secondary air pump with bracket.
Note
Disregard item -1-.
– Remove threaded pin from retainer -T10013- (to do so, re‐

lease circlip).
– Secure retainer -T10013- to gearbox lifting eye using bolt
M8x40 with nut and washer (25 mm outer diameter).
– Attach workshop hoist -VAS 6100- with hook -10 - 222 A /2-
to retainer -T10013- .

Audi TT 2007 ➤
– Remove bolts -1, 3, 5, 6, 7, 8, 9, 10- securing gearbox to en‐

gine.
Note
Disregard items marked -2, 4 and A-.

Audi TT 2007 ➤

equipment required
♦ Engine bracket -3269-
port -VAS 6095-
VAS 6100-
Procedure
– Lift engine off engine support -T40074- using workshop hoist
-VAS 6100- .

Audi TT 2007 ➤
Securing engine at gearbox end

– Secure engine and gearbox support -VAS 6095- to gearbox
end of cylinder block as shown in illustration.
Securing engine at side

– Secure engine bracket -3269- to side of cylinder block as
ing engine bracket -3269- .

Audi TT 2007 ➤
4 Installing engine
Tightening torques
Note

♦ Tolerance for tightening torques ± 15%.

Component Nm
Bolts/nuts M6 10
M7 15
M8 22
M10 40
M12 65
Earth cable 22

Item Bolt Nm
1 1), 3 M12x55 80
2 2) M12x65 80
4, 5 2) M10x50 40
6 2) M12x80 80
• 1) Bolt with M8 stud
• 2) Screwed into gearbox from engine side.

Audi TT 2007 ➤
Securing direct shift gearbox to engine

Item Bolt Nm
1, 3, 6 M12x55 80
5 M12x65 80
7, 8 M10x50 40
9 M10x45 40
10 M12x70 80
Note
Disregard items marked -2 and 4-.
Procedure
Note
♦ Renew self-locking nuts and bolts.


– Protected
Make sure that Copying
by copyright. clutchforplate
privateis
or properly centred.
Vehicles with todirect
with respect shift gearbox:
– Install needle bearing if not fitted in crankshaft ⇒ page 57 .

– Secure bracket -A- for bevel box ⇒ Rear final drive 02D/0AV;
Rep. Gr. 39 .
– Install secondary air pump ⇒ page 194 .
– Install coolant pipe going to gear oil cooler ⇒ page 164 .
Audi TT 2007 ➤
– Tighten bolts securing engine mounting to engine support

-arrows- initially hand-tight.
– Tighten bolts securing gearbox mounting to gearbox support

-arrows- initially hand-tight.
Note
– Bolt pendulum support to gearbox ⇒ page 39 .

– Install selector lever cable ⇒ Rep. Gr. 34 .

Caution

flange.
♦ Push engine/gearbox assembly towards bulkhead, guid‐
ing pin on bevel box flange carefully into propshaft flange.

Audi TT 2007 ➤
– Bolt pendulum support to subframe ⇒ page 39 .
Audi TT 2007 ➤
– Secure propshaft with flexible coupling to bevel box -arrows-

⇒ Rear final drive 02D/0AV; Rep. Gr. 39 .
note the following:
– Install front exhaust pipe ⇒ page 177 .
– Install exhaust system and align free of stress ⇒ page 179 .
– Install heat shield for drive shaft ⇒ Rep. Gr. 39 .
– Attach electrical connector to starter ⇒ Rep. Gr. 27 .
– Installing and adjusting selector mechanism ⇒ Rep. Gr. 34 .
Caution

♦ Do not operate clutch pedal before attaching pipe/hose
assembly to bleeder connection on clutch slave cylinder.
– Connect pipe/hose assembly to bleeder connection on clutch

slave cylinder and bleed clutch system ⇒ Rep. Gr. 30 .
Gr. 27 .
– Check oil level ⇒ page 141 .
Caution

Note

♦ the cylinder headpermitted
or cylinder block have been renewed.

Audi TT 2007 ➤
1 - Bolt
gearbox
Rep. Gr. 34
2 - Bolts
gearbox
❑ Renew
❑ 40 Nm + 90° (1/4 turn
further)
3 - Engine support
4 - Bolt
gine
❑ 45 Nm
5 - Engine mounting
❑ With support arm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
body
❑ Renew
❑ 40 Nm + 90° (1/4 turn
further)
8 - Bolt
❑ Connecting bracket to
engine mounting
❑ Renew
❑ 20 Nm + 90° (1/4 turn
further)
9 - Bolt
❑ Renew
❑ 20 Nm + 90° (1/4 turn further)
10 - Bolt
❑ Renew
11 - Bolts
❑ Renew
Audi TT 2007 ➤
13 - Bolt
❑ Renew
❑ 100 Nm + 90° (1/4 turn further)
14 - Bolt
15 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Gearbox mounting to body with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Illustration shows version for direct shift gearbox
17 - Bolt
18 - Bolt

Procedure
box:
Note



Audi TT 2007 ➤

equipment required
A-
♦ Hook -10 - 222 A /10-
♦ Shackle -10 - 222 A /12-
♦ Bracket -T10338-
T40093- with -T40093/3-2-
and -T40093/3-3-
Adjusting
– On rest-of-world vehicles pull activated charcoal filter with ho‐
ses attached upwards out of bracket -arrow- in engine com‐
partment and place to one side.
Audi TT 2007 ➤

J338- .
– Unbolt bracket for air cleaner housing -arrows-.

Audi TT 2007 ➤
– Secure bracket -T10338- to tapped hole at rear left of engine.

♦ 2x Rack -10 - 222 A /1-
♦ Hook -10 - 222 A /10- (spindle faces rear)
♦ Shackle -10 - 222 A /12-
♦ Connecting piece (2x) -T40091/3-
– Hook spindle -10 - 222 A /11- with shackle -10 - 222 A /12-
onto right-side engine lifting eye.
– Engage hook -10 - 222 A /10- in bracket -T10338- .
– Tighten spindles slightly to take up weight of engine/gearbox
assembly.

– Secure adapters to longitudinal members using one M8x30
bolt on each side -arrow-.
Note
Audi TT 2007 ➤
– Insert square-section pipes -T40091/1- in connecting pieces -

T40091/3- and supports -T40093/3- as shown in illustration.
– Slide connecting pieces -T40093/4- onto square-section
pipes.
WARNING

bolts.
– Fit spindle -10 - 222 A /11- onto sliding support and onto en‐
gine lifting eye.
ening three spindles.
– Remove bolts of assembly mounting at engine -arrows-.
– Remove bolts of assembly mounting at gearbox -arrows-.

– Renew each of the 5 bolts in turn (if not already done when
installing engine) and hand-tighten.
– Slacken bolts on left and right-hand support arms by about two
turns each.

Audi TT 2007 ➤

• The two bolt heads -2- must be parallel with the edge of the
support arm -3-.
Note

– Tighten bolts of assembly mounting at gearbox.
– Tighten bolts for assembly mounting.
note the following:
Gr. 50 .
– Install air filter element ⇒ Rep. Gr. 24 .
Audi TT 2007 ➤
1.1 Poly V-belt drive - exploded view
1 - Poly V-belt
❑ Check for wear
❑ Do not kink
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-tipped pen for re-in‐
stallation.

⇒ page 48
on pulleys.
⇒ page 51
3 - Bolt
❑ Renew
❑ 100 Nm + turn 180° fur‐
ther
❑ Use counterhold tool -
T10069- when loosen‐
ing and tightening
4 - Bolt
❑ 20 Nm
5 - Poly V-belt pulley for coolant pump
6 - Bolt
❑ 8 Nm
7 - Bolt
❑ 50 Nm
8 - Tensioner for poly V-belt
❑ Pivot with open-end spanner toProtected
slacken poly V-belt
❑ Lock in position with locking pin -T10060 A-the. correctness of information in this document. Copyright by AUDI AG.
with respect to

9 - Coolant pump

Audi TT 2007 ➤

11 - Bolt
❑ 23 Nm
12 - Alternator
13 - Bolt
❑ 3x
❑ Tightening torque and tightening sequence ⇒ page 47
14 - Dowel sleeve for air conditioner compressor
❑ Do not unscrew or disconnect refrigerant hoses or pipes.
16 - Bolt
❑ 25 Nm
17 - Fitted bolt
❑ 2x
18 - Idler rollers
19 - Bolt
❑ 40 Nm

1. Tighten bolts hand tight.
2. Tighten bolts to 23 Nm.
Note
Bolts -1- and -2- are fitted bolts.

Audi TT 2007 ➤
Sealing flange - tightening torque and tightening sequence


to 10 Nm.

Removing
– On rest-of-world vehicles pull activated charcoal filter upwards
out of bracket -arrow- in engine compartment and place to one
side with hoses attached.
Caution



Audi TT 2007 ➤
Installing
Note
Tighten alternator and A/C compressor mountings before fitting

poly-V-belt.
– Fit poly V-belt as Protected

follows: by copyright. Copying for private or commercial purposes, in part or in whole, is not
1- Idler roller with respect to the correctness of information in this document. Copyright by AUDI AG.
2- Vibration damper
3- Coolant pump
5- Alternator
6- Idler roller

T10060 A- .
– Release tensioner.
– Start engine and check that poly V-belt runs properly.

poly V-belt
Removing
Note
Do not lock tensioner.
– Remove bolt -arrow- and take off tensioner for poly-V-belt.

Installing

Audi TT 2007 ➤

cillaries
Removing
– Detach air conditioner compressor from engine ⇒ Rep. Gr.
87 and tie up on body with refrigerant lines connected.
– Spray rubber lugs -2 and 4- on flexible retainer for continued
coolant circulation pump -V51- -item 1- with silicone-free lu‐
bricant.
– Disengage rubber lugs from bracket -3- for continued coolant
circulation pump -V51- .
Note
Continued coolant circulation pump -V51- remains on engine with

coolant hoses connected.
Note
Disregard -arrow-.
Installing

Audi TT 2007 ➤
– Engage lugs -2- and -4- on flexible retainer for continued cool‐
ant circulation pump -V51- in bracket -3-.

er

Audi TT 2007 ➤
Removing
Caution



– Remove poly V-belt from pulley on vibration damper.
– Remove bolt for vibration damper using counterhold tool -

T10069- .
Installing


Audi TT 2007 ➤

♦ Safety goggles
Removing
– Carefully lever off sealing flange.
Installing
Caution

WARNING

– Remove sealant residue on sealing flange using rotating plas‐

tic brush or similar.

Audi TT 2007 ➤
– Cut off nozzle of tube at front marking (diameter of nozzle ap‐

prox. 2 mm).



Caution permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
Fit sealing flange within 5 minutes after applying sealant.

Audi TT 2007 ➤
– Carefully push sealing flange over assembly tool -T10215-

onto dowel pins -arrows- on cylinder block.
– Install sealing flange ⇒ page 48 .


Audi TT 2007 ➤
Note
When performing assembly work, secure engine to engine and

gearbox support ⇒ page 32 .
2.1 Dual-mass flywheel - exploded view of components
Note
-Items 4 ... 23- ⇒ page 80 .

1 - Bolt
❑ Renew
❑ 60 Nm + 90° (1/4 turn
further)
⇒ page 56
3 - Oil seal

wheel

Audi TT 2007 ➤
Removing
– Mark position of dual-mass flywheel on crankshaft for re-in‐
stallation.
Caution

– Counterhold by applying counterhold tool -T10069- to bolt for

vibration damper and remove dual-mass flywheel.
• Tightening torque ⇒ permitted
page 56 .

for crankshaft

Audi TT 2007 ➤
♦ Drift -VW 207 C- or centring mandrel -3176-
♦ -1- internal puller Kukko 21/1

♦ Depth gauge
Removing

Installing
– Drive in needle bearing with drift -VW 207 C- or centring man‐
drel -3176- .

Audi TT 2007 ➤
Installation position for needle bearing:

• The inscription on needle bearing must be visible when instal‐
led.
• Dimension -a- = 2.0 mm.
2.4 Renewing crankshaft oil seal

♦ Fitting tool -T10122-
♦ Extractor tool -T20143-
Procedure
– Pry out oil seal using extractor tool -T20143/2- .

Audi TT 2007 ➤
Note
Do not lubricate the oil seal before pressing in.
– Slide new oil seal -A- over the fitting sleeve -T10122/1- onto
the guide sleeve -T10122/2- .
• Fitting position: closed side faces fitting sleeve.
– Detach fitting sleeve from guide sleeve.
– Fit guide sleeve -T10122/2- with oil seal onto crankshaft.
– Press in oil seal uniformly until flush all round using thrust
piece -T10122/3- .
note the following:

Audi TT 2007 ➤
3 Crankshaft
Note

oil spray jets, oil cooler and oil filter.
3.1 Crankshaft Protected

- exploded view
1 - Cylinder block
❑ Checking cylinder bore
⇒ page 67
❑ Piston and cylinder di‐
mensions ⇒ page 68
2 - Oil spray jet (for cooling of
pistons)
❑ For crankshaft bearings
2 ... 7
❑ Opening pressure: 2.0
bar
⇒ page 130
3 - Bearing shell
❑ For cylinder block, with
oil supply drilling
shells
❑ Only supplied as a re‐
placement part with
“yellow” marking
4 - Crankshaft
❑ After removing, place it
down so that the sender
wheel -item 10- is not
damaged and the crank‐
shaft does not rest on
the sender wheel
ance ⇒ page 63
ance ⇒ page 64
❑ Crankshaft dimensions
⇒ page 63
❑ Chain sprocket is an integral part of crankshaft
5 - Thrust washer
❑ Note location
❑ Oil groove points towards crankshaft
3. Crankshaft 61
Audi TT 2007 ➤
6 - Bearing cap
❑ Bearing cap 1: Pulley end
❑ Bearing cap 5 with recesses for thrust washers
❑ Retaining lugs on bearing shells in cylinder block and bearing cap must be on the same side
7 - Bolt
❑ Renew
❑ 30 Nm + 180° (1/2 turn further)
❑ When measuring radial clearance, tighten used bolt to 30 Nm but not further
8 - Bearing shell
❑ For bearing cap, without drilling
❑ Mark used bearing shells
❑ Only supplied as a replacement part with “yellow” marking
9 - Thrust washer
❑ Note location
❑ Oil groove points towards crankshaft
10 - Sender wheel
❑ For engine speed sender -G28-
❑ Renew
11 - Bolt
❑ Renew
❑ Renew sender wheel if bolts have been unscrewed

Audi TT 2007 ➤
Installing sender wheel for engine speed sender -G28-
Note
Renew bolts and sender wheel if sender wheel bolts have been
unscrewed.
– Clean contact surface between crankshaft and sender wheel;

it must be free of oil and grease.
– Thinly coat contact surface between crankshaft and sender
wheel with locking fluid; for locking fluid refer to ⇒ Electronic
parts catalogue .
Installation position:
• The marking
Protected “VR6”
by copyright. -item
Copying for 2- must
private be positioned
or commercial purposes, inat the
part or inbore
whole,of
is not
thepermitted
bolt -3- which goes into the crankshaft conrod journal (out‐
line of crankshaft ⇒ dotted line -1-).
• The gap -arrow- in the starter gear ring is positioned opposite
the "VR6" marking.
Note
Ignore the second “VR6” marking -item 4-.
– Tighten sender wheel bolts in three stages as follows:

2. Tighten bolt -3- to 10 Nm and turn 90° (1/4 further).
3. Tighten the two remaining bolts to 10 Nm and turn 90° (1/4
turn) further.

Honing dimension Crankshaft main Conrod
(in mm) bearing journal di‐ bearing journal di‐
ameter ameter
Basic dimension 1) 59.958 … 59.978 53.958 … 53.978
• 1) Machining is not permitted.

3. Crankshaft 63
Audi TT 2007 ➤
Procedure
Axial clearance:
• New: 0.07 ... 0.23 mm.

shaft
♦ Plastigage
Procedure
Note

♦ Bearing shells worn down to the nickel layer must be renewed.
bearing on the bearing journal or bearing shell.
shell.
crankshaft.
Radial clearance:
• New: 0.02 ... 0.06 mm.

Audi TT 2007 ➤
1 - Bolt
❑ Renew
contact surface
❑ 30 Nm + 90° (1/4 turn
further)
clearance, tighten used
bolt to 30 Nm but not fur‐
Protectedther
2 -with
Conrod
respect tobearing capof information in this document. Copyright by AUDI AG.
the correctness
❑ Mark cylinder number
-B-
Markings -A- must be on
same side
3 - Bearing shells
shells
❑ The lugs on the bearing
shells must fit tightly in
the recesses
lugs of both bearing
shells must be on same
side of conrod
ance ⇒ page 68
ance ⇒ page 68
❑ As replacement parts,
the upper bearing shell
is supplied with colour-
coding “yellow”, the low‐
er bearing shell with col‐
our-coding “red”.
4 - Conrod
❑ With oil drilling for piston pin lubrication
❑ Mark cylinder number -B-
❑ Installation position: markings -A- must be on same side as lower side of piston crown (lower side of
piston crown faces towards centre of cylinder block)
5 - Circlip
6 - Piston pin
7 - Piston
❑ Mark installation position to conrod and cylinder allocation

Audi TT 2007 ➤
❑ Lower side of piston crown points towards centre of cylinder block

❑ Install with funnel -T10147- ⇒ page 67 .
8 - Piston rings
❑ “TOP” must face towards piston crown
9 - Piston ring
❑ 3 parts
❑ Offset gap of top steel element of piston ring by 120° to next compression ring
❑ Offset gaps of individual parts of oil scraper ring

– Insert piston ring from above as follows and use a piston with‐
out piston rings to push down ring into bottom cylinder open‐
ing.
• At right angle to cylinder wall.
• Up to approx. 15 mm from bottom of cylinder.
Dimensions in mm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Compression ring with respect to the
0.20 … 0.40
correctness of information in1.00
Tapered stepped ring 0.20 … 0.40 1.00

Checking ring-to-groove clearance

– Clean annular groove of piston.
Dimensions in mm
Tapered stepped ring 0.03 … 0.06 0.15

Audi TT 2007 ➤
Checking piston
– Measure as follows using micrometer, 75 … 100 mm:
• Approx. 6 mm from the bottom of piston skirt.
• At 90° to piston pin axis.
Maximum deviation from nominal dimension:
• 0.04 mm (maximum)
Nominal dimension

– Measure as follows using cylinder gauge, 50 … 100 mm:
• At 3 positions in both lateral direction -A- and longitudinal di‐
rection -B-.
Maximum deviation from nominal dimension:
Nominal dimension
Install piston with funnel -T10147- .
Note
If a new funnel -T10147- is used to install the pistons, first pass

piston (with oiled piston rings) twice through the funnel and re‐
move any resulting swarf. Then install piston with piston rings.
– Lubricate funnel and push piston in by hand.

• The flat side of the piston crown must face the projection on
the fitting tool -arrow-.
– Hold upper part of tool (with piston inserted) and press piston
in with both thumbs.
– Push piston in until it protrudes approx. 15 mm from the lower
edge of the fitting tool.
– Place piston in appropriate cylinder bore.
• Projection on funnel -arrow- must face centre of cylinder block.
– Hold fitting tool firmly against cylinder blockProtected
and push in the
piston. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi TT 2007 ➤

Honing dimension Diameter of piston Diameter of cylinder
(in mm) bore
Basic dimension 83.965 84.010
4.3 Measuring axial clearance of conrods

♦ Feeler gauge
Procedure
Axial clearance:
• New: 0.05 ... 0.31 mm.

bearing on the bearing journal or bearing shell.
shell.
crankshaft.
Radial clearance:
• New: 0.02 ... 0.07 mm.

Audi TT 2007 ➤

1 Cylinder head
1.1 Cylinder head and cylinder head cover - exploded view

❑ Renew
❑ If renewed, change en‐
gine oil and coolant
2 - Cylinder head
⇒ page 72
❑ Checking for distortion Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ If renewed, change en‐

gine oil and coolant

3 - Lifting eye
4 - Bolt
❑ 23 Nm
5 - Gaskets for cylinder head
cover
⇒ page 71
7 - Spacer sleeve
❑ With seal
❑ Renew seal if damaged
8 - Nut
❑ 10 Nm
9 - Filler cap
10 - Seal for filler cap
11 - Washer
12 - Ignition coil
❑ Remove with puller -T10095 A-
13 - Bolt
❑ With spacer sleeve and seal
❑ Renew seal if damaged
14 - Bolt
❑ 10 Nm
15 - Bolt
❑ 10 Nm
1. Cylinder head 69
Audi TT 2007 ➤
16 - Bracket
❑ For fuel line
17 - Bolt
❑ Renew
18 - Lifting eye
19 - Bolt
❑ 23 Nm
20 - Bolt
21permitted
- Combination valve
unless authorised for AG.
by AUDI secondary
AUDI AG does airnotsystem
❑ Version and fitting location ⇒ page 184
Cylinder head cover - tightening torque and tightening sequence

– Tighten bolts in the sequence -1 ... 11- to 10 Nm.
Slackening cylinder head bolts


Audi TT 2007 ➤
Cylinder head - tightening torque and tightening sequence

Note
The long cylinder head bolts are inserted in the middle bores in
cylinder head.

2. Pre-tighten bolts to 30 Nm.
3. Tighten bolts to 50 Nm.
4. Turn bolts 180° (1/2 turn) further.

– Measure at several points with straightedge and feeler gauge.
Permissible distortion:

cover
Removing
– Remove intake manifold ⇒ Rep. Gr. 24 .
– Unscrew bolts -arrows- and move bracket for fuel line to one
side.
– Remove bracket for electrical wiring from timing chain cover
(top).
1. Cylinder head 71
Audi TT 2007 ➤
– Slacken cylinder head cover bolts in the sequence -11 ... 1-.
Installing
Note
Renew gaskets and bolts for cylinder head cover if damaged.

– Install intake manifold ⇒ Rep. Gr. 24 .

♦ Camshaft bar -T10068 A-

Audi TT 2007 ➤
Removing
Note
Fit cable ties in the original positions when installing.

– On rest-of-world vehicles pull activated charcoal filter -1- up‐
wards out of bracket in engine compartment and place to one
side with hoses attached.
WARNING

nection.
– Disconnect fuel supply hose -4- by pulling release ring.

– Detach coolant hoses -2 and 3-.
– Unplug electrical connector -arrow- for knock sensor 1 -G61-

and move wiring clear.

– Unplug electrical connectors -1 ... 6- at injectors.
– Unclip wiring guide from fuel rail -arrows-.
1. Cylinder head 73
Audi TT 2007 ➤
– Detach coolant hoses -arrows-.
Note
Illustration shows coolant hoses on vehicle with direct shift gear‐

box.
– Remove thermostat housing ⇒ page 158 .

– Remove timing chain from camshafts ⇒ page 85 .
– Remove heat shield above exhaust manifold -arrows-.

Caution

10°.
– Remove nuts -1 ... 6- and push back front exhaust pipe slightly
from exhaust manifolds.
Note
Lambda probes remain installed.

Audi TT 2007 ➤
– Slacken cylinder head bolts in the sequence -1 ... 20- and re‐
move.
– Secure engine lifting eye (front left) again -arrows-.
Note
The engine lifting eye (left-side) was removed when removing in‐
take manifold.
1. Cylinder head 75
Audi TT 2007 ➤
– Engage lifting tackle -3033- as follows:

• Pulley end: position “3”.
• Gearbox end: position “10”.
Note
The positions marked “1 ... 12” on the lifting tackle -3033- face
towards gearbox end.
– Carefully lift off cylinder head.
Caution
The cylinder bores and pistons must be protected from dirt.

♦ Place clean cloths in cylinders.
Installing
Caution

cylinder block.
surfaces.
Ensure that cylinder head gasket seals properly:
terial.
gasket.
protectors fitted to protect the open with

valves
respectshould not beof information in this document. Copyright by AUDI AG.
to the correctness
valve gear.
erated.

Audi TT 2007 ➤
Note

faces between the hydraulic compensation elements, roller
rocker fingers and cams must be oiled before installing the
– Set camshafts to “TDC”
with respect before fitting
to the correctness cylinder
of information head. Copyright by AUDI AG.
in this document.
• You should be able to insert the camshaft bar -T10068 A- in

the slots in both camshafts.
– Check again that crankshaft is positioned at “TDC” -arrow-.
1. Cylinder head 77
Audi TT 2007 ➤

• Note position of centring pins in cylinder block.
• Check installation position of cylinder head gasket; the Part
No. should be legible from inlet side.
– Insert and hand-tighten cylinder head bolts.
Note
The long cylinder head bolts are inserted in the middle bores in
cylinder head.
Note

after repair work.
– Install exhaust manifold ⇒ page 181 .

– Install camshaft timing chain ⇒ page 89 .
Gr. 27 .

Audi TT 2007 ➤
Procedure
– Detach electric fuel pump 2 relay -J49- -item 2.1- and fuel
pump relay -J17- -item 5-.
-3122 B- .
– Check compression pressure
Protected by copyright.with compression
Copying testerpurposes,
for private or commercial - in part or in whole, is not
V.A.G 1763- (see ⇒ operating
permitted instructions
unless authorised by AUDI AG. forAUDIdetails of guarantee
AG does not how or accept any liability
to use tester). with respect to the correctness of information in this document. Copyright by AUDI AG.
– 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.
When new 10.0 … 13.0
Wear limit 7.0
The engine control unit will store faults when relays are unplug‐
ged.
VAS 5051B- .
1. Cylinder head 79
Audi TT 2007 ➤
2 Chain drive
2.1 Timing chain covers - exploded view
Note
-Items 1 ... 3- ⇒ page 56 .
4 - Bolt
⇒ page 81
5 - Thermostat housing
⇒ page 158
6 - Bolt
❑ 10 Nm
7 - Bracket
tion
8 - Gasket
9 - Oil seal permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 2x
❑ For inlet camshaft con‐
trol valve 1 -N205- and
exhaust camshaft con‐
trol valve 1 -N318-
leaking
10 - Bolt
❑ 10 Nm
11 - Hall sender
❑ 2x
❑ Mark electrical connec‐
tor before disconnecting
12 - O-ring
❑ 2x
❑ Renew
13 - Timing chain cover (top)
❑ Coat sealing surfaces with sealant when installing ⇒ page 93
14 - Dowel sleeve
❑ 2x
15 - Gasket
❑ Renew
16 - O-ring
❑ Renew

Audi TT 2007 ➤
17 - Seal
18 - Chain tensioner for camshaft timing chain
❑ Tightening torque ⇒ page 83
19 - Bolt
❑ Clean bores and fill with sealant ⇒ page 93
21 - Dowel pin
22 - Timing chain cover (bottom)
❑ Coat sealing surfaces with sealant when installing; for sealant refer to ⇒ Electronic parts catalogue
23 - Bolt
❑ 10 Nm
❑ Tighten in stages and in diagonal sequence
Timing chain cover (top) - tightening torque and tightening se‐

quence
1- Tighten bolts -1 - and -2- initially to 5 Nm.
2- Tighten bolts -3- to 23 Nm.
3- Tighten bolts -1- and -2- to 10 Nm.
2.2 Renewing oil seals in timing chain cover

(top)
2. Chain drive 81
Audi TT 2007 ➤
♦ Fitting sleeve -3378-
Procedure
– Remove timing chain cover (top) and detach timing chain from
camshafts ⇒ page 85 .
– Use drift to drive oil seals out of timing chain cover (top)
– Use fitting sleeve -3378- to fit oil seal in timing chain cover (top)
-1-.
– Press oil seal in flush with fitting sleeve from -3253/6- .
– Install camshaft timing chain ⇒ page 89 .

Audi TT 2007 ➤
2.3 Timing chain - exploded view of components

page 110
❑ Dismantling and assem‐
bling ⇒ page 108
❑ Check filter for dirt
⇒ page 108
❑ Lightly coat contact sur‐
faces of oil seals before
installing
2 - Bolt
❑ Renew
❑ 8 Nm
3 - Camshaft timing chain
running direction in col‐
our ⇒ page 85
❑ Removing from
Protected by cam‐
shafts ⇒ page
permitted unless85
⇒ page 94
4 - Camshaft adjuster - ex‐
haust
❑ Identification: “32A”
⇒ “2.4 Detaching and re-
fitting timing chain on
camshafts”, page 85
5 - Intermediate shaft
6 - Thrust washer
7 - Bolt
❑ 8 Nm
8 - Tensioning rail for timing chain
❑ To remove and install it is first necessary to remove both timing chain covers (top and bottom)
9 - Pivot pin
10 - Chain tensioner for camshaft timing chain
❑ Removing and installing ⇒ “2.4 Detaching and re-fitting timing chain on camshafts”, page 85
❑ 40 Nm
11 - Oil seal
12 - Sprocket for drive chain for valve gear
⇒ “2.5 Removing and installing camshaft timing chain and drive chain for valve gear”, page 94
13 - Sprocket for camshaft timing chain
2. Chain drive 83
Audi TT 2007 ➤
14 - Bolt
❑ To loosen and tighten use counterhold tool -T10069- to counterhold vibration damper.
❑ Renew

❑ For drive chain
❑ Before installing, release locking spline in chain tensioner with a small screwdriver and press tensioning
rail against chain tensioner
❑ Integral part of crankshaft
17 - Drive chain for valve gear
❑ Before removing, mark running direction in colour ⇒ page 85
18 - Guide rail for drive chain for valve gear
19 - Pin
❑ For guide rail
❑ 10 Nm
20 - Pivot pin
❑ 18 Nm
21 - Bolt
❑ 23 Nm
22 - Camshaft adjuster - inlet
❑ Identification: “24E”
23 - Bolt
❑ To loosen and tighten, counterhold with open-end spanner on hexagon flats of camshaft ⇒ page 85
❑ Renew
❑ Contact surface of sender wheel at bolt head must be dry when installing.
24 - Guide rail for camshaft timing chain

❑ For inlet camshaft
❑ Mark electrical connector before disconnecting
26 - Exhaust camshaft control valve 1 -N318-
❑ For exhaust camshaft
❑ Mark electrical connector before disconnecting
27 - Guide rail for camshaft timing chain
❑ Clipped onto valve timing housing

Audi TT 2007 ➤
Marking rotation direction of timing chains

– Mark rotation direction of timing chains with coloured arrows
for re-installation -arrows-.
Caution
Avoid damage to timing chains.

♦ Do not mark chains by means of centre punch, notch or
the like.
Markings on valve timing housing on MPI engines

-A- Illustration shows flywheel end
-B- Illustration shows vibration damper end
Notches -arrows- serve as reference points for markings on cam‐
shaft adjusters.
2.4 Detaching and re-fitting timing chain on

camshafts
2. Chain drive 85
Audi TT 2007 ➤
Detaching camshaft timing chain

Vehicles with engine code letters BUB:
– Disconnect hose -2- from combination valve for secondary air
system.
Note
Disregard item -1-.

– Disconnect hose -1- and vacuum hose -2- from combination
valve for secondary air system (left-side).
Note
Disregard items marked -3- and -arrows-.

– Mark electrical connectors and unplug:
– Remove bracket for electrical wiring -arrows-.
– Place bracket with electrical wiring to front.

Audi TT 2007 ➤
– Turn crankshaft in direction of engine rotation via bolt for vi‐

bration damper until marking is at “TDC” -arrow-.
– Cams -A- of cylinder 1 must face each other.
– At the same time insert camshaft bar -T10068 A- in the slots

on both camshafts; if necessary, turn the crankshaft 1 rotation
further.
– Remove chain tensioner -arrow- for camshaft timing chain.
2. Chain drive 87
Audi TT 2007 ➤
Caution
Avoid damage to cylinder head gasket.

♦ Pull timing chain cover (top) off cylinder head horizontally.
– Unscrew bolts -arrows- and remove guide rail -1-.

– Remove camshaft bar -T10068 A- .
• The camshaft bar -T10068 A- must not be in place when loos‐
ening and tightening the securing bolts for the camshaft ad‐
justers.
– Remove bolt at camshaft adjuster (inlet side); counterhold with

open-end spanner on hexagon flats of camshaft.
– Remove camshaft adjuster (inlet side).
– Remove bolt at camshaft adjuster (exhaust side); counterhold

with open-end spanner on hexagon flats of camshaft.
– Remove camshaft adjuster (exhaust side).
– Place camshaft timing chain over camshaft control valves.

Audi TT 2007 ➤

• Tightening torques ⇒ page 80 , ⇒ page 81 and ⇒ page 83 .
– Install guide rail -1- and tighten bolts -arrows-.
– Check again that crankshaft is positioned at “TDC” -arrow-.
– Check TDC position of camshafts:


2. Chain drive 89
Audi TT 2007 ➤
– If necessary, turn camshafts at hexagon flats -arrows- to cor‐

rect position using a 32 mm open-end spanner.
Caution

the camshafts are turned.

rect position using a open-end spanner.
Note
The two camshaft adjusters (marking 24E on inlet side and 32A
on exhaust side) can only be secured to camshaft mounting in
one position -arrows- (due to a dowel pin fitted).

♦ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– First install camshaft adjuster (inlet side):
– Turn sender wheel -1- clockwise -arrow- in camshaft adjuster
as far as the stop.

Audi TT 2007 ➤
– Tighten the camshaft adjuster (inlet side) in this position to the

inlet camshaft finger-tight.
• Contact surface of sender wheel at bolt head must be dry when
installing.
• The marking “24E” -item 1- and the tooth just behind it must
align with the notch -2- in the valve timing housing. Markings
on valve timing housing ⇒ page 85
– Lay the camshaft timing chain in this position tautly onto the
chain sprocket of camshaft adjuster (inlet side).
– Now count exactly 16 rollers on timing chain to the right start‐

ing at gear aligning with marking “24E”. Mark this roller with
coloured pen.
Note
The camshaft adjuster (exhaust side) is locked in “rest position”,

so the sender wheel cannot be turned out of position when ad‐
justing the valve timing. If the camshaft adjuster is not locked in
“rest position”, turn adjuster by hand in both directions until it en‐
gages. If this is not possible, renew camshaft adjuster.
– Fit camshaft adjuster (exhaust side) “32A” into camshaft roller

chain with gear tooth at marking -1-, so that there are exactly
the 16 counted rollers between marking “24E” and “32A” and
the markings -1- and -2- align.
– It must be easily possible to attach camshaft adjuster (exhaust
side) to camshaft (exhaust side) and to tighten it hand-tight.
2. Chain drive 91
Audi TT 2007 ➤
– Check again that both camshaft adjusters are positioned cor‐

rectly.

– Tighten bolt at camshaft adjuster (inlet side); counterhold with
open-end spanner on hexagon flats of camshaft.
– Tighten bolt at camshaft adjuster (exhaust side); counterhold

with open-end spanner on hexagon flats of camshaft.
Caution
Prevent timing chain from slipping.

♦ When turning the crankshaft, it is necessary to press the
tensioning rail firmly against the camshaft timing chain
manually (to replace function of chain tensioner) -arrow-.

Audi TT 2007 ➤
– Turn crankshaft via the bolt for vibration damper 2 rotations in

the normal direction of rotation until the marking is at “TDC”
-arrow-.
• You should then be able to insert the camshaft bar -T10068

A- in the slots in both camshafts.
– If the camshaft bar cannot be inserted, adjust valve timing
again.
– Clean old sealant from the 3 mm bores -arrows- in the cylinder

head gasket.
Note
With the cylinder head installed the holes in the cylinder head
gasket are only half visible.
– Fill 3 mm bores in cylinder head gasket with sealant.

– Renew oil seals in timing chain cover (top) ⇒ page 81 .
– Check that dowel sleeves -2- and -3- are fitted in timing chain
cover (top).
– Insert a new oil seal -1- and a new seal -4-.
– Thinly coat clean surfaces -hatched area- on timing chain cov‐
er (top) with sealant.
– Also apply a thin coat of sealant to the surface beneath the
cylinder head gasket (do not kink gasket).
2. Chain drive 93
Audi TT 2007 ➤
Note
Fit timing chain cover (top) within 5 minutes after applying sealant.
– Fit timing chain cover (top) and tighten bolts ⇒ page 81 .
– Secure chain tensioner -arrow- for camshaft timing chain.

– Turn crankshaftProtected
at boltbyfor vibration
copyright. Copyingdamper 2commercial
for private or rotations in nor‐
mal direction ofpermitted
rotation until
unless marking
authorised is AG.
by AUDI at “TDC”.
– Checking valve timing again.
– Install thermostat housing ⇒ page 158 .
2.5 Removing and installing camshaft tim‐

ing chain and drive chain for valve gear

Audi TT 2007 ➤
Removing
– Remove engine ⇒ page 11 .
– Separate engine and gearbox: vehicles with manual gearbox
⇒ page 27 , vehicles with direct shift gearbox ⇒ page 29 .
Vehicles with engine code letters BUB:
– Disconnect hose
Protected -2- fromCopying
by copyright. combination
for private or valve forpurposes,
commercial secondary air
system. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
Disregard item -1-.

– Disconnect hose -1- and vacuum hose -2- from combination
valve for secondary air system (left-side).
Note
Disregard items marked -3- and -arrows-.

– Mark electrical connectors and unplug:
– Remove bracket for electrical wiring -arrows-.
– Place bracket with electrical wiring to front.
2. Chain drive 95
Audi TT 2007 ➤
– Turn crankshaft in direction of engine rotation via bolt for vi‐

bration damper until marking is at “TDC” -arrow-.
– At the same time insert camshaft bar -T10068 A- in the slots

on both camshafts; if necessary, turn the crankshaft 1 rotation
further.
– Remove chain tensioner -arrow- for camshaft timing chain.

Audi TT 2007 ➤
Caution

♦ Pull timing chain cover (top) off cylinder head horizontally.
– Remove bolts for for timing chain cover (bottom) -arrow-.
Caution

♦ Pull timing chain cover (bottom) off cylinder block hori‐
zontally.
– Press crankshaft oil seal out of timing chain cover (bottom).
– Mark rotation direction of timing chains with coloured arrows

for re-installation -arrows-.
Caution
Avoid damage to timing chains.

♦ Do not mark chains by means of centre punch, notch or
the like.
2. Chain drive 97
Audi TT 2007 ➤
– Unscrew bolts -arrows- and remove guide rail -1-.

– Remove camshaft timing chain from chain sprocket for inter‐
mediate shaft.
– Pull out camshaft timing chain carefully from behind the pro‐
jection on the cylinder head gasket.
– Slacken off bolt -arrow- for chain sprockets approx. 1 turn.
– Use counterhold tool -T10069- to counterhold bolt for vibration
damper.
– Unscrew chain tensioner for drive chain for valve gear

-arrows-.

Audi TT 2007 ➤
– Unscrew bolt -arrow- and remove drive chain together with

chain sprockets from intermediate shaft.
Installing
– Note the marking for rotation direction -lower arrow- when re‐
installing a used drive chain for valve gear.
– Install drive chain together with large sprocket on intermediate

shaft.
• Can only be installed in one position.
– Turn intermediate shaft slightly if large sprocket cannot be fit‐
ted.
– Check whether the crankshaft is still positioned at “TDC”:
• The ground-down tooth
Protected of the Copying
by copyright. drive chain sprocket
for private or commercialmust align
with the main bearing joint -arrow A-.
• The notch on the sprocket for intermediate shaft must align
with the groove -arrow B- on the thrust washer for intermediate
shaft.
2. Chain drive 99
Audi TT 2007 ➤
– Fit small sprocket to intermediate shaft.

• Can only be installed in one position.
– Renew bolt for chain sprockets of intermediate shaft.
– Hand-tighten bolt -arrow- for chain sprockets.
– Release locking spline in chain tensioner with a small screw‐

driver -arrow-.
– Press tensioning rail against chain tensioner and secure chain

tensioner in this position -arrows-.
– Tighten bolt for chain sprockets -arrow-.

Audi TT 2007 ➤
– Use counterhold tool -T10069- to counterhold bolt for vibration

damper.
– Fit timing chain onto camshaft adjusters. Make sure that the
two individual copper-coloured chain links -C- align with mark‐
ings on camshaft adjuster. In some cases the camshaft ad‐
juster (inlet side) must be turned slightly.
– Fit timing chain onto small chain sprocket. The marking -B-
must align with the copper-coloured chain link in the middle
-A-.
– Install guide rail -1- and tighten bolts -arrows-.

Caution
Prevent timing chain from slipping.

♦ When turning the crankshaft, it is necessary to press the
tensioning rail firmly against the camshaft timing chain
manually (to replace function of chain tensioner) -arrow-.
2. Chain drive 101

Audi TT 2007 ➤
– Turn crankshaft via the bolt for vibration damper 2 rotations in

the normal direction of rotation until the marking is at “TDC”
-arrow-.
– You should then be able to insert the camshaft bar -T10068

A- in the slots in both camshafts.
Note
The marked chain links will now be in an undefined position.

If the camshaft bar cannot be inserted:
– Repeat adjustment of valve timing.
– Clean old sealant from 3 mm bores -arrows- in cylinder head

gasket.
Note

Audi TT 2007 ➤
– Check that dowel pins for timing chain cover (bottom) are fitted
in cylinder block.
– Thinly coat clean surfaces -hatched area- of timing chain cover
(bottom) with sealant.
Note
Fit timing chain cover (bottom) within 5 minutes after applying

sealant.
– Tighten bolts for timing chain cover (bottom) -arrow-.

– Fill 3 mm bores -arrows- in cylinder head gasket with sealant.
Note
2. Chain drive 103

Audi TT 2007 ➤
– Renew oil seals in timing chain cover (top) ⇒ page 81 .

– Check that dowel sleeves -2- and -3- are fitted in timing chain
cover (top).
– Insert a new oil seal -1- and a new seal -4-.
– Thinly coat clean surfaces -hatched area- of timing chain cover
(top) with sealant.
– Also apply a thin coat of sealant to the surface beneath the
cylinder head gasket (do not kink gasket).
Note
Fit timing chain cover (top) within 5 minutes after applying sealant.
– Fit timing chain cover (top) and tighten bolts ⇒ page 81 .
– Secure chain tensioner -arrow- for camshaft timing chain.

– Turn crankshaft at bolt for vibration damper 2 rotations in nor‐
mal direction of rotation until marking is at “TDC”.
– Checking valve timing again.
– Install crankshaft oil seal ⇒ page 59 .
– Install thermostat housing ⇒ page 158 .
– Install engine ⇒ page 34 .
– Fill with engine oil and check oil level ⇒ page 141 .

Audi TT 2007 ➤
3 Valve gear
Caution

valve gear.
erated.
1 - Camshaft adjuster - ex‐

haust
❑ Identification: “32A”
2 - Bolt
❑ To remove and install,
counterhold with open-
end spanner on hexa‐
gon flats of camshaft
⇒ page 85
❑ Renew
⇒ Item 23 (page 84) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Camshaft adjuster - inlet with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Identification: “24E”
page 110
❑ Check filter of valve tim‐
ing housing for dirt be‐
fore installing
⇒ page 108
❑ When installing, lightly
oil contact surfaces of oil
seals
❑ Dismantling and assem‐
bling ⇒ page 108
6 - Valve spring
❑ Installation position: large ∅ points downwards
3. Valve gear 105

Audi TT 2007 ➤

8 - Valve cotters
9 - Rectangular section seals
❑ 3x for each camshaft
❑ Renew all if leak detected
❑ Do not stretch rectangular section seals too much when fitting
❑ When installing valve timing housing -item 4- lightly oil contact surfaces of rectangular section seals
10 - Nut
11 - Bearing cap
❑ Installation sequence ⇒ page 107
12 - Inlet camshaft
❑ Runout: max. 0.01 mm by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
14 - Roller rocker finger with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Check roller bearing
❑ Before installing, check camshaft axial clearance ⇒ page 108
❑ Lubricate contact surface
❑ Assembly: attach to hydraulic compensation element using securing clip -item 15-
15 - Securing clip
❑ Before installing, check camshaft axial clearance ⇒ page 108
❑ Lubricate contact surface
17 - Cylinder head
❑ Machining valve seats ⇒ page 124
18 - Inlet valve
19 - Exhaust valve

Audi TT 2007 ➤

20 - Bolt
❑ 8 Nm
Camshaft identification
The camshaft identification is located between the cam pairs for
cylinder No. 4 and 5.
A - Exhaust camshaft; identification 022 - index 101
B - Inlet camshaft; identification 022 - index 102
Coat contact surface of bearing caps 7 and 8 with lubricating

paste
– Lightly coat contact surface -hatched area- of bearing caps 7
and 8 with lubricating paste; for lubricating paste refer to ⇒
Electronic parts catalogue .
Installation position of bearing caps for camshafts

• The pointed section of the bearing caps -arrow A- for inlet and
exhaust camshafts faces outwards.
3. Valve gear 107

Audi TT 2007 ➤
Camshafts - tightening torque and tightening sequence

– Tighten nuts on inlet camshaft -A- in five stages as follows:
1- Tighten nuts for bearing caps 5 and 9 alternately and diag‐
onally until bearing caps make contact.
2- Tighten nuts for bearing caps 5 and 9 to 5 Nm and turn 45°
(1/8 turn) further.
(1/8 turn) further.
4- Tighten nuts for bearing cap 7 to 5 Nm and turn 45° (1/8 turn)
further.
(1/8 turn) further.
– Tighten nuts on exhaust camshaft -B- in five stages as follows:
1- Tighten nuts for bearing caps 6 and 10 alternately and di‐
agonally until bearing caps make contact.
(1/8 turn) further.
(1/8 turn) further.
4- Tighten nuts for bearing cap 8 to 5 Nm and turn 45° (1/8 turn)
further.
(1/8 turn) further.
Dismantling and assembling valve timing housing

1- Guide rail; clipped onto valve timing housing
2- Valve timing housing
4- Exhaust camshaft control
Protected valveCopying
by copyright. 1 -N318-
5- Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.
Cleaning filter of valve timing housing

– Unclip the filter -2- on the back of valve timing housing -1- and
clean off any dirt.


Audi TT 2007 ➤
Procedure
– Remove roller rocker fingers and hydraulic compensation el‐
ements
• Axial bearing cap for appropriate camshaft remains attached.
– Attach dial gauge bracket -VW 387- with dial gauge -VAS
6079- to cylinder head.
Axial clearance:

shafts
Procedure
– Fit bearing cap and tighten to 5 Nm without rotating camshaft
⇒ page 108 .
Radial clearance:
3. Valve gear 109

Audi TT 2007 ➤

♦ Lubricating paste ⇒ Electronic parts catalogue

Removing
Note
– Remove timing chain from camshafts ⇒ page 85 .

– Unbolt valve timing housing -arrows- and detach carefully from
the oil
Protected seals for
by copyright. theforcamshafts.
Copying private or commercial purposes, in part or in whole, is not

Audi TT 2007 ➤
– Remove inlet camshaft -A- as follows:

1- Unbolt bearing caps 1 and 13.
3- Unbolt bearing cap 7.
4- Loosen bearing caps 5 and 9 alternately in a diagonal se‐
quence and remove.
– Remove exhaust camshaft -A- as follows:
3- Unbolt bearing cap 8.
4- Loosen bearing caps 6 and 10 alternately in a diagonal se‐
quence and remove.
– Carefully take out the camshafts and place them on a clean
surface.
Installing
Caution

♦ The crankshaft must not be at “TDC” at any
Protected cylinder
by copyright. when
the camshafts are turned. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Fit hydraulic compensation elements in cylinder head.

– Fit roller rocker fingers -1- onto ends of valve stems and clip
onto hydraulic compensation elements -2-.

– The camshaft identification is located between the cam pairs
for cylinder No. 4 and 5:
A - Exhaust camshaft; identification 022 - index 101
B - Inlet camshaft; identification 022 - index 102
3. Valve gear 111

Audi TT 2007 ➤
– Position camshafts in cylinder head so that cams -A- of cylin‐

der 1 face each other.
– Installation position of bearing caps:

• The pointed section -arrow A- of the bearing caps for inlet and
exhaust camshafts faces outwards.
• The identification markings for the bearing caps are legible
from the inlet side.
– Lightly coat contact surface -hatched area- of bearing caps 7

and 8 with lubricating paste
– Tighten camshaft bearing caps ⇒ page 108 .

Audi TT 2007 ➤
– Set camshafts to “TDC”.


rect position using a 32 mm open-end spanner.
Note
The crankshaft must not be at TDC at any cylinder when the

camshafts are turned. Otherwise, there is a risk of damage to
valves and piston crowns.
– Unclip filter -2- on the back of valve timing housing -1- and
clean off any dirt.
– Lightly oil the contact surfaces for the camshaft oil seals in the
valve timing housing.
– Lightly oil contact surfaces of oil seals on the camshafts and
carefully push the valve timing housing over the camshaft oil
seals.
– Secure valve timing housing -arrows-.

– Install camshaft timing chain (adjust valve timing) ⇒ page 89 .
Caution

valve gear.
erated.
3. Valve gear 113

Audi TT 2007 ➤
3.5 Renewing valve stem oil seals with cylinder head installed

equipment required
tension -3122 B-
-3364-
-3365-
5161- with guide plate -
VAS 5161/25-
Procedure
• Engine removed
-3122 B- .

Audi TT 2007 ➤
– Apply drift -VAS 5161/3- to valve spring plate.

– Use plastic-headed hammer to release sticking valve cotters.
– Fit guide plate -VAS 5161/25- from removal / installing device

for valve cotters -VAS 5161- on cylinder head.
– Secure guide plate with nut -1- to cylinder head.
– Screw adapter -T40012- with seal hand-tight into the corre‐
sponding spark plug thread.
– Connect hose to compressed air.
• Air pressure: at least 6 bar Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Rear row of valves:

– Move knurled screw back and forth slightly.
cartridge.
3. Valve gear 115

Audi TT 2007 ➤
Front row of valves:

VAS 5161/5- onto cylinder head.
– Slide knurled spacer ring -VAS 5161/17- onto assembly car‐
– Insert assembly cartridge in guide plate.
– Move knurled screw back and forth slightly.
cartridge.
Continuation for both rows of valves:


Audi TT 2007 ➤
Note
♦ To press on the green-coloured valve stem seals (as currently

supplied), the valve stem oil seal fitting tool -3365- must be
drilled out to ∅ 10.5 mm.
♦ Mark the drilled-out fitting tool so it can be used again later.
Caution
ling.



• Installation position: the larger diameter -arrow- of the valve
spring faces the cylinder head.
3. Valve gear 117

Audi TT 2007 ➤
Rear row of valves:

– Secure guide plate back onto cylinder head as shown in illus‐
tration.
– Insert assembly cartridge in guide plate.
sition.
Front row of valves:

plate.
sition.
Caution

valve gear.
erated.

Audi TT 2007 ➤
3.6 Renewing valve stem oil seals with cylinder head removed

equipment required
-3364-
-3365-
5161- with guide plate -
VAS 5161/25-
port -VAS 6095-
♦ Cylinder head tensioning
device -VAS 6419-

♦
Procedure
3. Valve gear 119

Audi TT 2007 ➤
– Attach tensioning device -VAS 6419- to engine and gearbox

support -VAS 6095- .
– Secure cylinder head in tensioning device -VAS 6419- as il‐
lustrated.
– Connect compressed air line to tensioning device -VAS 6419- .
where valve stem oil seals are to be removed.
with valve heads.
– Apply drift -VAS 5161/3- to valve spring plate and knock valve
cotters loose using a plastic hammer.
– Fit guide plate -VAS 5161/25- from removal / installing device

for valve cotters -VAS 5161- on cylinder head.
– Secure guide plate with one nut -1-.
Procedure for rear row of valves:

– Insert assembly cartridge -VAS 5161/8- into guide plate.
– Release the pressure fork.
– Remove assembly cartridge.
– Remove valve spring with valve spring plate.

Audi TT 2007 ➤
Procedure for front row of valves:

VAS 5161/5- onto cylinder head.
– Slide knurled spacer ring -VAS 5161/17- onto assembly car‐
– Insert assembly cartridge into guide plate.
– Release the pressure fork.
– Remove assembly cartridge.
– Remove valve spring with valve spring plate.
Continuation for both rows of valves:

– Remove valve stem oil seals using the valve stem seal puller
-3364- .
3. Valve gear 121

Audi TT 2007 ➤
Note
♦ To press on the green-coloured valve stem seals (as currently

supplied), the valve stem oil seal fitting tool -3365- must be
drilled out to ∅ 10.5 mm.
♦ Mark the drilled-out fitting tool so it can be used again later.
♦ A plastic sleeve -A- is included with the new valve stem oil
seals.
– Fit plastic sleeve -A- onto the valve stem to prevent damage
to the new valve stem oil seal -B-.
– Lightly lubricate sealing lip of valve stem oil seal.
– Slip valve stem oil seal over plastic sleeve.
– Carefully press the valve stem oil seal onto valve guide using
fitting tool -3365- .
– Remove plastic sleeve.

need to be put into insertion device -VAS 5161/18- first.
– Install valve spring and valve spring plate.

Position of valve spring:
• The larger diameter -arrow- faces the cylinder head.
Procedure for rear row of valves:

– Bolt guide plate onto cylinder head again, as shown in the il‐
lustration.
– Insert assembly cartridge into guide plate.
– Push pressure fork down and pull knurled screw upwards,
while turning screw in both directions – this will insert the valve
cotters.
sition.

Audi TT 2007 ➤
Procedure for front row of valves:

– Insert assembly cartridge with knurled spacer ring into guide
plate.
– Push pressure fork down and pull knurled screw upwards,
while turning screw in both directions – this will insert the valve
cotters.
sition.
Note
♦ After installing camshafts, wait for approx. 30 minutes before

starting engine. Hydraulic valve compensation elements have
to settle (otherwise valves will strike pistons).
♦ After working on the valve gear, turn the engine carefully at
least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.
Note

is permitted.

short ver‐ long ver‐ short ver‐ long ver‐
sion sion sion sion
∅a mm 31.00 31.00 27.00 27.00
∅b mm 5.96 5.96 5.94 5.94
c mm 102.20 136.10 102.50 136.40
α ∠° 45 45 45 45
WARNING
Care must be taken when disposing of old sodium-cooled ex‐

haust valves - risk of injury.
♦ The valves must be sawn in two with a metal saw between
the centre of the stem and valve head. When doing so, the
valves must not come into contact with water.
♦ Then throw a maximum of ten valves into a bucket of water
and step away immediately.
♦ A sudden chemical reaction will occur upon contact with
water in which the sodium filling burns.
♦ After performing these steps the valves can beProtected
disposedby copyright. Copying for private or commercial purposes, in part or in whole, is not
of in the normal way. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
3. Valve gear 123

Audi TT 2007 ➤

If a good seating pattern cannot be obtained by grinding the valve
seats (lapping), they must be refaced (machined).
Note
♦ When servicing engines with leaking valves, it is not sufficient

to machine (reface) the valve seats and renew the valves. The
valve guides must also be checked for wear. This is particu‐
larly important on high-mileage engines ⇒ page 126 .
♦ Valve seats should only be machined to the extent required to
give a proper seating pattern.
♦ Calculate the maximum permissible machining dimension be‐
fore machining valve seats.

♦ Depth gauge
♦ Valve seat machining tool
Calculating maximum permissible machining dimension
Note
If the valve has to be renewed as part of a repair, use a new valve

for the measurement.
– Insert valve and press firmly against valve seat.

Audi TT 2007 ➤
– Measure distance -a- between end of valve stem and upper

cylinder head surface with a depth gauge.
– Calculate maximum permissible machining dimension from
measured distance and minimum dimension.
Measured distance minus minimum dimension = max. per‐
missible machining dimension.
Minimum dimension for inlet Minimum dimension for ex‐
valve haust valve
short version long version short version long version
31.8 mm 10.2 mm 31.8 mm 10.2 mm
Example for long inlet valve:

Measured distance 10.6 mm
Minimum dimension – 10.2 mm
Maximum permissible machining dimension = 0.4 mm
– If the calculated maximum permissible machining dimension
is 0 mm or less than 0 mm, repeat the measurement with a
new valve.
– If the maximum permissible machining dimension is then still
0 mm or less than 0 mm, renew cylinder head.
Note
If the machining dimension is below specification, the proper

functioning of the hydraulic valve clearance compensation cannot
be ensured.
Machining inlet valve seat

a - ∅ 30.6 mm
b - Maximum permissible machining dimension ⇒ page 124
c - 0.9 … 1.5 mm
d - Maximum ∅ 35.0 mm
r2 - Radius 2.0 mm
Z - Bottom surface
Protected of cylinder
by copyright. headfor private or commercial purposes, in part or in whole, is not
Copying
α - 45° valve seat angleto the correctness of information in this document. Copyright by AUDI AG.
with respect
β - 30° upper correction angle

γ - 60° lower correction angle
3. Valve gear 125

Audi TT 2007 ➤
Machining exhaust valve seat

a - ∅ 26.7 mm
b - Maximum permissible machining dimension ⇒ page 124
c - 1.2 … 1.7 mm
d - Maximum ∅ 29.0 mm
r2 - Radius 2.0 mm
Z - Bottom surface of cylinder head
α - 45° valve seat angle
β - 30° upper correction angle
γ - 60° lower correction angle

Procedure Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note


• End of valve stem must be flush with valve guide.

Audi TT 2007 ➤
– Determine amount of sideways play.

new valves.
Note

faces.
– Renew valve Protected
if scoring is clearly visible.
3. Valve gear 127

Audi TT 2007 ➤
17 – Lubrication
1 Oil pump and sump
Note

when performing engine repairs, this is an indication of dam‐
age 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, oil cooler and oil filter.
♦ Refer to ⇒ Maintenance tables for engine oil capacity, vis‐
cosity grades and oil specifications.
Caution
Risk of damage to catalytic converter.

♦ The oil level must not be above the “max” mark on the
dipstick.

Audi TT 2007 ➤
1.1 Oil pump and sump - exploded view
1 - Bolt
❑ Secured to intake mani‐
fold
❑ 5 Nm
2 - Oil dipstick
3 - Guide tube for oil dipstick
4 - Cylinder block
5 - Oil return valve
⇒ page 130
tion
6 - Bolt
❑ 8 Nm
7 - Cover for oil pump drive
8 - O-ring
❑ Renew
❑ Lubricate before instal‐
ling
9 - Oil pump drive
10 - Intermediate shaft
11 - Thrust washer
12 - Bolt
logue
❑ 10 Nm
13 - Oil spray jet (for cooling of
pistons)
❑ For crankshaft bearings 2 ... 7
❑ Opening pressure: 2.0 bar
14 - Input shaft for oil pump drive
15 - Oil pump
❑ Dismantling and assembling ⇒ page 134
❑ Coat oil pressure pipe at cylinder block and at oil pump housing with sealant; for sealant refer to ⇒
Electronic parts catalogue
16 - Bolt
❑ 23 Nm
17 - Oil drain plug
❑ 30 Nm
18 - Sump

Audi TT 2007 ➤

20 - Bolt
Sump - tightening torque and tightening sequence

sequence initially to 5 Nm.
2. Tighten bolts securing sump to gearbox -arrows-
⇒ page 34 .
sequence to 12 Nm.
Note
Disregardpermitted
item -1-.
Removing and installing oil return valve

Removing:
– Screw in bolt M8x1.5 approx. 4 turns into valve -arrow-.
– Pull out valve.
Installing:
– Lubricate O-ring with oil.
– Press valve into oil passage by hand.
Removing and installing oil spray jet
Note
Oil spray jets are installed in crankshaft main bearings 2 ... 7.
Removing:
– Use drift with ∅ 4 mm to press out oil spray jet towards crank‐
shaft bearing.
Installing:
– Use drift with ∅ 6 mm to press in oil spray jet -arrow- by hand.

Audi TT 2007 ➤
Removing and installing oil level and oil temperature sender -

G266-
1- Bolt, 10 Nm (self-locking); renew
2- Seal; renew
3- Electrical connector
4- Oil level and oil temperature sender -G266-

♦ Safety goggles
Removing
– Place used oil collection and extraction unit -V.A.G 1782- be‐
neath engine and drain off engine oil.

Audi TT 2007 ➤
– Remove bolts -1 and 2-.

– Loosen bolt -4- and move secondary air pump with bracket
clear to the front.
Note
Disregard item -3-.


sender -G266- .
– Remove bolts securing sump to gearbox -arrows-.
– Unscrew bolts for sump -2- in diagonal sequence and remove.
– Take off sump: if necessary loosen it by striking lightly with a
rubber hammer.
Installing
– Carefully remove any remaining sealant from cylinder block.
WARNING

– Remove remaining sealant from sump (with rotating plastic

brush or similar).
– Cut off nozzle of tube at front marking (∅ of nozzle approx. 1.5

mm).

Audi TT 2007 ➤
– Apply sealant -arrow- onto clean sealing surface of sump as

• Width of sealant bead: 2 mm.
Caution

Note
♦ Take extra care when applying sealant in the area around the
timing chain cover (bottom).
♦ Fit sump within 5 minutes after applying sealant.
– Tighten bolts securing sump -2- ⇒ page 130 .

– Connect electrical connector -1- for oil level and oil tempera‐
ture sender -G266- .
Caution
Take care to avoid leakage at sump.

♦ After fitting sump assembly, the sealant must dry for ap‐
prox. 30 minutes. Then (and only then) fill the engine with
engine oil.
– Fill with engine oil and check oil level ⇒ page 141 .

Audi TT 2007 ➤
1.3 Oil pump - exploded view
1 - Input shaft for oil pump drive

2 - Oil pump housing
3 - Bolt
❑ 23 Nm
4 - Gears
❑ Measuring backlash
⇒ page 134
❑ Checking axial clear‐
ance ⇒ page 135
5 - Oil pump cover
valve
❑ Opening pressure of
pressure relief valve:
5.3 ... 5.7 bar
6 - Bolt
logue
❑ 8 Nm
7 - Oil pressure pipe
❑ Apply sealing paste at
cylinder block and at oil
pump housing; for seal‐
ing paste refer to ⇒
logue by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
❑ 10 Nm
9 - Seal
Measuring backlash

Audi TT 2007 ➤
Checking axial clearance

– Check clearance using feeler gauge and straightedge.

Audi TT 2007 ➤
2 Oil cooler and oil filter housing
2.1 Oil cooler, oil filter housing - exploded view
1 - Sealing cap
❑ 25 Nm
2 - O-ring
❑ Renew
let 810
❑ With oil retention valve
5 - Bolt
❑ 23 Nm
6 - Screw plug
❑ 15 Nm
7 - Seal
❑ If seal is leaking, cut
open and renew
8 - Seal
❑ If seal is leaking, cut
open and renew
❑ Black insulation
❑ Opening/closing pres‐
sure 1.4 bar
⇒ page 139
❑ 25 Nm
10 - Seals
❑ Renew
11 - Sealing cap
❑ 25 Nm
12 - Seal
13 - Oil cooler
❑ Ensure clearance from adjacent components
❑ Diagram of coolant hose connections ⇒ page 144
❑ See note if making repairs on engine ⇒ page 128
14 - Seal
❑ Clamp onto oil cooler together with plastic element -item 15-

Audi TT 2007 ➤
15 - Plastic element
❑ Insert into oil cooler together with seal -item 14-
Installation position of seal and plastic element in oil cooler

– Coat seal with oil and insert in oil cooler.
– Insert plastic element into oil cooler.
• The side of the plastic element without the support must align
with the lug -arrow- of oil cooler.
2.2 Removing and installing oil filter housing

♦ Assembly tool -T10118-permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Removing
WARNING

hot.
2. Oil cooler and oil filter housing 137

Audi TT 2007 ➤

– Detach hose for secondary air system -arrow-.
– Move coolant hose at bottom of radiator cowl clear.

– Unscrew bracket -2- for coolant pipe going to gearbox oil cool‐
er on vehicles with direct shift gearbox.
– Use hose clamps -3094- to clampof off

to the correctness coolant
information in thishoses
with respect document. Copyright by AUDI AG.
-2 and 3-.
– Detach coolant hoses -2 and 3- from oil filter housing.
– Unscrew bolts -arrows- and remove oil filter housing.
Installing
Note
Renew seal.

Audi TT 2007 ➤

switch -F1-
Removing
– Unscrew bolt -3- and pull out guide tube for oil dipstick -2- and
– Unplug electrical connector -1- for magnetic clutch at AC com‐

pressor and move electrical wiring clear.
WARNING


ses at front of noise insulation frame (refrigerant hoses remain
connected).

Audi TT 2007 ➤
– Unplug electrical connector -arrow- at oil pressure switch -F1-

using assembly tool -T10118- .
– Remove oil pressure switch -F1- .
Installing
2.4 Checking oil pressure and oil pressure switch -F1-

equipment required
♦ Oil pressure tester -
V.A.G 1342-
♦ Voltage tester -V.A.G
1527B-
V.A.G 1594C-
Procedure
• Oil level OK
• The message “OK” must light up in the driver information dis‐
play.

Audi TT 2007 ➤
– Connect oil pressure tester -V.A.G 1342- with adapter -

V.A.G 1342/14- to bore for oil pressure switch.

V.A.G 1342- .
– Install guide tube for oil dipstick and insert oil dipstick.
Checking oil pressure switch
– Connect brown wire of oil pressure tester to earth “–”.
auxiliary measuring set -V.A.G 1594C- to oil pressure switch
and battery positive (“+”).
– Renew oil pressure switch if LED lights up when engine is not
running.
– Start engine.
Note

when starting.

– Renew oil pressure switch if LED does not light up.
Checking oil pressure
– Start engine.
• Minimum oil pressure at 1500 rpm: 1.7 bar.
• Minimum oil pressure at 2000 rpm: 2.5 bar.
Assembling
2.5 Engine oil

Refer to ⇒ Maintenance tables for engine oil capacity, viscosity

grades and oil specifications.

Procedure
• Vehicle must be level (horizontal).
• Wait a few minutes after switching off the engine to allow the
oil to flow back into the sump.
– Wipe dipstick off with a clean cloth and insert it again as far as
it will go.
– Pull out the dipstick again and read off the oil level.

Audi TT 2007 ➤
Markings on oil dipstick:

a - Do not top up oil.
b - Oil may be topped up.
c - Oil must be topped up.
Note
The oil level must not be above the “max” marking -arrow 1- and
not below the “min” marking -arrow 2-.

Audi TT 2007 ➤
19 – Cooling
1 Cooling system
WARNING

hot.
Note
must align when installing.

Audi TT 2007 ➤
1 - Radiator
⇒ page 168
with fresh coolant
tion pump -V51-
⇒ page 156
4 - Oil cooler
with fresh coolant
5 - Coolant pump
6 - Cylinder head and cylinder with respect to the correctness of information in this document. Copyright by AUDI AG.
block
with fresh coolant
8 - Filler cap for expansion tank
valve
lief valve ⇒ page 172
with fresh coolant
10 - Thermostat
together with connection ⇒ page 160
❑ Only on vehicles with direct shift gearbox
12 - Gearbox oil cooler
13 - Auxiliary radiator
❑ Depending on equipment

Audi TT 2007 ➤

equipment required
-VAS 6208-
V.A.G 1921-
-VAS 6096-
Draining
Note
Collect drained coolant Protected

in a clean container
by copyright. forforre-use
Copying private or or disposal.
WARNING

hot.

Audi TT 2007 ➤
drain off coolant.
Note
Disregard item -1-.

Audi TT 2007 ➤

Note

box.
Filling
Note

♦ Use only the radiator antifreeze/anti-corrosion agent approved
for this engine ⇒ Electronic parts catalogue . Other coolant
additives could seriously impair in particular the anticorrosion
properties. The resulting damage could lead to loss of coolant
and consequently to serious engine damage.
♦ The specified radiator antifreeze/anti-corrosion agent pre‐
vents frost and corrosion damage and stops scaling. Such
additives also raise the boiling point of the coolant. For these
reasons the cooling system must be filled all year round with
the correct antifreeze and anticorrosion additive.
ical climates.
concentration of radiator antifreeze/anti-corrosion agent can
be increased, but only up to 60% (this gives frost protection to
about –40 °C). If the concentration exceeds 60%, frost pro‐
tection decreases again and cooling efficiency is also im‐
paired.
coolant. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Contaminated
with or dirty
respect coolant
to the must
correctness not beinused
of information again.Copyright by AUDI AG.
this document.

fractometer -T10007- .

Audi TT 2007 ➤
– Connect bottom coolant hose to radiator -arrow-.
Note
Disregard item -1-.
– Connect the coolant hose to the continued circulation coolant

pump -V51- -arrow-.
Note

box.

• “G12+” (40 %) and water (60 %) for frost protection to -25 °C
• “G12+” (50 %) and water (50 %) for frost protection to -35 °C
• “G12+” (60 %) and water (40 %) for frost protection to –40 °C
ant expansion tank.
V.A.G 1274/8- .
Note

rection of flow). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Connect hose -3- to compressed air. with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi TT 2007 ➤

zone.
in the green zone. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Close valve -B-. with respect to the correctness of information in this document. Copyright by AUDI AG.
sequent filling.
Note
ess.
tained.

– Open valve -A-.
is then filled.

Audi TT 2007 ➤

rpm.
running.
– Start engine and run until radiator fan cuts in.
WARNING

hot.

• When the engine is at normal operating temperature, coolant
level must be at “max” mark, when engine is cold it must be
between “min” and “max” marks.
– Switch off engine.

Audi TT 2007 ➤
2 Coolant pump, thermostat, coolant

pipes
WARNING

hot.
2.1 Thermostat
Protectedhousing - exploded
by copyright. Copying view purposes, in part or in whole, is not
for private or commercial
1 - O-rings
❑ Renew
2 - Retaining clips
3 - Thermostat housing
⇒ page 158
4 - Bracket
tion
5 - Bolts
❑ 10 Nm
6 - Thermostat
together with connec‐
tion -item 7-
⇒ page 160
7 - Connection
⇒ page 160
8 - Gasket
❑ Renew
9 - Coolant temperature send‐
er -G62-
⇒ page 161
10 - Sealing plug
2. Coolant pump, thermostat, coolant pipes 151

Audi TT 2007 ➤
Coolant pipe leading to gear oil cooler - tightening torque

– Tighten bolt -1- to 10 Nm.
Coolant pipe leading to gear oil cooler - tightening torque

– Tighten bolt -1- to 10 Nm.

Audi TT 2007 ➤

equipment required
A-
♦ Shackle -10 - 222 A /12-
♦ Water pump wrench -
V.A.G 1590-
V.A.G 1921-
-VAS 6208-
♦ Bolt M8x40
Removing
J338- .
Note

Audi TT 2007 ➤
– Secure shackle -10 - 222 A /12- to engine lifting eye (rear

right).
– Set up support bracket -10 - 222 A- on top edges of body
flanges.
• The spindle is located at rear.
– Engage hook on spindle in shackle.
– Apply light tension to spindle.
– Remove bolts -arrows- of assembly mounting (left-side) at en‐

gine.
– Lower engine via spindle approx. 60 mm.

Audi TT 2007 ➤
– If water pump spanner -V.A.G 1590- has not been filed down
previously, file down the 3 round corners on the water pump
spanner -V.A.G 1590- to dimension -a-.
• Dimension -a- = 1 mm.
– Remove poly-V-belt pulley (use water pump spanner -

V.A.G 1590- to hold poly V-belt pulley in position).
Note
If the engine has been removed, the coolant pump bolts are ac‐
cessible through the holes in the pulley. In this case it is not
necessary to remove the poly V-belt pulley.
– Remove bolts -1- for coolant pump -2-.

– Pivot coolant pump out towards the front.
Installing
Note
Renew O-ring.

– Lubricate O-ring with coolant additive “G12+”.

– Tighten coolant pump bolts -1-.
– Install poly-V-belt pulley.

Audi TT 2007 ➤
2.3 Removing and installing continued coolant circulation pump -V51-

equipment required
to 25 mm -3094-
V.A.G 1921-
-VAS 6208-
Removing
WARNING
Hot steam/hot coolant can unless
permitted escape - riskbyof
authorised scalding.
hot.


Audi TT 2007 ➤

WARNING

– Remove bolts -arrows- for air conditioner compressor.

ses at front of noise insulation frame (refrigerant hoses remain
connected).
– Unplug electrical connector -3- at continued circulation coolant

pump -V51- -item 2-.
– Use hose clamps -3094- to clamp off coolant hoses -1- and
-4-.
– Disconnect coolant hoses from continued coolant circulation
pump -V51- .

Audi TT 2007 ➤
– Spray lugs -2- and -4- on flexible bracket for continued coolant
circulation pump -V51- -item 1- with silicone-free lubricant.
– Disengage rubber lugs from bracket -3- for continued coolant
circulation pump -V51- .
Installing
2.4 Removing and installing thermostat

housing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Removing with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove bolt -1- for coolant pipe -A-.
Note
Disregard items marked -2 and arrows-.

J338- .

Audi TT 2007 ➤
– Release and detach relay lever -arrow-.permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Detach vacuum unit for intake manifold flaps from intake mani‐
fold and move clear to one side (vacuum hose -3- remains
connected).
– Unplug electrical connector -arrow- at coolant temperature

sender -G62- .

Audi TT 2007 ➤
– Detach coolant hoses -arrows-.

– Unscrew bolt -1- and pull coolant pipe to the left.
Caution
Take care to avoid pulling out coolant pipe unintentionally.

♦ Use lever to press coolant pipe -1- towards coolant pump
-left arrow- when detaching thermostat housing -2-
-right arrow-.
Installing
Note
Renew seals and gaskets.
– Install vacuum unit for intake manifold flaps ⇒ Rep. Gr. 24 .

2.5 Removing and installing hose connec‐

tion with thermostat
Removing
– Unscrew bolts -arrows- and remove connection -1-.

Audi TT 2007 ➤
– Remove O-ring -3- with thermostat -2- from thermostat hous‐

ing -1-.
Installing
Note
Renew seals and O-ring.
– Clean sealing surface for O-ring.

– Fit thermostat -2-.
• Installation position: Vent valve -arrow- faces upwards.
– Coat new O-ring -3- with coolant “G12+”.
– Secure connection to thermostat housing.
– Install thermostat housing -1- ⇒ page 158 .

approx. 80 °C approx. 105 °C 1) at least 7 mm
• 1) Cannot Protected
be tested.by copyright. Copying for private or commercial purposes, in part or in whole, is not

ature sender -G62-

Audi TT 2007 ➤
Removing
• Engine cold.
– Release and detach relay lever -arrow-.
– Detach vacuum unit for intake manifold flaps from intake mani‐
fold and move clear to one side (vacuum hose -3- remains
connected).
– Unplug electrical connector -arrow- at coolant temperature

sender -G62- using assembly tool -T10118- .
– Pull retaining clip for coolant temperature sender -G62- up‐
wards.
– Remove coolant temperature sender -G62- out of thermostat
housing.
Installing
Note
♦ Fit new O-ring.

♦ Insert new coolant temperature sender -G62- immediately in
thermostat housing to avoid loss of coolant.
– Install vacuum unit for intake manifold flaps ⇒ Rep. Gr. 24 .


Removing
– Unscrew bolt -3- and pull out guide tube for oil dipstick -2- and
– Remove bolt -4- and detach vacuum reservoir -1- from intake
manifold.
– Move vacuum reservoir clear to one side (with pipes/hoses
connected).

Audi TT 2007 ➤
– Unclip bracket -arrows- for wiring harness (left and right) from
coolant pipe.
– Detach coolant hose -1- going to oil cooler from coolant pipe.
– Pull coolant pipe out of cylinder block.
Installing
Note
Fit new O-rings.
– Clean and smoothen sealing surface for O-ring in cylinder

block.
– Lubricate new O-ring -1- with “G 12+” and push onto coolant
pipe -2-.
– Slide coolant pipe into bore in cylinder block.
– Install thermostat housing ⇒ unless
pageauthorised
158 . by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted

Audi TT 2007 ➤
2.9 Removing and installing coolant pipe going to gear oil cooler

equipment required
to 25 mm -3094-
V.A.G 1921-
-VAS 6208-
Removing
WARNING

hot.

Audi TT 2007 ➤

J338- .
– Use hose clamp -3094- to clamp off coolant hose at coolant

pipe going to gear oil cooler.
Note

Audi TT 2007 ➤
– Detach coolant hose -1- from coolant pipe going to gear oil
cooler.
– Detach coolant hose -2- from coolant pipe going to gear oil
cooler.
– Remove coolant pipe going to gear oil cooler upwards (turn
coolant pipe anti-clockwise).
Installing

Audi TT 2007 ➤

⇒ page 174
2 - Nut
❑ 10 Nm
❑ To connection for ther‐
mostat
4 - Retaining clip
5 - Radiator fan thermal switch
-F18-
❑ 35 Nm
6 - O-ring
❑ Renew
7 - O-ring
❑ To connection at cylin‐
der head
9 - O-ring
10 - Radiator
⇒ pageCopying
Protected by copyright. 168 for private or commercial purposes, in part or in whole, is not

11 - Bracket
❑ For radiator
12 - Bolt
❑ 5 Nm
13 - Rubber bush
14 - Nut
❑ 10 Nm
15 - Radiator cowl
16 - Bolt
❑ 5 Nm

Audi TT 2007 ➤

Removing
Note
WARNING

hot.


Audi TT 2007 ➤

drain off coolant.

– Pull out retaining clip and disconnect top coolant hose

-arrow- from radiator.
– Swivel top edge of radiator slightly to rear.
– Lift radiator out of bottom mounting points.
– Push radiator towards engine.
– Support radiator from below to prevent radiator from dropping.

Audi TT 2007 ➤
WARNING

Caution
not damaged.

– Disconnect condenser from radiator.
– Move condenser to front and place in lock carrier, then secure
with cable ties to prevent from dropping.
– Take out radiator downwards
Installing

Audi TT 2007 ➤

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

Audi TT 2007 ➤
Procedure
WARNING

hot.

– Fit cooling system tester -V.A.G 1274 A- with adapter -

– Fit cooling system tester -V.A.G 1274 A- with adapter -
1.4 ... 1.6 bar.

scribed.

Removing

Audi TT 2007 ➤
– Remove top bolts -upper arrows- for radiator cowl.

Audi TT 2007 ➤
– Detach electrical connectors -1- for radiator fans at bottom of

radiator cowl.
– Remove bolts -bottom arrows- at bottom of radiator cowl.
– Remove radiator cowl with both radiator fans from below.
Installing

Removing
– Move electrical wiringProtected
clear. by copyright. Copying for private or commercial purposes, in part or in whole, is not

Installing

Audi TT 2007 ➤
1 Silencers
Note
Use screwdriver to unfasten and tighten lock washers for heat

shields. Tightening torque: 2 Nm
1 - Bolt
❑ 23 Nm
3 - Centre silencer
❑ Combined with rear si‐
lencer
⇒ page 179
4 - Rubber mounting
❑ Renew if damaged Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Nut with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 23 Nm
7 - Bolt
❑ 23 Nm
8 - Mounting
9 - Bolt
❑ 23 Nm
10 - Tunnel brace
11 - Nut
❑ Renew
❑ 40 Nm
12 - Gaskets
❑ Renew
13 - Lambda probes before
catalytic converter
❑ The threads on the new Lambda probes are coated with a special assembly paste.
❑ If re-installing old Lambda probe, coat thread with high-temperature paste: Refer to ⇒ Electronic parts
catalogue for high-temperature paste
❑ The assembly paste/high-temperature paste must not get into the slots on the probe body.
14 - Lambda probes after catalytic converter
❑ The threads on the new Lambda probes are coated with a special assembly paste.
❑ If re-installing old Lambda probe, coat thread with high-temperature paste: Refer to ⇒ Electronic parts
catalogue for high-temperature paste
1. Silencers 175
Audi TT 2007 ➤
❑ The assembly paste/high-temperature paste must not get into the slots on the probe body.
15 - Front exhaust pipe with catalytic converters and front silencer
Caution
Avoid damage to flexible
joints.
Do
♦ not bend flexible
joints in front exhaust
pipe more than 10°.
❑ Install flexible joint so that it is not under tension.

❑ Take care not to damage wire mesh on flexible joint.
❑ Do not remove protective packaging from replacement part until you are ready to fit the flexible joint
16 - Nut
❑ 23 Nm
17 - Clamp
❑ Align exhaust system so it is free of stress before tightening clamp ⇒ page 179
❑ Tighten bolt connections evenly Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
18 - Rear silencer permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Combined with centre silencer
20 - Nut
❑ 23 Nm

• α = approx. 20°.

Audi TT 2007 ➤

pipe with catalytic converter and front si‐
lencer
Removing
J338- .


1- For Lambda probe 2 -G108-
2- For Lambda probe -G39-
Note
Disregard item -3-.
1. Silencers 177
Audi TT 2007 ➤
– Unscrew nuts (accessible from above) securing front exhaust

pipe to exhaust manifold.
– Remove nuts -1- and -2- on underside of vehicle.

– Detach cover from bracket for electrical connectors for Lamb‐
da probes.
– Remove bolt -3- and move electrical wiring to Lambda probes
clear.

1- For Lambda probe after catalytic converter -G130-
2- For Lambda probe 2 -G131- (after catalytic converter)

Audi TT 2007 ➤
– Unscrew nuts (accessible from below) securing front exhaust

pipe to exhaust manifold.
Caution

10°.

– Detach front exhaust pipes with catalytic converters and front
silencer.
Installing
Note
Renew seals, gaskets and self-locking nuts.

• The exhaust
permitted system
unless authorised by must
AUDI AG. beAUDI
aligned
AG doeswhen it is cool.
1. Silencers 179
Audi TT 2007 ➤
– Loosen bolt connections for clamp ⇒ Item 17 (page 176) .

– Push rear silencer towards front of vehicle -arrow- so that rub‐
ber mounting (left-side) on rear silencer is preloaded by -a- =
11 ... 13 mm.

• α = approx. 20°.

– Adjust the rear silencer so that there is an even distance be‐
tween the bumper cut-outs and the tailpipes.
• Dimension -a- = approx. 18.5 mm.
• Distance -b- = -b-.

– Listen for noise at connection points (exhaust manifold/cylin‐
der head, front exhaust pipe/exhaust manifold, etc.) to locate
any leaks.

Audi TT 2007 ➤
2 Exhaust manifold
2.1 Exhaust manifold - exploded view
1 - Nut
❑ Renew
❑ 23 Nm
2 - Exhaust manifold
❑ Removing and Protected
installing
3 - Gasket
❑ Renew
4 - Gasket
❑ With heat shield
❑ Renew
5 - Heat shield
6 - Bolt
❑ 10 Nm
7 - Bracket
❑ Riveted to heat shield
(depending on version)
8 - Bolt
❑ 20 Nm
9 - Bracket
10 - Bolt
❑ 10 Nm
2.2 Removing and installing exhaust mani‐

fold
Removing
Note
2. Exhaust manifold 181

Audi TT 2007 ➤

– Disconnect vacuum hose -arrow-.
Note
– Remove bolts -arrows- and move pipe to one side with com‐
bination valve for secondary air system (right-side) attached.

– Remove heat shield above exhaust manifold -arrows-.

Audi TT 2007 ➤
Caution

10°.
– Remove nuts -1 ... 6- and push back front exhaust pipe slightly
from exhaust manifolds. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
Lambda probes can remain fitted.
– Unscrew the 7 nuts -arrows- on both exhaust manifolds and

remove together with washers.
– Pull off exhaust manifold to rear.
Installing
Note
Renew seals, gaskets and self-locking nuts.
– Install front exhaust pipe ⇒ page 177 .

2. Exhaust manifold 183

Audi TT 2007 ➤
3 Secondary air system
3.1 Principle and function

Principle
Because of the over-enrichment of the mixture in the cold start
phase, the proportion of unburned hydrocarbons in the exhaust
gas is higher. The secondary air system improves the afterburn‐
ing (oxidation) process in the catalytic converter, and thus re‐
duces toxic emissions. The heat generated by oxidisation
accelerates the light off of the catalytic converter and significantly
improves exhaust gas quality during warm-up.
Function
In the warm-up phase, the engine control unit activates the sec‐
ondary air pump via the secondary air pump relay. The stream of
air from the secondary air pump opens the combination valve for
secondary air and permits air to flow into the exhaust system up‐
stream of the catalytic converter.
3.2 Secondary air system - exploded view
Note
♦ Fitting location for secondary air pump

Protected relay
by copyright. -J299-
Copying ⇒ page
for private 188 purposes, in part or in whole, is not
or commercial
♦ Fitting location for secondarywith
airrespect
pump fuse
to the ⇒ page
correctness 188 . in this document. Copyright by AUDI AG.
of information

Audi TT 2007 ➤
Vehicles with engine code letters BUB
1 - Secondary air pump motor

-V101-
⇒ page 194
2 - Rubber mounting
3 - Bolt
❑ 9 Nm
4 - Bracket
❑ For secondary air pump
motor -V101-
5 - Nut
❑ 9 Nm
6 - Bolt
❑ 9 Nm
7 - Hose
ment
8 - Gasket
❑ Renew
9 - Connection
❑ For coolant and combi‐
nation valve for secon‐
dary air system
10 - Bolt
❑ 9 Nm
12 - Gasket
❑ Renew
13 - Combination valve for secondary air system
14 - O-ring
15 - Hose
16 - O-ring
17 - O-ring
18 - Connecting piece
❑ To air cleaner
19 - Air cleaner
❑ Clean if dirty
3. Secondary air system 185

Audi TT 2007 ➤
Vehicles with engine code letters CBRA
1 - Secondary air pump motor

-V101-
⇒ page 194
2 - Rubber mounting
3 - Bolt
❑ 9 Nm
4 - Bracket
❑ For secondary air pump
motor -V101-
5 - Nut
❑ 9 Nm
6 - Bolt
❑ 9 Nm
7 - Hose
ment
8 - Vacuum hoses
9 - Secondary air inlet valve 2
-N320-
⇒ page 188
10 - Vacuum hoses
11 - Secondary air inlet valve -
N112- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 188
12 - Gasket
❑ Renew
13 - Connection
❑ For coolant and combination valve for secondary air system (left-side)
14 - Bolt
❑ 9 Nm
15 - Gasket
❑ Renew
16 - Connection
❑ For combination valve for secondary air system (right-side)
17 - Bolt
❑ 9 Nm
18 - Hose
19 - Bolt
❑ 9 Nm
20 - Connection
❑ For combination valve for secondary air system (right-side)

Audi TT 2007 ➤
21 - Bolt
❑ 9 Nm
22 - Gasket
❑ Renew
23 - Combination valve for secondary air system (right-side)
24 - Gasket
❑ Renew
25 - Bolt
❑ 9 Nm
26 - Elbow Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For combination valve for
with secondary air system
respect to the correctness (right-side)
27 - Hose
28 - Bolt
❑ 9 Nm
29 - Pipe
30 - Gasket
❑ Renew
31 - Combination valve for secondary air (left-side)
32 - Gasket
❑ Renew
33 - Bolt
❑ 9 Nm
34 - O-ring
35 - Sender 1 for secondary air pressure -G609-
36 - Bolt
❑ 3.5 Nm
37 - O-ring
❑ Renew
38 - Pipe
39 - Bolt
❑ 9 Nm
40 - O-ring
41 - O-ring
42 - Connecting piece
❑ To air cleaner

Audi TT 2007 ➤
43 - Air cleaner
❑ Clean if dirty
Fitting location of secondary air pump relay -J299-

♦ In electronics box in engine compartment.
3 - Secondary air pump relay -J299-
Fitting location of fuse for secondary air pump motor -V101-

♦ In electronics box in engine compartment.
F - 40 A fuse for secondary air pump motor -V101-
Fitting location of secondary air inlet valve(s)

♦ At vacuum reservoir on front of intake manifold
1- Secondary air inlet valve -N112-
2- Secondary air inlet valve 2 -N320- -Protected
only with engine code
CBRA permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi TT 2007 ➤
3.3 Checking combination valve for secon‐

dary air system for proper operation and
leakage - engine code BUB
Procedure
• Vacuum hoses and hose connections do not leak.
• Vacuum hoses are not clogged.
– Disconnect hose -arrow- and attach test hose to hose leading
to combination valve for secondary air system.
– Blow lightly into test hose with your mouth (do not use com‐
pressed air).
• The combination valve for secondary air system should be
closed; it should not be possible to blow through the hose.
– Blow into test hose with your mouth using more pressure (do
not use compressed air).
• The combination valve for secondary air system should open;
it should now be possible to blow through the hose.
– Renew combination valve for secondary air if you cannot de‐
termine the switching point ⇒ page 189 .
3.4 Removing and installing combination

valve for secondary air system - engine
code BUB
Removing
system.
– Unscrew bolts -1- and detach combination valve for secondary
air system.
Installing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
3.5 Checking combination valves for secon‐

dary air system for proper operation and
leakage - engine code CBRA

Audi TT 2007 ➤
♦ Hose clamps, up to Ø 25 mm -3094- for combination valve for

secondary air system (left-side)
Procedure
• Vacuum hoses and hose connections do not leak.
• Vacuum hoses are not clogged.
Combination valve for secondary air system (left-side):
– Disconnect air pipe -arrows-.
Note
Disregard item -1-.
– Disconnect vacuum hoses -1, 2, 4- at rear of intake manifold.

– Unbolt hose bracket from intake manifold -arrows- and move
clear to rear, with hoses attached.
Note
Disregard item -3-.

Audi TT 2007 ➤
– Disconnect secondary air hose -arrow-, move hose clear to‐

wards the top and clamp off using hose clamp -3094- .
– Disconnect vacuum hose from combination valve for secon‐

dary air system (left-side).
connection on combination valve for secondary air system.
– Disconnect secondary air hose at the position marked with an

-arrow-.
– Blow lightly into secondary air hose with your mouth (do not
use compressed air).
– Operate hand-operated vacuum pump to produce a vacuum.
– Renew combination valve for secondary air system (left-side)
if valve does not react as described ⇒ page 192 .

Audi TT 2007 ➤
Combination valve for secondary air system (right-side):

– Remove combination valve for secondary air (right-side)
⇒ page 193 .
connection -1- on combination valve (right-side) for secondary
air system.
– Connect a suitable test hose -2- onto combination valve for
secondary air system.
– Blow lightly into test hose with your mouth (do not use com‐
pressed air).
– Operate hand-operated vacuum pump to produce a vacuum.
– Renew combination valve for secondary air system (right-side)
if valve does not react as described ⇒ page 193 .
Assembling Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation is carried out in the reverse order; note thewithfollowing:
– Install combination valve for secondary air (right-side)

⇒ page 193 .

valve for secondary air system (left-
side) - engine code CBRA
Removing
system.
– Remove bolts -arrows- and move secondary air pipe to one
side.
– Remove bolts -3- and detach combination valve (left-side) for
secondary air system.
Note
For illustration purposes, the installation position is shown from

the rear and with the engine removed.
Installing
Note

Audi TT 2007 ➤

valve for secondary air system (right-
side) - engine code CBRA
Removing
– Disconnect vacuum hoses -1, 2, 4- at rear of intake manifold
and move hoses clear.
– by
Protected Unbolt hose
copyright. Copyingbracket
for privatefrom intakepurposes,
or commercial manifold
in part-arrows- and
or in whole, is not move
clearauthorised
permitted unless to rear,bywith
AUDI AG.hoses
AUDI attached.
Note
Disregard item -3-.
– Remove bolts -arrows- and detach bracket -1- for heat shield.
Note
For illustration purposes, the installation position is shown from

the rear and with the engine removed.
– Disconnect vacuum hose -arrow-.

– Remove bolt -1- and detach combination valve for secondary
air system (right-side) from secondary air hoses -2- and -3-.
Note
Disregard item -4-.
Installing
Note

– Install bracket for heat shield ⇒ page 181 .

Audi TT 2007 ➤
3.8 Removing and installing secondary air

pump
Removing
– Disconnect air hose -arrow-.
– Move hose going to secondary air pump clear.

– On vehicles with direct shift gearbox: Remove bolt -2- securing
bracket for coolant pipe going to gearbox oil cooler.
Installing

Audi TT 2007 ➤
3.9 Removing and installing sender 1 for

secondary air pressure -G609- - engine
code CBRA
Removing
– Remove bolts -arrows- and detach sender 1 for secondary air
pressure -G609- .
Installing
Note
Fit new O-ring.

Service
Workshop Manual
Audi TT 2007 ➤
Direct petrol injection and ignition system (5-cyl. 2.5 ltr.
4-valve turbo)
Engine ID
CEP
A
Edition 03.2009

Service
Repair Group

Copyright © 2010 Audi AG, Ingolstadt D3E801CE821

Audi TT 2007 ➤
Direct petrol injection and ignition system (5-cyl. 2.5 ltr. 4-valve turbo) - Edition 03.2009
Contents

1.1 General notes on self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Important: Required procedure prior to opening high-pressure injection system . . . . . . . . 4
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Fitting locations - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Intake manifold (top section) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.7 Removing and installing intake air temperature sender G42 / intake manifold pressure sender
G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.9 Removing and installing intake manifold (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.10 Intake manifold (bottom section), fuel rail and injectors - exploded view . . . . . . . . . . . . . . 23
2.11 Removing and installing intake manifold (bottom section) with fuel rail . . . . . . . . . . . . . . . . 24
2.14 Checking fuel pressure and residual pressure (up to high-pressure pump) . . . . . . . . . . . . 31
2.17 Removing and installing high-pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.18 Lambda probes - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.20Protected
Removing and
Copying for privateLambda
or commercialprobe
purposes,after catalytic
in part or in whole,converter
is not G130 with Lambda probe 1
heater
permitted after
unless catalytic
authorised by AUDIconverter
AG. AUDI AG Z29 does not .guarantee
. . . . .or. accept
. . . . any
. . liability
............................. 42
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.3 Removing and installing ignition coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.4 Removing and installing knock sensors G61 / G66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.5 Removing and installing Hall senders G40 / G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Contents i
Audi TT 2007 ➤
ii Contents
Audi TT 2007 ➤

cleanliness
1.1 General notes on self-diagnosis

♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and fault finding, the fault memory must
be interrogated. The vacuum hoses and connections must al‐
so be checked (unmetered air).
♦ Fuel hoses in enginepermitted
compartment must
unless authorised onlyAG.
by AUDI beAUDI
secured
AG doeswith
spring-type clips. O-type clips toorthescrew-type
with respect clips must
correctness of information in thisnot be Copyright by AUDI AG.
document.
used.
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 probes.
♦ 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 control
unit.

Audi TT 2007 ➤

WARNING

erly secured.
secured.
the passenger.
WARNING

cause injury.
♦ The fuel system is pressurised. The fuel pressure in the
high-pressure section of the injection system must be re‐
duced to a residual pressure prior to opening; for proce‐
dure see ⇒ page 4 .
♦ The connection must be opened immediately after reduc‐
ing the pressure; wrap a cloth around the connection and
allow the residual pressure (approx. 7 bar) to dissipate.
To prevent injuries to persons and/or damage to the fuel injection

and ignition system, the following must be noted:

Audi TT 2007 ➤
♦ Persons wearing a cardiac pacemaker must at all times main‐

tain a safe distance from high-voltage components such as the
ignition system and gas-discharge headlights.
ning.
necting injection or ignition system wiring or tester cables.
♦ If the fault memory has been erased, you must generate the
readiness code again.
damaged.
nectors from the ignition coils.
♦ Additionally unplugProtected
electrical connector -arrow- for injectors.
– Then connect vehicle diagnostic, testing and information sys‐
tem -VAS 5051B- and generate readiness code in engine

control unit using “Guided Fault Finding” mode.

opening.

Audi TT 2007 ➤
1.4 Important: Required procedure prior to

opening high-pressure injection system
WARNING

cause injury.
♦ The injection system consists of a high-pressure section
(maximum approx. 125 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‐
low.
Reducing fuel pressure in high-pressure section

– Then select function read “Measured values”.

– Select measured value block 140.
– With engine idling the fuel pressure is displayed in zone 3.

– With engine idling, pull out fuse for fuel pump control unit -
J538- ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
Note
Removing the fuse will interrupt the voltage supply “terminal 30”
for the fuel pump control unit -J538- .
– Observe fuel pressure displayed on diagnostic system.

fuel from the fuel tank by the fuel pump -G23- .
– Switch off ignition as soon as fuel pressure has dropped to
approx. 8 bar.
Note

Audi TT 2007 ➤
WARNING

♦ The fuel lines are still filled with fuel, however the fuel is
no longer under high pressure. Wear safety goggles and
protective clothing when opening the fuel system.
♦ Before opening the high-pressure section, wrap a cloth
around the connection.
– The high-pressure system must be opened “immediately” after

reducing the fuel pressure; wrap a clean cloth around the con‐
nection. Catch the escaping fuel.
The following operations must be performed after completing re‐
pair work:
– Refit fuse.

Procedure
♦ Cracks


other vacuum lines leading to other components.

Audi TT 2007 ➤
2 Injection system
2.1 Technical data

Idling speed is not adjustable (con‐ 680 ... 920 rpm
trolled by idling speed stabilisation).
Maximum rpm governed by deacti‐ 6900 rpm
vation of fuel injectors
Fuel pressure Initial fuel pressure up to high-pres‐ 7 bar
sure pump (generated by electric
fuel pump in fuel tank)
Pressure in high-pressure fuel cir‐ 17.5 ... 125 bar (depending on op‐
cuit (generated by mechanical sin‐ erating conditions)
gle-plunger pump) at a coolant
temperature of approx. 85°C.
2.2 Fitting locations - overview

Part 1
1 - Intake manifold flap valve -

N316-
2 - Fuel pressure sender for
low pressure -G410-
⇒ page 26
❑ Inlet side
⇒ page 56
6 - Ignition coil 1 with output
stage -N70- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

stage -N127-
stage -N291-
stage -N292-
stage -N323-
11 - Camshaft control valve 1 -
N205-
⇒ page 11
⇒ Rep. Gr. 15

Audi TT 2007 ➤
12 - Intake air temperature sender -G42- / intake manifold pressure sender -G71-
13 - Intake manifold flap potentiometer -G336-
❑ After renewing, perform “Adaption” in “Guided Functions” under “Adapting potentiometer for air flow
control flaps”
14 - Charge air pressure sender -G31- / intake air temperature sender 2 -G299-
❑ 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 electric throttle -G188-
❑ After renewing, perform “Adaption” in “Guided Functions”
19 - Oil pressure
Protected byswitch
copyright.-F22-
❑ Removing andto installing
with respect the correctness⇒of Rep. Gr.in this
information 17document. Copyright by AUDI AG.
20 - Activated charcoal filter solenoid valve 1 -N80-
Part 2
Audi TT 2007 ➤

⇒ page 57
ic converter -Z29-
❑ Fitting location of con‐
nector ⇒ page 10
⇒ page 42
3 - Coolant temperature send‐
er -G62-
⇒ Rep. Gr. 19
tion valve -N249-
⇒ Rep. Gr. 21
5 - Exhaust camshaft control
valve 1 -N318-
⇒ Rep. Gr. 15
❑ Combined with high-
pressure pump
❑ Cannot be renewed
separately
❑ Exhaust side Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

10 - Lambda probe before catalytic converter -G39- with Lambda probe heater -Z19-
❑ Fitting location of connector ⇒ page 10

Audi TT 2007 ➤

♦ In electronics box (plenum chamber)
♦ Removing and installing ⇒ page 47
Fitting location of accelerator position sender -G79- with acceler‐

ator position sender 2 -G185-
♦ Combined with accelerator pedal module
♦ Removing and installing accelerator pedal module ⇒ Rep. Gr.
20
Note
The illustration shows the set-up for left-hand drive vehicles.
Fitting location of brake light switch -F- Protected

with brake pedal switch -
F47-
1- Brake light switch -F- with brake pedal switch -F47-
♦ On brake master cylinder
Audi TT 2007 ➤

Fitting location of electrical connectors for Lambda probes

1- For Lambda probe, before catalytic converter -G39- with
2- For Lambda probe after catalytic converter -G130- with
Lambda probe 1 heater after catalytic converter -Z29-
♦ At plenum chamber partition panel
Fitting location of electrical connectors for knock sensors

1- For knock sensor 2 -G66-
♦ On cylinder head cover
Fitting location of electrical connectors on cylinder head

1 - For engine speed sender -G28-
3 - For injectors

Audi TT 2007 ➤
Fitting location of fuel pump control unit -J538-

3 - Bracket
♦ On underside in front of fuel tank
Camshaft control valve 1 -N205-
Fitting location of continued coolant circulation pump -V51-

2 - Continued coolant circulation pump -V51-
♦ On cylinder block (inlet side)
Fitting location of solenoid for coolant circuit -N492-

1- Solenoid for coolant circuit -N492-
♦ On cylinder block (inlet side)
Audi TT 2007 ➤
1 - Front air duct

and salt deposits
2 - Clip nut
3 - Bolt
❑ 1.5 Nm
and salt deposits
5 - Air duct cover
6 - Bolt
❑ 5 Nm
7 - Hose
8 - Air hose
9 - Bolt
❑ 3 Nm
10 - Air pipe
11 - Seal
❑ Clean out salt deposits,
dirt and leaves, etc.
⇒ page 13
14 - Bolt
❑ With captive rubber grommet
❑ 10 Nm
15 - Bracket
❑ For air cleaner housing
16 - Bolt
❑ With captive rubber grommet
❑ 10 Nm
17 - Water drain
❑ Clean Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
18 - Retaining peg with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 10 Nm
19 - Rubber grommet
❑ Clean out salt deposits, dirt and leaves, etc.

Audi TT 2007 ➤
21 - Seal
❑ Clipped into air cleaner (bottom section)

ment
Removing
– Lift off engine cover panel -1- -arrows-.
Audi TT 2007 ➤
– Remove all bolts from air cleaner (top section) -arrow- and
swivel air cleaner (top section) away upwards.
– Take out air filter element.
Installing
Note

♦ The inside of the air cleaner housing must be clean.
♦ To prevent malfunctions, cover the air pipes etc. with clean
cloths when blowing out the air cleaner housing with com‐
pressed air.
♦ Do not use any lubricants containing silicone when assem‐
bling.
hose clips before installing. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
(top and bottom sections), using a vacuum cleaner if neces‐
sary.
– Check for salt residue, dirt and leaves in air hoses (engine
intake side).
– When fitting air filter element, check that it is properly centred
in the retainer in the air cleaner (bottom section).
– Carefully fit top section of air cleaner onto bottom section,
without using any force. When doing so, make sure that the
air cleaner (top section) is fitted straight on the air filter element
(note the position of the sealing lip on the air filter element).

Audi TT 2007 ➤

housing
Removing
Note
– Release hose clips -2- and -3- and disconnect air hoses.
– Move clear electrical wiring harness -1- at bracket for air clean‐
er housing.
– Unscrew bolts -arrows- and detach air cleaner housing.
Installing
Note
bling.
Audi TT 2007 ➤
2.6 Intake manifold (top section) - exploded view
1 - Seal
❑ Renew
J338-
⇒ page 18
❑ After renewing, perform
“Adaption” in “Guided
Functions”
4 - Bolt
❑ 9 Nm
enoid valve 1 -N80-
6 - Bracket
7 - Bolt
❑ 9 Nm
8 - Intake manifold (top sec‐

tion)
⇒ page 20
9 - Bolt
10 - Gasket
❑ Renew
11 - Hose
12 - O-ring
❑ Renew
13 - O-ring
❑ Renew
14 - Intake air temperature sender -G42- / intake manifold pressure sender -G71-
15 - Bolt
❑ 9 Nm
16 - Gasket
❑ Renew
17 - Union
❑ 20 Nm
18 - Intake connecting pipe
19 - Bolt
❑ 9 Nm

Audi TT 2007 ➤
20 - O-ring
❑ Renew
22 - Bolt
❑ 9 Nm
23 - O-ring
❑ Renew
24 - Charge air pressure sender -G31- / intake air temperature sender 2 -G299-
❑ Removing and installing ⇒ Rep. Gr. 21 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 9 Nm
Intake manifold (top section) - tightening torque and sequence

– Tighten bolts for intake manifold in the sequence -1 to 5-.
♦ Initially screw in bolts by hand until they make contact.
♦ Subsequently tighten to 9 Nm
2.7 Removing and installing intake air tem‐

perature sender -G42- / intake manifold
pressure sender -G71-
Removing
Audi TT 2007 ➤

– Unscrew bolts -2- and detach intake air temperature sender -
G42- / intake manifold pressure sender -G71- .
Installing
⇒ “2.6 Intake manifold (top section) - exploded view”,
page 16
Note
Fit new O-ring.

module -J338-
Removing
– Release hose clip -arrow- and detach air hose.

– Unplug electrical connector -3- at charge air pressure sender
-G31- / intake air temperature sender 2 -G299- .
Note
Disregard -item 1-.

Audi TT 2007 ➤

Note
Disregard -item 2-.
– Disengage activated charcoal filter solenoid valve 1 -N80-

-item 1-.
– Release hose clip -3- and detach hose.

J338- -item 1- with connection from air hose -2-.
Installing
page 16 and ⇒ “2.3 Air cleaner - exploded view”, page 12
Note
♦ Renew gasket and O-ring.

bling.
– After renewing, perform “Adaption” in “Guided Functions” -

VAS 5051B- .
Audi TT 2007 ➤

(top section)
Removing
– Release hose clip -arrow- and detach air hose.

– Unplug electrical connector -3- at charge air pressure sender
-G31- / intake air temperature sender 2 -G299- .
Note
Disregard -item 1-.

Audi TT 2007 ➤

1- Throttle valve module -J338-
2- Intake air temperature sender -G42- / intake manifold pres‐
sure sender -G71-
3- Turbocharger air recirculation valve -N249-

-item 1-.
Audi TT 2007 ➤

-arrow-.
– Unscrew bolts -1 ... 5- and detach intake manifold (top sec‐
tion).
Caution

♦ Block off the openings of the intake ports in the cylinder
head with a clean cloth to prevent small items from drop‐
ping into the engine.
Installing
page 16 ,
⇒ Fig. “ Intake manifold (top section) - tightening torque and
sequence “ , page 17 and
⇒ “2.3 Air cleaner - exploded view”, page 12 .
Note
♦ Renew gasket and O-ring.

bling.

Audi TT 2007 ➤
2.10 Intake manifold (bottom section), fuel rail and injectors - exploded view
1 - Bolt
❑ 9 Nm
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.
❑ Reducing fuel pressure

in high-pressure section
of injection system
⇒ page 4
❑ Connections must not
be damaged
⇒ page 37
❑ 27 Nm
3 - Threaded connection
❑ 40 Nm
4 - Fuel rail Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 24
5 - Bracket
6 - Bolt
❑ 9 Nm
7 - Bolt
❑ 9 Nm
8 - Intake manifold (bottom section)
❑ With vacuum unit for intake manifold flaps
9 - Locking pin
10 - Vacuum unit
11 - Bolt
❑ 9 Nm
12 - Gasket
❑ Renew
Audi TT 2007 ➤
13 - Dowel pin
14 - Seal
15 - Washer
❑ After renewing, perform “Adaption” in “Guided Functions” under “Adapting potentiometer for air flow
control flaps”
17 - Bolt
❑ 2.5 Nm
18 - Bolt
❑ 9 Nm
19 - Sealing element (top)
20 - Sealing element (bottom)
21 - Circlip
22 - Combustion chamber ring seal
❑ Do not apply grease to ring seal or use any other lubricants
❑ Renewing ⇒ “2.12 Removing and installing injectors”, page 26
23 - Injector
24 - Spacer ring
25 - O-ring
❑ Renew
❑ Lubricate lightly with clean engine oil
26 - Support ring
❑ Renew
❑ Via this support ring, the fuel rail exerts the clamping force that holds the injector in the cylinder head
❑ Clipped to -item 23-
❑ 25 Nm
Intake manifold (bottom section) - tightening torque and tightening

sequence
– Tighten bolts and nuts for intake manifold (bottom
Protected section)
by copyright.in
the sequence -1 to 11- in 2 stages. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Tighten initially to 7 Nm
♦ Subsequently tighten to 9 Nm

(bottom section) with fuel rail
Removing
– Remove intake manifold (top section) ⇒ page 20 .

Audi TT 2007 ➤
– Remove high-pressure pipe ⇒ page 37 .

Note
– Pull out oil dipstick -2-.

– Remove bolts -arrows- and lift off guide tube -1- for oil dipstick.

1 - Intake manifold flap valve -N316-
– Disconnect vacuum hose -2- and hose -3- from activated char‐
coal filter and move clear.
Audi TT 2007 ➤

– Remove bolts and detach intake manifold (bottom section).
Caution

♦ Block off the openings of the intake ports in the cylinder
head with a Protected
clean cloth to prevent small items from drop‐
ping into the permitted
engine.
Note
Injectors must be removed before gasket for intake manifold (bot‐

tom section) can be detached.
– Remove injectors ⇒ page 26 .

Installing
⇒ Fig. “ Intake manifold (bottom section) - tightening torque
and tightening sequence “ , page 24 .
Note
♦ Renew gaskets and O-rings.

♦ Injectors must be installed after gasket for intake manifold
(bottom section) has been attached.
– Install injectors ⇒ page 26 .

– Secure dipstick guide tube ⇒ Rep. Gr. 17 .
– Install high-pressure pipe ⇒ page 37 .
– Install intake manifold (top section) ⇒ page 20 .

♦ Tool set for FSI engines -T10133-
Removing

Audi TT 2007 ➤
– Remove intake manifold (bottom section) ⇒ page 24 .

– Unplug electrical connectors -1 to 5- at injectors.
– Detach support ring -4- from injector -1-.
– Apply puller -T10133/2A- to groove on injector.

– Attach removal tool -T10133/16- to puller.
– Pull out injector by screwing in bolt -1-.
– Repeat procedure for each injector.
– Detach gasket for intake manifold (bottom section).
Audi TT 2007 ➤
Dismantling injector
– Pull O-ring -3- and spacer ring -2- off injector -1-.
– Detach circlip -7-, sealing element (top) -5- and sealing ele‐
ment (bottom) -6-.
– Carefully remove old combustion chamber ring seal -8-. 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
– Clean bore in cylinder head with nylon cylinder brush -

T10133/4- .
Note
♦ Renew combustion chamber ring seal and O-ring.

♦ Renew spacer ring if damaged.
– When re-installing an injector, clean any combustion residue

off groove for combustion chamber ring seal and injector stem
with a clean cloth.
– 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.

Audi TT 2007 ➤
– Turn round assembly sleeve -T10133/6- and slide combustion

chamber ring seal into groove.
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.
– Push calibration sleeve -T10133/8- onto injector as far as it will

go and simultaneously turn it slightly (approx. 180°).
opposite direction.
– Before installing new injector -1-, lubricate new O-ring -3- light‐
ly with clean engine oil.
Note
The combustion chamber ring seal -8- must not be lubricated.
– Fit gasket for intake manifold (bottom section). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Audi TT 2007 ➤
– Use assembly tool -T10133/9- to push injector as far as it will

go into hole in cylinder head.
Note
It should be possible to insert injector easily. If necessary wait

until the combustion chamber ring seal has contracted sufficient‐
ly.
– Check that injector is seated correctly in cylinder head:

• Electrical connector of injector must engage in recess in cyl‐
inder head.
– Install intake manifold (bottom section) ⇒ page 24 .

sender -G247-
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
WARNING

cause injury.

tem ⇒ page 4 .
-item 1-.
Note
Place a cloth underneath to catch escaping fuel.

Installing
⇒ “2.10 Intake manifold (bottom section), fuel rail and injectors
- exploded view”, page 23 and

Audi TT 2007 ➤
2.14 Checking fuel pressure and residual pressure (up to high-pressure pump)

equipment required
♦ K-Jetronic pressure tester -
V.A.G 1318-
♦ Adapter set -V.A.G
1318/17A-
♦ Connector -V.A.G 1318/23-
1348/3A- for V.A.G 1348
with adapter cable -V.A.G
1348/3-3-
V.A.G 1594C-

Test conditions
• Fuel filter OK.
Audi TT 2007 ➤

• Fuel pump control unit -J538- OK; check in “Guided Fault
Finding” mode using vehicle diagnostic, testing and informa‐
tion system -VAS 5051B- .
• Ignition off.
Checking fuel pressure
– TT Coupé: Remove rear seat bench ⇒ Rep. Gr. 72 .
– TT Roadster: Remove back panel trim (right-side) ⇒ Rep. Gr.
70 .
– Unclip retaining tabs -arrows- for flange cover.
– Connect remote control -V.A.G 1348/3A- for V.A.G 1348 to

contact -1- using adapter cable -V.A.G 1348/3-3- and test lead
from auxiliary measuring set -V.A.G 1594C- .
– Tape off 2nd connector contact of adapter cable -V.A.G
1348/3-3- with insulating tape -arrow- to prevent short circuits.
auxiliary measuring set -V.A.G 1594C- .
– Connect crocodile clip to battery “+” (remote positive terminal
in engine compartment).

Audi TT 2007 ➤
– Disengage fuel supply line from retainer and remove heat in‐
sulation sleeve -1- at fuel supply line connection.
WARNING

nection.
– Disconnect fuel supply line -3- (pull release ring -2-).

– Screw connector -V.A.G 1318/23- and adapter -V.A.G

1318/17A- onto K-Jetronic pressure tester -V.A.G 1318- .
– Fit adapter -V.A.G 1318/17A- onto disconnected fuel supply
line.
– Screw adapter -V.A.G 1318/11- onto K-Jetronic tester -V.A.G
1318- .
– Attach test hose -arrow- and hold end of hose in measuring
container.
– Open cut-off valve on pressure tester.
• Lever must point in direction of flow.
– Press and hold remote control switch until K-Jetronic pressure
tester -V.A.G 1318- shows no further increase in pressure.
• Specification: approx. 6 bar (4 ... 8 bar)
If specification is not attained, check delivery rate of fuel pump ⇒
Rep. Gr. 20 .
– Check system for leaks and check residual pressure by watch‐
ing the drop in pressure on the K-Jetronic pressure tester -
V.A.G 1318- .
• After 10 minutes pressure should still be at least 3.0 bar.
If the residual pressure drops below 3 bar:
♦ Check union between K-Jetronic pressure tester -V.A.G 1318-
and fuel supply line for leaks.
♦ Check K-Jetronic pressure tester -V.A.G 1318- for leaks.
♦ Check fuel lines and their connections for leaks.
♦ Renew fuel filter with integral fuel pressure regulator ⇒ Rep.
Gr. 20 .
♦ If fuel filter is OK, renew fuel pump ⇒ Rep. Gr. 20 .
Assembling
Audi TT 2007 ➤
Note
Before removing the pressure tester, release the fuel pressure by

opening the cut-off valve. Hold end of test hose -arrow- in meas‐
uring container.
– Re-attach fuel supply line -3- (make sure that all parts are
clean and that there are no leaks).
– Engage fuel supply line at retainer and re-attach heat insula‐
tion sleeve -1- at fuel supply line connection.
– TT Coupé: Install rear seat bench ⇒ Rep. Gr. 72 .
– TT Roadster: Install back panel trim (right-side) ⇒ Rep. Gr.

Audi TT 2007 ➤
WARNING
Risk of injury - fuel sys‐
tem operates under high
pressure.
The
♦ fuel pressure in the
high-pressure section of
the injection system must
be reduced to a residual
pressure prior to opening
the system.
❑ Reducing fuel pressure

in high-pressure section
of injection system
⇒ page 4
❑ Version fitted in vehicle Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
may differ from illustra‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
tion with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Tighten connecting
piece to 40 Nm (always
make sure that connect‐
ing piece is tightened to
specified torque before
installing fuel line)
❑ Connections must not
be damaged
❑ Lubricate thread lightly
with oil
⇒ page 37
2 - Bolt
❑ 9 Nm
3 - Union nut
❑ Connections must not be damaged
❑ 27 Nm
5 - Bolt
❑ 20 Nm
6 - Seal
❑ Renew
7 - Screw plug
❑ 15 Nm
8 - O-ring
❑ Renew
9 - Roller tappet
10 - Union nut
❑ Connections must not be damaged
❑ 27 Nm
Audi TT 2007 ➤
11 - Fuel supply pipe

pump
Removing
WARNING

cause injury.

tem ⇒ page 4 .


– Release hose clips -1- and -2- and remove air pipe.

Audi TT 2007 ➤
Note
Place a cloth underneath to catch escaping fuel.
– Unscrew union nuts -1- and -2-.

– Unplug electrical connector -3- for fuel metering valve -N290- .
– Carefully press fuel lines to the side and detach high-pressure
fuel pump. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
♦ Renew O-ring for high-pressure pump.

♦ The connections of the high-pressure pipes must not be dam‐
aged.
– Check roller tappet -1- for damage and renew if necessary.

– Lightly lubricate roller tappet with oil and fit in cylinder head so
that guide -2- is in correct position -arrow-.
– Fit high-pressure pump and press downwards in guide as far
as stop.
– Tighten bolts hand tight in small steps.
– Tighten bolts alternately to specified torque.
⇒ “2.15 High-pressure pump - exploded view”, page 35 .

pipe
Audi TT 2007 ➤
♦ Puller -T10055-
Removing
WARNING

cause injury.

tem ⇒ page 4 .
– Release electrical connectors and unplug connectors from ig‐
nition coils -1 ... 5- simultaneously.
– Move electrical wiring harness to left side.

Audi TT 2007 ➤
– Unplug electrical connector -1- at exhaust camshaft control

valve 1 -N318- .
Note
Disregard -arrow-.
– Remove bolts -arrows- and union nut -4-.

– Release hose clip -2- and detach fuel hose.
– Detach fuel supply line.
– Remove union nuts -1- and -3- and detach high-pressure pipe.
Note
Do not attempt to bend high-pressure pipe to a different shape.
Installing
Note
♦ The connections of the high-pressure pipe must not be dam‐

aged.
♦ Do not attempt to bend high-pressure pipe to a different shape.
– First tighten union nut by hand until it makes contact, making

sure that high-pressure pipe is not under tension.
– Tighten union nut with torque wrench -V.A.G 1331- and 17 mm
tool insert -V.A.G 1331/6- ; to do so, counterhold at hexagon

flats of threaded connection with an open-end spanner.
⇒ “2.15 High-pressure pump - exploded view”, page 35 and
⇒ “2.10 Intake manifold (bottom section), fuel rail and injectors
– Do not tighten bolt for retainer until high-pressure pipe has
been tightened.
Audi TT 2007 ➤
2.18 Lambda probes - overview
Note
♦ Threads of new Lambda probes are already coated with assembly paste; the paste must not get into the
slots on the 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 probe body. For high-temperature paste refer to ⇒ Electronic parts catalogue
♦ When installing, it is important to re-attach the Lambda probe wiring at the same locations to prevent it from
coming into contact with the exhaust pipe.
❑ For exhaust tempera‐
ture sender 1 -G235-
2 - Bolts
❑ 5 Nm
ic converter -Z29-
⇒ page 42
❑ 55 Nm
⇒ page 40
❑ 55 Nm
5 - Turbocharger
sender 1 -G235-
⇒ Rep. Gr. 26
7 - Starter catalytic converter


Audi TT 2007 ➤
Removing
Note

– Release hose clips -1- and -2- and remove air pipe.
– Remove electrical connector -1- for Lambda probe -G39- from

bracket and unplug connector.
– Move clear electrical wiring for Lambda probe.
Note
Audi TT 2007 ➤
– Unscrew Lambda probe -G39- -item 2- using a tool from

Lambda probe open ring spanner set -3337- .
Note
Disregard -item 1-.
Installing
⇒ “2.18 Lambda probes - overview”, page 40 .
Note

body.
slots on the probe body. For high-temperature paste refer to
⇒ Electronic parts catalogue
♦ When installing, it is important to re-attach the Lambda probe
wiring at the same locations to prevent it from coming into


after catalytic converter -G130- with

Lambda probe 1 heater after catalytic
converter -Z29-

Audi TT 2007 ➤
Removing
Note
– Release hose clips -arrows- and detach air pipe -1-.
– Remove electrical connector -2- for Lambda probe after cata‐

lytic converter -G130- from bracket and unplug connector.
– Protected
Movebyclear electrical wiring for Lambda probe.
Note
Audi TT 2007 ➤
– Unscrew Lambda probe after catalytic converter -G130-

-item 1- using a tool from Lambda probe open ring spanner
set -3337- .
Note
Disregard -item 2-.
Installing
Installation is carried out in the reverseProtected
order;bynote theCopying
copyright. following:
• Tightening torque with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ “2.18 Lambda probes - overview”, page 40 .
Note

body.
slots on the probe body. For high-temperature paste refer to
⇒ Electronic parts catalogue
♦ When installing, it is important to re-attach the Lambda probe
wiring at the same locations to prevent it from coming into
bling.

Audi TT 2007 ➤

box -V.A.G 1598/42-
♦ Adapter cable -V.A.G 1598/39-
♦ Test box -V.A.G 1598/42-

Audi TT 2007 ➤
Note
♦ The test box -V.A.G 1598/42- has 105 sockets. It can be con‐
nected to the engine control unit via 2 different adapter cables.
♦ The engine control unit is connected to the vehicle's wiring
harness via two connectors, one of which has 60 pins, the
other has 94 pins.
adapter cable -V.A.G 1598/39-2- mustProtected
be connected to con‐
nectors -A- and -B- on the test box. For components
permitted connec‐
ted to 94-pin wiring harness connector ⇒ withCurrent flow
and to the engine control unit itself at the same time. The ad‐
vantage of this is that the electronic engine control system
remains fully functional when the test box is connected (for
example, for measuring signals when the engine is running).
♦ The instructions for performing the individual tests indicate
connected to the test box.
♦ Always use auxiliary measuring set -V.A.G 1594C- to connect
test equipment (e.g. voltage tester -V.A.G 1527B- , hand-held
multimeter -V.A.G 1526D- etc.).
The engine control unit has to be removed before connectors can

be unplugged from engine control unit ⇒ page 47 .
Caution
Electronic components are susceptible to damage.

♦ Select the appropriate measuring range before connect‐
ing the test leads and observe test requirements.

Audi TT 2007 ➤
– Connect test box -V.A.G 1598/42- to wiring harness with

– Carry out test as described in relevant repair procedure.
– The locking plate must always be re-fitted on the engine con‐
trol unit ⇒ page 47 .
– Interrogate and, if necessary, erase fault memory: vehicle di‐
agnostic, testing and information system -VAS 5051B- .
Note
After completion of the “Guided Fault Finding” routine, the diag‐

nostic system will attempt to erase the fault memories of all control
units. If this is not successful, the remaining faults registered in
the memories must be rectified before all fault memories can be
erased.

unit -J623-
Note
♦ A metal locking plate -5- is bolted to the engine control unit

fluid.
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- -1- with shrink element for hot
air blower -VAS 1978/15A- -2- from wiring harness repair set
-VAS 1978B-
♦ Small vice-grip pliers -3- (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, testing and information system -
VAS 5051B- .
– Switch off ignition and take out ignition key.

Audi TT 2007 ➤

wiper shafts.
Note
Use puller (commercially available) to remove wiper arms if nec‐

essary.
Caution

♦ Apply a small amount of soap solution to transition be‐
tween windscreen and plenum chamber cover.
– Starting at edge of windscreen, carefully pull plenum chamber

cover -2- vertically upwards off retainer at windscreen
-arrows-.
Note

partition panel.
– Release clips -arrows- and take out engine control unit -J623- .
Note
Cover painted surfaces with a cloth to prevent scratching.

Audi TT 2007 ➤

engine control unit, the control unit is secured by means of shear
bolts to a locking plate and a metal casing.
air blower.

WARNING

Audi TT 2007 ➤
20 ... 30 seconds.

in illustration).
– Detach metal locking plate from connectors.
– Unscrew both securing bolts from engine control unit -J623- .
– Release connectors -1- on engine control unit -J623- and un‐

plug connectors.
– Take out old engine control unit -J623- and install new engine
Note
When the connectors are unplugged from the engine control unit,
the learnt values are erased, but the contents of the fault memory
remain intact.
Installing
– Re-fit locking plate on engine control unit.
– Use new shear bolts.
After installing a new engine control unit, the following operation
must be performed:
– Activate engine control unit via vehicle diagnostic, testing and
information system -VAS 5051B- in “Guided Functions”, test
sequence/function “Replace engine control unit”.

Audi TT 2007 ➤
tions

carrying out repairs and fault finding, the fault memory must
be interrogated.


erly secured.
secured.
the passenger.


Audi TT 2007 ➤
♦ Do not touch or disconnect ignition coils when the engine is

running or being turned at starter speed.
♦ The ignition must be switched off before disconnecting or con‐
necting ignition system wiring, high-voltage wires and test
leads.
damaged.
nectors from the ignition coils.
♦ Additionally unplug electrical connector -arrow- for injectors.

Audi TT 2007 ➤
2.1 Test data

Idling speed (not adjustable)
Ignition timing Not adjustable (determined by control unit)
Ignition system Multi-coil system with 5 ignition coils (output stages
integrated) connected directly to spark plugs via
spark plug connectors
Spark plugs Designations ⇒ Data sheets for exhaust emission test
Tightening torque ⇒ Maintenance ; Booklet 810
Firing order 1-2-4-5-3
1 - 4-pin connector
❑ For ignition coil
2 - Bolt
❑ 10 Nm
3 - 3-pin connector
❑ For Hall sender Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4 - Hall sender with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Hall sender -G40-
❑ Hall sender 3 -G300-
⇒ page 56
5 - O-ring
clean engine oil
6 - Bolt
❑ The tightening torque in‐
fluences the function of
the knock sensor
❑ 20 Nm
7 - Knock sensor
❑ Knock sensor 1 -G61-
❑ Knock sensor 2 -G66-
❑ Contact surfaces be‐
tween knock sensor and
cylinder block must be
free of corrosion, oil and
grease
⇒ page 55
8 - Spark plug
❑ Remove and install with spark plug socket and extension -3122 B- ⇒ Maintenance ; Booklet 810

Audi TT 2007 ➤
9 - Ignition coil
❑ Ignition coil 1 with output stage -N70-
Electrical connectors for ignition coils - tightening torque

Engine speed sender -G28- - tightening torque

– Tighten bolts -1- to 4.5 Nm.

♦ Puller -T40039-

Audi TT 2007 ➤
Removing
– Release electrical connectors and unplug connectors from ig‐
nition coils -1 ... 5- simultaneously.
– Slide puller -T40039- onto ignition coil with output stage and
pull off ignition coil -arrow-.
Installing
– 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).
– Secure electrical wiring guide for ignition coils to cylinder head
cover ⇒ page 54 .
2.4 Removing and installing knock sensors

-G61- / -G66-
Removing
– Remove turbocharger ⇒ Rep. Gr. 21 .
– Detach appropriate electrical connector from bracket and un‐

plug:
Note
Disregard -arrows-.

Audi TT 2007 ➤
– Remove bolts -arrows- and detach heat shield -1-.
– Remove corresponding bolt and detach knock sensor:

Installing
⇒ “2.2 Ignition system - exploded view”, page 53 .
– Install turbocharger ⇒ Rep. Gr. 21 .
2.5 Removing and installing Hall senders -

G40- / -G300-
Removing
Hall sender -G40-
– Unscrew bolt -1- and remove Hall sender -G40- .
Hall sender 3 -G300-

– Unplug electrical connector -1-.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unscrew bolt -2- and remove Hallwith
sender 3 the
respect to -G300- . of information in this document. Copyright by AUDI AG.
correctness
Installing
⇒ “2.2 Ignition system - exploded view”, page 53 .
Note
Fit new O-rings.

Audi TT 2007 ➤

sender -G28-
Removing
Note
– Move electrical connector -2- clear and disconnect.

– Move electrical wiring harness clear -arrows-.
– Unscrew bolts -1- and detach engine speed sender -G28- .
Installing
⇒ Fig. “ Engine speed sender -G28- - tightening torque “ , page
54 .

Service
Workshop Manual
Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 2.0 ltr.
4-valve turbo)
CDL CDL CDM
Engine ID BWA BPY B A A
Edition 01.2008

Service
Repair Group


Audi TT 2007 ➤
Contents

2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Overviews - fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Air cleaner / engine cover panel - exploded view (engines with code letters BWA and
BPY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 Removing and installing engine cover panel with air filter element - engines with code letters
BWA and BPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Removing and installing air mass meter G70
Protected - engines
by copyright. Copyingwith codeor letters
for private commercial BWA and
purposes, BPY
in part . . is22
or in whole, not
2.6 Air cleaner - exploded view (enginespermitted with code letters CDLA, CDLB and CDMA) . . . . . .
23
2.7 Removing and installing engine cover panel - engines with code letters CDLA, CDLB and
CDMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.8 Removing and installing air filter element - engines with code letters CDLA, CDLB and
CDMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.9 Removing and installing air cleaner housing - engines with code letters CDLA, CDLB and
CDMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.10 Removing and installing air mass meter G70 - engines with code letters CDLA, CDLB and
CDMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.12 Fuel rail - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.13 Removing and installing intake manifold with fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.15 Checking fuel pressure (low pressure) up to high-pressure pump . . . . . . . . . . . . . . . . . . . . 37
2.20 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.21 Removing and installing intake manifold flap motor V157 with intake manifold flap
potentiometer G336 - engines with code letters BWA and BPY . . . . . . . . . . . . . . . . . . . . 49
2.22 Removing and installing intake manifold flap motor V157 with intake manifold flap
potentiometer G336 - engines with code letters CDLA, CDLB and CDMA . . . . . . . . . . . . 50
2.23 Removing and installing Lambda probe G39 and Lambda probe heater Z19 before catalytic
converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.24 Removing and installing Lambda probe after catalytic converter G130 and Lambda probe 1
heater, after catalytic converter Z29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.1 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.3 Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Contents i
Audi TT 2007 ➤
ii Contents
Audi TT 2007 ➤

cleanliness

♦ The engine control permitted
unit has a self-diagnosis capability. Before
carrying out repairs and fault finding the fault memory must be
interrogated. The vacuum hoses and connections must also

be checked (unmetered air).
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. Clamping-type or screw-type clips must not
be used.
damage the Lambda probe.
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 2 .

Audi TT 2007 ➤

WARNING

erly secured.
secured.
the passenger.
WARNING
The fuel system is pressurised. The fuel pressure in the high-

pressure part of the injection system must be reduced to a
residual pressure prior to opening; for procedure see
⇒ page 4 .
The connection must be opened
Protected byimmediately
copyright. Copying after reducing
the pressure; wrap a cloth around the connection and allow the
residual pressure (approx. 6 bar) to dissipate.

To avoid any risk of injuries to persons and/or damage to the fuel

injection and ignition system, always observe the following safety
precautions.

Audi TT 2007 ➤
♦ For safety reasons, the battery must be disconnected before

opening the fuel system to prevent the fuel pump from being
activated by the contact switch on the driver's door.
ning.
♦ If engine is to be operated at cranking speed without it starting
(e.g. compression test), unplug connectors from ignition coils
and remove fuse for electric fuel pump.
♦ If the fault memory has been erased, you must generate the
damaged.
♦ If the engine has to be operated at the starting speed without
actually starting (e.g. to test compression pressure), detach
the four connectors from the ignition coils using assembly tool
-T40039- ⇒ page 64 . Also remove fuse for fuel pump control
unit -J538- . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
♦ The fuse is located in the fuse holder in the luggage compart‐

ment (right-side).
♦ Removing fuse -SF 6- will interrupt the voltage supply “termi‐
nal 30” for the fuel pump control unit -J538- .

tem. When working on the fuel supply/injection system, pay care‐
ful attention to the following basic rules:
opening.
immediately.

Audi TT 2007 ➤

opening high-pressure injection system
Caution
The injection system consists of a high-pressure section (max‐

imum approx. 150 bar) and a low-pressure section (approx. 7
bar).
Prior to opening the high-pressure section (e.g. when removing
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 below.

♦ Specification: between 45 and 55 bar

Audi TT 2007 ➤
– The fuse is located in the fuse holder in the luggage compart‐

ment (right-side).
– With engine idling, pull out fuse -SF 6- for fuel pump control
unit -J538- .
Note
Removing fuse -SF 6- will interrupt the voltage supply “termi‐

– Observe fuel pressure displayed on tester.

fuel by the fuel system pressurisation pump -G6- .
approx. 8 bar.
Note
WARNING
The fuel lines are still filled with fuel, however the fuel is no
longer under high pressure. Wear safety goggles and protec‐
tive clothing when opening the fuel system to avoid possible
injury and skin contact.
Before opening the high-pressure section, wrap a cloth around
the connection.

pair work:
– Refit fuse.
– Erase fault memory and generate readiness code in engine
control unit in “Guided Functions” mode, using vehicle diag‐
nostic and service information system -VAS 5052 A- .

Audi TT 2007 ➤
2 Injection system
2.1 Technical data

Engine data 2.0 ltr. turbo FSI engine
Idling speed is not adjustable; con‐ 640 ... 800 rpm
trolled by the idling speed stabili‐
sation
Maximum rpm governed by deac‐ 6500 rpm
tivation of fuel injectors
Fuel pressure Initial fuel pressure up to approx. 6.0 bar (identical for all operating
high-pressure pump (gen‐ conditions)
erated by electric fuel pump
in fuel tank)
Pressure in high-pressure approx. 50 bar at idling speed
fuel circuit (generated by approx. 110 bar in certain parts of operating
mechanical single-plunger range.
pump) at a coolant temper‐
ature of approx.Protected
85°C.by copyright. Copying for private or commercial purposes, in part or in whole, is not
2.2 Overviews - fitting locations

Overview of fitting locations - engines with code letters BWA and
BPY ⇒ page 6
Overview of fitting locations - engines with code letters CDLA,
CDLB and CDMA ⇒ page 9
2.2.1 Overview of fitting locations - engines

with code letters BWA and BPY
Components A to N are not shown in the exploded view.

Audi TT 2007 ➤

❑ Located directly on tur‐
bocharger ⇒ page 17
tion valve -N249-
stages
⇒ page 64
❑ Ignition coil 1 with output
stage -N70-
stage -N127-
stage -N291-
stage -N292-
❑ Puller -T40039- is re‐
quired for removing igni‐
tion coils from cylinder
head.
4 - Lambda probe -G39- and
⇒ page 16
⇒ page 52
⇒ page 57
6 - Single-plunger high-pressure pump
9 - 6-pin connector
❑ For Lambda probe -G39- and Lambda probe heater -Z19- (black) ⇒ page 16
10 - Fuel pressure sender for low pressure -G410-
❑ 15 Nm
❑ Oil pressure sender -G10-
❑ Electrical connectors for knock sensor 1 -G61- and for knock sensor 2 -G66-
13 - Intake manifold flap motor -V157- with intake manifold flap potentiometer -G336-
❑ After the fuel rail has been removed or renewed, intake manifold flap potentiometer -G336- must be
adapted to the engine control unit -J623- ; see vehicle diagnostic and service information system -VAS
5052- , “Guided Functions”
Audi TT 2007 ➤

16 - Connector
❑ For Hall sender -G40- and fuel pressure sender -G247-
17 - 8-pin connector for injectors
18 - Throttle valve module -J338- , 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
electric throttle -G188-

❑ After the throttle valve module -J338- has been renewed, it must be adapted to the engine control unit -
J623- , see vehicle diagnostic and service information system -VAS 5052- “Guided Functions”
19 - Intake air temperature sender -G42-
❑ 22 Nm
21 - Hall sender -G40- (camshaft position sensor)
❑ Electrical connector ⇒ page 13
A - Air mass meter -G70-
❑ In air cleaner (top section) ⇒ page 14
B - Fuel pump control unit -J538-
❑ ⇒ page 14
❑ Adaption of fuel pump must be performed after renewing fuel pump control unit -J538- . Basic setting,
measured value block 103, see ⇒ Rep. Gr. 20 or via vehicle diagnosis and service information system
-VAS 5052- “Guided Functions”
C - Brake light switch - F- and brake pedal switch -F63-
❑ On accelerator pedal (both senders are accommodated in one housing)
❑ If accelerator pedal module or engine control unit is renewed, kick-down function must be adapted on
vehicles with automatic gearbox
E - Clutch position sender -G476-
❑ Removing and installing, see Power transmission, clutch ⇒ Rep. Gr. 30
F - Relay and fuse holder in electronics box
❑ Relay and fuse assignment see ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
G - Radiator fan control unit -J293-
H - Injectors
❑ In fuel rail
❑ Injector, cylinder 1 -N30-

Audi TT 2007 ➤

The fuel injectors are high-pressure injectors. They inject fuel at high pressure (maximum approx. 110 bar)
directly into the cylinder.
I - Lambda probe after catalytic converter -G130- and Lambda probe heater 1 after catalytic converter -Z29-
J - Knock sensor 1 -G61-
❑ For cylinders 1 and 2
❑ Fitting location ⇒ page 15 to the correctness of information in this document. Copyright by AUDI AG.
with respect
K - Knock sensor 2 -G66-

❑ 20 Nm
L - Oil pressure switch -F1-
❑ Removing, installing and testing ⇒ Rep. Gr. 17
M - Radiator outlet coolant temperature sender -G83-
N - Continued coolant circulation pump -V51-
2.2.2 Overview of fitting locations - engines

with code letters CDLA, CDLB and
CDMA
Components A to L are not shown in the overview.
Audi TT 2007 ➤

stages
⇒ page 64
stage -N70-
stage -N127-
stage -N291-
stage -N292-
tion coils from cylinder Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
head. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
3 - Lambda probe -G39- and
⇒ page 16
⇒ page 52
⇒ page 57
low pressure -G410-
❑ 15 Nm
6 - Single-plunger high-pres‐
sure pump
9 - 6-pin connector
❑ For Lambda probe -G39- and Lambda probe heater -Z19- (black) ⇒ page 16
❑ Electrical connectors for knock sensor 1 -G61- and for knock sensor 2 -G66-
13 - Intake manifold flap motor -V157- with intake manifold flap potentiometer -G336-
❑ After the fuel rail has been removed or renewed, intake manifold flap potentiometer -G336- must be
adapted to the engine control unit -J623- ; see vehicle diagnostic and service information system -VAS

Audi TT 2007 ➤

❑ For injectors, Hall sender -G40- and fuel pressure sender -G247-
18 - Throttle valve module -J338- , throttle valve drive for electric throttle operation -G186-
20 - Continued coolant circulation pump -V51-
❑ 22 Nm
A - Fuel pump control unit -J538-
❑ Adaption of fuel pump must be performed after renewing fuel pump control unit -J538- . Basic setting for
measured value block 103, see ⇒ Rep. Gr. 20 or via vehicle diagnosis and service information system
-VAS 5052- “Guided Functions”
B - Brake light switch - F- and brake pedal switch -F63-
❑ byFitting
Protected copyright.location
Copying for⇒ page
private 15
❑ unless
permitted Removing
authorisedand
by AUDIinstalling
AG. AUDI AG ⇒ does
Rep. Gr. 45 or accept any liability
not guarantee
C - Accelerator position sender -G79- and accelerator position sender 2 -G185-
D - Clutch position sender -G476-
E - Relay and fuse holder in electronics box
F - Radiator fan control unit -J293-
Audi TT 2007 ➤
G - Injectors
❑ In fuel rail
The fuel injectors are high-pressure injectors. They inject fuel at high pressure (maximum approx. 110 bar)
directly into the cylinder.
H - Lambda probe after catalytic converter -G130- and Lambda probe heater 1 after catalytic converter -Z29-
I - Knock sensor 1 -G61-
❑ 20 Nm
J - Knock sensor 2 -G66-
❑ 20 Nm
K - Oil pressure switch -F1-
❑ Removing, installing and testing ⇒ Rep. Gr. 17
L - Exhaust flap 1 valve -N321-

er 2 -G185-
2 - Electrical connector for accelerator pedal module

Audi TT 2007 ➤
Radiator outlet coolant temperature sender -G83- -1-
Fuel pressure sender -G247- -1-

• Removing and installing ⇒ page 36
Hall sender -G40- -1-
Audi TT 2007 ➤
Air mass meter -G70- -1- “engines with code letters BWA and
BPY”
Air mass meter -G70- -1- “engines with code letters CDLA, CDLB
and CDMA”
Fuel pump control unit -J538- -1-

• Adaption of fuel pump must be performed after renewing fuel
pump control unit -J538- . Basic setting, measured value block
103, refer to ⇒ Rep. Gr. 20

Removing and installing, see Power transmission, clutch ⇒ Rep.
Gr. 30

Audi TT 2007 ➤
Brake light switch -F- and brake pedal switch -F63-

1 - 3-pin connector (green) for knock sensor 1 -G61-
2 - 3-pin connector (brown) for knock sensor 2 -G66-
4 - Engine speed sender Protected
-G28- by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - 3-pin electrical connector (grey) for engine speed sender -
G28-
Fitting locations of components below intake manifold

4 - 3-pin connector (brown) for knock sensor 2 -G66-
5 - 3-pin electrical connector (grey) for engine speed sender -
G28-
6 - Electrical connector for Hall sender -G40- and fuel pressure
sender -G247-
Charge air pressure sender -G31- -2-
Audi TT 2007 ➤
Radiator fan control unit -J293-

1 - Connector for radiator fan control unit -J293-
Note
The radiator fan control unit -J293- is integrated into the radiator
fan -V7- .
Continued coolant circulation pump -V51-
Electrical connector -arrow-

- Lambda probe -G39- and Lambda probe heater -Z19-
Lambda probe -G39- -arrow-

Audi TT 2007 ➤
Electrical connector -arrow-

- Lambda probe, after catalytic converter -G130- and Lambda
probe heater 1, after catalytic converter -Z29- on right-side un‐
derbody
Lambda probe after catalytic converter -arrow-

- Lambda probe, after catalytic converter -G130- and Lambda
probe heater 1, after catalytic converter -Z29-
Components on turbocharger “engines with code letters BWA and

BPY”
1 - Removing and installing turbocharger ⇒ Rep. Gr. 21
2 - Tighten charge pressure control solenoid valve -N75- to 3 Nm
3 - Tighten turbocharger air recirculation valve -N249- to 7 Nm
(note installation position, refer to next illustration)
Note installation position of turbocharger air recirculation valve -

N249- “engines with code letters BWA and BPY”
Audi TT 2007 ➤
Component on turbocharger “engines with code letters CDLA,

CDLB and CDMA”
Turbocharger air recirculation valve -N249- -2- “engines with code

letters CDLA, CDLB and CDMA”
Note installation position of turbocharger air recirculation valve -

N249- “engines with code letters CDLA, CDLB and CDMA”
The marks -arrows- must align.

Audi TT 2007 ➤
Exhaust flap 1 valve -N321-

1 - Electrical connector for exhaust flap 1 valve -N321-
Checking vacuum unit for exhaust flap ⇒ Rep. Gr. 26
2.3 Air cleaner / engine cover panel - exploded view (engines with code letters
BWA and BPY)

⇒ page 22
2 - 3 Nm
section/engine cover panel)
❑ Clean any salt deposits
or leaves and dirt out of
air cleaner housing (top
section)
5 - Intake air duct
❑ To air cleaner housing
❑ Clean any leaves and
dirt out of intake air duct
6 - Filter element
⇒ page 20
Booklet 810
7 - Air cleaner housing (bottom
section)
air cleaner housing (bot‐
tom section)
8 - 3 Nm
9 - Heat shield
10 - Rubber sleeve
❑ Note assembly markings
11 - Air hose
❑ Note assembly markings
❑ To turbocharger
❑ Check air intake hose for dirt and leaves
Audi TT 2007 ➤

panel with air filter element - engines
with code letters BWA and BPY
The air filter element is integrated in the engine cover panel.
Removing engine cover panel
air mass meter.
– Release spring-type clip -4- and detach air intake hose from
engine cover panel.
– Carefully pull engine cover panel off positions -1 - 2 - 3 - 4-

one after the other.
Caution
Always observe sequence (risk of breaking engine cover pan‐

el).
– Cover open intake hose with a clean cloth.

Removing air filter
permitted unless element
– Remove all bolts -arrows-.

– Unbolt heat shield.

Audi TT 2007 ➤
– Open engine cover panel (note retainers -arrows-).
– Pull air filter element out of engine cover panel.

Installing air filter element
Note

♦ The air cleaner housing must be clean.
pressed air.
– Check for dirt in air intake hose from air duct.
– Ensure secure fit of intake hose at air mass meter -G70- .
quence.
Audi TT 2007 ➤

-G70- - engines with code letters BWA
and BPY
Installing
♦ Use a silicone-free lubricant when installing the intake hose.
⇒ page 20
quence.

Audi TT 2007 ➤
2.6 Air cleaner - exploded view (engines with code letters CDLA, CDLB and
CDMA)
1 - Gasket
❑ Clipped into air cleaner
housing (bottom sec‐
tion)
2 - Front air duct
and salt deposits
3 - Bolt
❑ 2 Nm
and salt deposits
5 - Air duct cover
6 - Bolt
❑ 5 Nm
7 - Bolt
❑ 3 Nm
8 - Air hose
⇒ page 26
10 - Seal
section)
air cleaner housing (top
section)
❑ Always use genuine part for air filter element
13 - Air cleaner housing (bottom section)
❑ Clean any salt deposits or leaves and dirt out of air cleaner housing (bottom section)
Protected ⇒ page
by copyright. Copying for 25
with respect and
to the salt deposits
14 - Bolt
❑ 10 Nm
15 - Rubber grommet
16 - Bolt
❑ 10 Nm
17 - Bracket for air cleaner housing
18 - Retaining peg
❑ 10 Nm
Audi TT 2007 ➤
19 - Rubber grommet

panel - engines with code letters CDLA,
CDLB and CDMA
Removing
– Carefully pull off engine cover panel -arrows-. Do not jerk the
cover panel away, and do not try to pull on one side only.
Installing
– Press engine cover panel back carefully into its retainers.

ment - engines with code letters CDLA,
CDLB and CDMA
Removing
– Detach air intake hose -1- at air mass meter -G70- .
– Detach air cleaner housing (top section) -arrows- and take out
air filter element.
Installing
Note
is calculated.
pressed air.

Audi TT 2007 ➤
centred in the retainer in the air cleaner housing (bottom sec‐
tion).
♦ Tightening torque: refer to air cleaner - exploded view
⇒ page 23

housing - engines with code letters
CDLA, CDLB and CDMA
Removing
– Unscrew air cleaner housing (lower section) -arrows-.

Installing
Note

pressed air.
Audi TT 2007 ➤
♦ Tightening torque: refer to air cleaner - exploded view
⇒ page 23

-G70- - engines with code letters CDLA,
CDLB and CDMA
Removing
Note
Disregard arrows.
– Loosen hose clip -1- and detach air intake hose.

Audi TT 2007 ➤

– Then carefully pull air mass meter -G70- out of guide on air
cleaner housing (top section).
Installing
Note
♦ Renew O-ring.
is calculated.
♦ Use silicone-free lubricant when fitting air intake hose.
Audi TT 2007 ➤
1 - Screw for intake air temper‐

ature sender -G42-
❑ 5 Nm
2 - Intake air temperature
sender -G42-
3 - Intake manifold
⇒ page 31
enoid valve 1 -N80-
5 - Bolt for single-plunger high-
pressure pump
❑ 3x
❑ 10 Nm
valve -N276-
7 - Mechanical single-plunger
high-pressure pump
❑ With fuel pressure regu‐
lating valve -N276- and
fuel pressure sender,
low pressure -G410-
❑ An electric fuel pump
(fitted in fuel tank) sup‐
plies fuel to the mechan‐
ical high-pressure pump
at a pressure of approx.
6 bar.
❑ When installing the
high-pressure fuel
pump, it is essential to
ensure that no dirt en‐
ters the fuel system.
❑ The fuel system must
not be under pressure; procedure for reducing fuel pressure ⇒ page 4
❑ Fuel pipes must be free of tension when installed.
8 - Connection for fuel return pipe to fuel tank
❑ Fuel pipe must be free of tension when installed (make sure all parts are clean)
9 - Fuel supply pipe to fuel rail
❑ Renew connecting piece
❑ Tighten connecting piece to 30 Nm
❑ Fuel line must be free of tension when installed (make sure all parts are clean); tightening torque: 27 Nm
10 - Intake manifold flap motor -V157- with intake manifold flapauthorised
permitted unless potentiometer
by AUDI AG.-G336-
❑ After the fuel rail has been renewed, intake manifold flap potentiometer -G336- must be adapted to the
engine control unit with the vehicle diagnostic and service information system -VAS 5052- , “Guided
Functions”
11 - Bolt for intake manifold flap motor -V157- with intake manifold flap potentiometer -G336-
❑ 7 Nm

Audi TT 2007 ➤
12 - Intake manifold support

13 - Bolt for intake manifold support
❑ 23 Nm
15 - Bolt for throttle valve module -J338-
❑ 4x
❑ 7 Nm
16 - Securing nut for intake manifold support
❑ 10 Nm
17 - Seal
❑ Renew
18 - Fuel rail
❑ 20 Nm
Audi TT 2007 ➤
2.12 Fuel rail - exploded view
1 - Radial compensation ele‐

ment
2 - Injector
❑ With combustion cham‐
ber ring seal (teflon ring
seal): always renew
❑ Renew O-rings
❑ Ensure correct installa‐
tion position.
⇒ page 44
3 - Support ring
4 - Fuel rail
⇒ page 31
5 - Fuel pressure sender -
G247-
❑ 22 Nm
❑ Tighten connecting
piece to 30 Nm
low pressure -G410-
valve -N276-
8 - Mechanical single-plunger
high-pressure pump Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

lating valve -N276- and
fuel pressure sender,
low pressure -G410-
plies fuel to the mechanical high-pressure pump at a pressure of approx. 6 bar.
❑ When installing the high-pressure fuel pump, it is essential to ensure that no dirt enters the fuel system.
❑ The fuel system must not be under pressure when installing the high-pressure pump; procedure for
reducing fuel pressure ⇒ page 4
11 - Intake air temperature sender 2 -G299-
❑ 5 Nm
12 - Bolts for intake manifold
❑ 9 Nm

Audi TT 2007 ➤

with fuel rail
After the fuel rail has been renewed, intake manifold flap poten‐
tiometer -G336- must be adapted to the engine control unit -
J623- , see vehicle diagnostic and service information system -
VAS 5052- , “Guided Functions”
Note
♦ The injectors can only be accessed after removal of the intake

manifold and fuel rail with air flow control flap. (Additional or
fewer steps may be required depending on the model.)
♦ The combustion chamber (teflon) ring seal and the O-ring
must always be renewed.
♦ Intake manifold - exploded view ⇒ page 28
♦ Fuel rail - exploded view ⇒ page 30
Removing
– Remove engine cover panel.
WARNING

⇒ page 4 .
– Unplug all electrical connectors as necessary.

– Disconnect vacuum hose between intake manifold and vac‐
uum pump at intake manifold.
Note
♦ This vacuum hose and the vacuum pump (located at rear of

cylinder head) are only fitted on vehicles with automatic gear‐
box.
♦ Ignore items marked 1 and 2 in illustration.
– Disconnect hose connections -arrows- at cylinder head cover.
Audi TT 2007 ➤
– Disconnect vacuum line -2- leading to activated charcoal filter.
– Disconnect fuel supply pipe -arrow-.
Note
The fuel system must not be under pressure.
– Open both fuel pipe connections -2 and 3- at high-pressure

pump.

Audi TT 2007 ➤

Step required only for engines with code letters CDLA, CDLB and
CDMA

ted).
All engine codes
– Loosen hose clip -2- and detach air pipe from throttle valve
module -J338- .
Note
– Unplug electrical connector -1- at intake air temperature send‐

er -G42- .
Note
Ignore -arrow-.
Audi TT 2007 ➤

2 - For injectors (remove electrical connectors from bracket)
3 - For activated charcoal filter solenoid valve 1 -N80-
4 - Intake manifold flap motor -V157-
5 - For fuel pressure sender -G247- and Hall sender -G40- (re‐
move electrical connectors from bracket)

J338- .
– Unscrew nut -2- and bolt -1- and remove support for intake
manifold.
– Unplug electrical connector -1- at fuel pressure sender -

G247- .
– Unscrew all bolts from intake manifold.
– Carefully pull intake manifold and fuel rail off cylinder head.
Note
The injectors can remain in the fuel rail.
– Removing and installing fuel rail ⇒ page 35

Installing
– Install in reverse order.
♦ Tightening torques: refer to intake manifold - exploded view
⇒ page 28
♦ Tightening torques: refer to fuel rail - exploded view
⇒ page 30

Audi TT 2007 ➤
2.13.1 Removing and installing fuel rail

If the fuel rail has been renewed, intake manifold flap potentiom‐
eter -G336- must be adapted to the engine control unit -J623- ,
see vehicle diagnostic and service information system -VAS
Note
Intake manifold must be removed; removing intake manifold

⇒ page 31 .
– Remove hoses from activated charcoal filter.

– To do this, unfasten hose clip -1-.
– Unscrew two bolts -arrows- on fuel rail.
– Detach hose connection -1- from intake manifold and unscrew
two bolts -arrows-.
– Disconnect fuel pipes -2 and 3-.

– Carefully pry off linkage from intake manifold flap motor -V157-
-4-.
– Unbolt intake manifold flap motor -V157- -5-.
Audi TT 2007 ➤
– Pry fuel rail over retaining lugs -arrows- on intake manifold.

– Pull fuel rail off intake manifold.
Installing
– Installing intake manifold ⇒ page 31

sender -G247-
♦ Double hexagon socket, 27 mm -VAS 5301/7-
Removing:

⇒ page 4 .

Audi TT 2007 ➤
– Detach coolant pipe and dipstick guide tube from intake mani‐
fold -arrows- and pull dipstick guide tube upwards off engine.
– Release connector on fuel pressure sender -G247- using as‐
sembly tool -T10118- .
– Unscrew fuel pressure sender -G247- using double hexagon

socket, 27 mm -VAS 5301/7- .
Installing:
– Make sure that connecting piece is tightened to specified tor‐
que “30 Nm” before installing fuel pressure sender -G247- .
♦ Tightening torque for fuel pressure sender -G247- , refer to
fuel rail - exploded view ⇒ page 30 .

up to high-pressure pump
Note
♦ Control unit for electric fuel pump OK.

♦ Fuel pump OK.
♦ Fuel filter OK Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Battery voltage at least 11 Volt with respect to the correctness of information in this document. Copyright by AUDI AG.
– Connect vehicle diagnosis and service information system -
VAS 5052- and select engine control unit.
– With ignition on, the fuel pressure (low pressure) is indicated
in display zone 1.
Note
When the ignition is switched off and on, the control unit for the
electric fuel pump -J538- will activate the fuel pump for several
seconds.
– Measure the fuel pressure (low pressure).

♦ Specification: approx. 6 bar (5 ... 7 bar)
Audi TT 2007 ➤
– If reading does not match specification, check delivery rate of

electric fuel pump ⇒ Rep. Gr. 20 .
– Check fuel pressure and residual pressure using K-Jetronic
pressure tester -V.A.G 1318- ⇒ page 38 .
2.16 Checking fuel pressure and residual pressure (up to high-pressure pump)

equipment required
♦ K-Jetronic pressure tester -
V.A.G 1318-
♦ Adapter -V.A.G 1318/17-1- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
from adapter set -V.A.G with respect to the correctness of information in this document. Copyright by AUDI AG.
1318/17-
♦ Connector -V.A.G 1318/23-
1348/3 A- with adapter ca‐
ble -V.A.G 1348/3-3-
V.A.G 1594 C- or -V.A.G
1594 A-
♦ Fuel-resistant measuring
container
Test conditions
• Fuel filter OK
• Fuel pump control unit -J538- OK (check)
• Ignition off.

Audi TT 2007 ➤
Test sequence
– Remove rear seat ⇒ General body repairs, interior; Rep. Gr.
72 .
– Unclip the retaining tabs -arrows- for the flange cover.
– Connect remote control -V.A.G 1348/3 A- with adapter cable

-V.A.G 1348/3-3- to contact -1- using a test lead from auxiliary
measuring set -V.A.G 1594 C- .
– Tape off 2nd connector contact of the adapter cable -
V.A.G 1348/3-3- with insulating tape -arrow- to prevent short
circuits.
auxiliary measuring set -V.A.G 1594 C- .
– Connect crocodile clamp to positive (+) terminal of battery.
WARNING
Fuel system is pressurised (low pressure). Wear safety gog‐

gles and protective clothing to avoid possible injury and skin
contact. Before opening the fuel system, wrap a cloth around
the connection. Then dissipate residual pressure by carefully
detaching the connection.
– Disconnect fuel supply pipe -arrow-.
Audi TT 2007 ➤
– Screw connector -V.A.G 1318/23- and adapter -

V.A.G 1318/17-1- onto K-Jetronic tester -V.A.G 1318- .
– Fit adapter -V.A.G 1318/17-1- onto the disconnected fuel sup‐
ply pipe.
1318- .
– Attach test hose -arrow- and hold end of hose in measuring
container.
– Open cut-off valve on K-Jetronic pressure tester -V.A.G
1318- . Lever must point in direction of flow.
– Bleed fuel system by pressing remote control button briefly.
– Close cut-off valve on K-Jetronic pressure tester -V.A.G

1318- . Lever is at right angle to direction of flow -arrow-.
– Press and hold remote control switch until K-Jetronic pressure
tester -V.A.G 1318- shows no further increase in pressure.
• Specification: approx. 6 bar (4 ...8 bar)
– Check delivery rate of fuel pump ⇒ Fuel supply system, petrol
engines; Rep. Gr. 20 .
– Check leak-tightness and residual pressure by watching the
drop in pressure on the K-Jetronic pressure tester -V.A.G
1318- .
• After 10 minutes pressure should still be at least 3 bar.
and fuel supply line for leaks.
♦ Renew fuel filter with integrated fuel pressure regulator ⇒ Fuel
supply system, petrol engines; Rep. Gr. 20 . Then repeat the
test.
♦ If fuel filter is OK, renew fuel pump ⇒ Fuel supply system,
petrol engines; Rep. Gr. 20 .
Assembly is carried out in the reverse order; note the following:
– The ignition must be switched off.
Note
Before removing the pressure tester, release the fuel permitted
pressure byauthorised by AUDI AG. AUDI AG does not guarantee or accept any liability
unless
opening the cut-off valve. Hold auxiliary hose in a container.
– Re-attach fuel supply line (make sure that all parts are clean
and that there are no leaks).

Audi TT 2007 ➤
WARNING
Fuel system operates under high pressure. Always dissipate

fuel pressure prior to opening fuel system. For procedure, refer
to ⇒ page 4
1 - Air guide plates

❑ Removable
❑ Check for damage and
correct fitting
2 - Sleeve
❑ May remain lodged in
cylinder head when
high-pressure pump is
removed; it can be re‐
moved
3 - O-ring
4 - Mechanical single-plunger with respect to the correctness of information in this document. Copyright by AUDI AG.
high-pressure pump
at a pressure of approx.
6 bar.
high-pressure fuel
not be under pressure;
procedure for reducing
fuel pressure ⇒ page 4
❑ Fuel pipes must be free
of tension when instal‐
led.
⇒ page 42
valve -N276-
6 - Fuel pressure sender for low pressure -G410-
❑ 15 Nm
7 - Securing bolts for high-pressure pump
❑ 10 Nm
8 - Connecting piece for fuel return pipe to fuel tank
❑ It is important to leave the old seal in the pump when replacing the threaded connection. When it is first
installed at the supplier it becomes crushed and cannot be removed. For this reason, the threaded con‐
nection has a deformable sealing lip.
9 - Connecting piece for fuel supply pipe to fuel rail
❑ Renew connecting piece
Audi TT 2007 ➤
❑ Tighten connecting piece to 30 Nm

❑ Union nut on fuel supply line must be free of tension when installed (make sure all parts are clean);
tightening torque: 27 Nm
10 - Bore in cylinder head for high-pressure pump
11 - Injectors
❑ Renew O-rings
❑ Ensure correct installation position.

pump
WARNING

to ⇒ page 4
If the battery is not disconnected, the fuse -SF 6- for the fuel pump
control unit -J538- must be removed as a precautionary measure
before opening the fuel system, because the fuel pump will oth‐
erwise be activated by the contact switch on the driver's door.
Note

ment (right-side).
♦ Removing fuse -SF 6- will interrupt the voltage supply “termi‐
Note
♦ The high-pressure fuel pump should only be removed and in‐

stalled when the engine is cold.
♦ Use a cloth to catch escaping fuel.
♦ The O-ring must always be renewed.
♦ Banjo bolt for fuel return line must always be renewed.
♦ Always ensure that the high-pressure fuel pipes are free of
tension when tightening the connections.
Removing

Audi TT 2007 ➤
– Detach electrical connectors from fuel pressure sender (low

pressure) -G410- -1- and fuel pressure regulating valve -
N276- -2-.
– Disconnect fuel pipes -2 and 3-.
– Remove 3 bolts -arrows-.

– Carefully pull out high-pressure fuel pump. It is possible that
the sleeve may remain lodged in the cylinder head.
Installing
– Renew O-ring for high-pressure pump.
– Carefully fit high-pressure pump and sleeve in cylinder head
bore (check sleeve for damage first).
– Tighten bolts hand-tight.
– Make sure that connecting pieces on high-pressure pump are
tightened to specified torque before installing fuel lines.

♦ Tightening torque for connecting piece for fuel return line, refer
to high-pressure pump - exploded view ⇒ page 41
♦ Tightening torque for connecting piece for fuel supply line, re‐
fer to high-pressure pump - exploded view ⇒ page 41
– Now tighten bolts to specified torque (it is important to tighten
them alternately).
♦ Tightening torque: refer to exploded view of high-pressure
pump ⇒ page 41 .
– Firmly fit hose for fuel return line onto connection (use hose
clip). Align so that parts are free of tension.
– Tighten union nut on fuel supply line hand-tight. Align so that
parts are free of tension.
♦ Tightening torque for fuel supply line (union nut), refer to high-
pressure pump - exploded view ⇒ page 41 .
Audi TT 2007 ➤
– Reattach electrical connectors for fuel pressure sender (low

pressure) -G410- and fuel pressure regulating valve -N276- .
– Put back fuse if it has been removed.
Note

Remove intake manifold and fuel rail ⇒ page 31 .
Removing injectors (from fuel rail)
Carefully pull injectors out of fuel rail.
Removing injectors (from cylinder head)
♦ Tool kit with puller -T10133-
Note
Special tool T10133/2 (puller) has been modified and now has the
designation puller T10133/2 A . If you have not yet received the
new tool you can make the modification yourself.
Modifying special tool T10133/2 (puller) to make it equivalent to

puller T10133/2 A
♦ Round file, approx. 6 mm
– File out a semi-circular recess as shown in the illustration. The
recess allows the tool to be pushed further onto the injector so
the contact surface is increased.

Audi TT 2007 ➤
– For identification purposes, mark the modified tool with the

letter “A” after the tool number.
Illustration shows injector assembly:

1 - Radial compensation element, renew if damaged
2 - Combustion chamber ring seal (teflon ring seal) - renew; when
fitting, do not grease ring or use any other lubricant
3 - Groove on injector
4 - Spacer ring (renew if damaged)
5 - O-ring (renew; apply thin coating of clean engine oil prior to
installation)
6 - Support ring (via this support ring, fuel rail exerts force which
secures injector in cylinder head)
Note
The radial compensation element -1- is clipped into the support

ring -6- with the injector fitted. To remove the injector, the support
ring must be removed from the injector so that the puller -
T10133/2- can be inserted into the groove on the injector -3-.
– Cover open inlet ports with a clean cloth.

– Unplug electrical connector at injector that is to be removed.
– Use a screwdriver to bend retainer tabs of radial compensation

element to side, and pull support ring off injector.
Audi TT 2007 ➤

– Then attach removal tool -T10133/16- and pull out injector by
turning bolt -1-.
Note
The combustion chamber ring seal must always be renewed prior

to reinstalling the high-pressure injector ⇒ page 46 .
2.19.1 Renewing combustion chamber ring

seal (teflon ring seal)
Note

to reinstalling the high-pressure injector.
Illustration shows injector assembly:

1 - Radial compensation element, renew if damaged
3 - Groove on injector
installation)
6 - Support ring (via this support ring, fuelunless
permitted railauthorised
exerts by force
AUDI which
secures injector in cylinder head) with respect to the correctness of information in this document. Copyright by AUDI AG.
– Carefully remove old teflon ring using suitable tools (e.g. cut
open ring using razor blade, or prise open ring with small
screwdriver and then pull off forwards). It is important to en‐
sure that the groove and the continuous ridge in the bottom of
the groove are not damaged.
Note
The injector must be renewed if the groove is damaged.
– Before new teflon ring is fitted, any combustion residue must

be removed from ring groove and injector stem using a clean
cloth.
Note
The illustration shows an injector with “offset connector”. This can

be ignored since it is not relevant when replacing the combustion
chamber ring seal.

Audi TT 2007 ➤
– Fit the assembly cone -T10133/5- with new teflon seal -1- onto
the injector -2-.
– Use assembly sleeve -T10133/6- to press teflon ring seal fur‐

ther onto assembly cone -T10133/5- until it seats in groove.
Do not use any lubricants during this procedure.
Note
The teflon ring is widened as it is pushed onto the injector. The

teflon ring must therefore be compressed again after it has been
fitted. This is done in two steps. The procedure is described be‐
low.
Step 1 of teflon ring seal calibration permitted
(adaption)unless is done by
authorised with
AUDIcali‐
bration sleeve -T10133/7- . with respect to the correctness of information in this document. Copyright by AUDI AG.
– Slide calibration sleeve -T10133/7- onto injector as far as the

stop by pressing lightly and turning approx. 180°. Pull calibra‐
tion sleeve -T10133/7- off again by turning it in the opposite
direction.
Step 2 of teflon ring seal calibration (adaption) is done with cali‐
bration sleeve -T10133/8- .
– Slide calibration sleeve -T10133/8- onto injector as far as the

stop by pressing lightly and turning approx. 180°. Pull calibra‐
tion sleeve -T10133/8- off again by turning it in the opposite
direction.
– Fit new O-ring on injector. Lubricate O-ring lightly with clean
engine oil before installing.
– The teflon ring must not be lubricated.
Audi TT 2007 ➤
– Use supplied nylon brush -T10133/4- to thoroughly clean

holes for injectors in cylinder head prior to installing injectors.
Note
An open inlet valve may prevent cleaning. If so, the engine must
be cranked by hand by rotating the crankshaft with a spanner.
– Refit support ring -1- on injector and clip radial compensation

element -2- onto support ring.
Note
♦ The teflon seal on the injector must not be oiled or greased.

♦ Make sure there is no cleaning fluid or oil in the cylinder head
bores when installing the injectors.
– Use assembly tool -T10133/9- to push injector as far as it will

go into hole in cylinder head. Ensure that the injector is prop‐
erly seated in the cylinder head.
– The remaining installation steps are carried out in the reverse
sequence.
Important: the following points must always be observed:
• The teflon seal on the injector must not be oiled or greased.
• Make sure there is no cleaning fluid or oil in the cylinder head
• Coat O-rings of high-pressure injectors with clean engine oil
to facilitate insertion into fuel rail.
• Renew all seals.
• Fuel rail must be positioned on injectors and pressed in evenly.
• Install intake manifold with fuel rail ⇒ page 31 .
2.20 Cleaning injectors

Note
Observe safety precautions and operating instructions for ultra‐

sonic unit.
– Fill up ultrasonic unit with cleaning agent supplied.


Audi TT 2007 ➤
Note
Ultrasonic unit must be filled with cleaning agent up to top edge

of apertures (see detail in illustration).
– Insert injectors -1- in retainer provided -2- as far as stop.
– Immerse injectors together with retainer into cleaning agent.

– Set rotary knob -4- to a temperature of 50°C.
– Select a cleaning time of 30 minutes with rotary knob -5-.
– Switch on ultrasonic unit with button -3-.
Note
The time set starts to elapse as soon as a cleaning temperature

of 50°C is reached.
permitted– unless
After cleaning,
authorised by AUDIalways
AG. AUDIrenew
AG does combustion chamber
not guarantee or accept ring
any liability seal
(teflon ring seal) for each injector ⇒ page 46 .
– Then re-install injectors ⇒ page 44 .

flap motor -V157- with intake manifold
flap potentiometer -G336- - engines with
code letters BWA and BPY
For fitting location of intake manifold flap motor -V157- , refer to
exploded view of intake manifold ⇒ page 28 .
♦ Standard 1/4 inch ratchet
♦ Torx insert 30
Removing
Audi TT 2007 ➤
– Detach vacuum lines -arrows-.
– Remove bracket -arrow- for wiring harness

– Unplug electrical connectors connected to wiring harness and
move wiring harness as far as necessary to one side.
Note
The nut marked with the arrow on the left only has to loosened
far enough to allow the bracket to be pivoted to the side.
-4-.
Note
The illustration shows the intake manifold flap motor -V157- with
the intake manifold removed.
Installing
♦ Tightening torque: refer to intake manifold - exploded view
⇒ page 28

flap motor -V157- with intake manifold
flap potentiometer -G336- - engines with
code letters CDLA, CDLB and CDMA
For fitting location of intake manifold flap motor -V157- , refer to
exploded view of intake manifold ⇒ page 28 .

Audi TT 2007 ➤

♦ Standard 1/4 inch ratchet
♦ Torx insert 30
Removing
– Detach vacuum lines -arrows-.
– Unplug electrical connector at turbocharger air recirculation

valve -N249- -1-.
– Release hose clip -3- and detach turbocharger air recirculation
valve -N249- .
Note
Cover opening of intake hose.
– Remove bracket -arrow- for wiring harness

– Unplug electrical connectors connected to wiring harness and
move wiring harness as far as necessary to one side.
– Pull bracket for connectors off coolant pipe.
-4-.
Audi TT 2007 ➤
Note
The illustration shows the intake manifold flap motor -V157- with
the intake manifold removed.
Installing
♦ Tightening torque: refer to intake manifold - exploded view
⇒ page 28

-G39- and Lambda probe heater -Z19-
before catalytic converter
Removing Lambda probe

Lambda probe heater -Z19- .

Audi TT 2007 ➤
– Unscrew Lambda probe -arrow- using tool from Lambda probe

open ring spanner set -3337- -arrow-.
Installing Lambda probe
Note

body.
slots on the probe body. High-temperature paste ⇒ Parts
catalogue
♦ Tightening torque: 55 Nm.

after catalytic converter -G130- and

Lambda probe 1 heater, after catalytic

converter -Z29-
Removing Lambda probe

– Unscrew nuts -1 and 2- from cover.
Audi TT 2007 ➤
– Detach cover and unplug electrical connector -arrow- for

Lambda probe after catalytic converter -G130- and Lambda
probe 1 heater, after catalytic converter -Z29- .
– Unscrew Lambda probe after catalytic converter -G130- and

Lambda probe 1 heater, after catalytic converter -Z29-
-arrow- using a tool from the Lambda probe open ring spanner
set -3337- .
Installing Lambda probe
Note

body.
slots on the probe body. High-temperature paste ⇒ Parts
catalogue
tached at the same locations to prevent
Protected it from
by copyright. coming
Copying for privateinto
♦ Tightening torque: 55 Nm.

Audi TT 2007 ➤

box -V.A.G 1598/42-
♦ Test box -V.A.G 1598/42-

Audi TT 2007 ➤
Note
♦ The test box has 105 contacts. The connecting cable can be
adapter lead -V.A.G 1598/39-1- is connected to connector
adapter lead -V.A.G 1598/39-2- must be connected to con‐
ning). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ The relevant test
withprocedure will state
respect to the correctness whetherin itthisisdocument.
of information necessary
♦ Always use auxiliary measuring set -V.A.G 1594 C- to connect
test equipment (e.g. voltage tester -V.A.G 1527 B- , hand-held
multimeter -V.A.G 1526 C- etc.).
WARNING

The engine control unit has to be removed before multi-pin con‐

nectors can be unplugged from engine control unit ⇒ page 57 .
– Connect test box -V.A.G 1598/42- to wiring harness connec‐
tor. The earth clip on the test box must be connected to the
negative battery terminal. The instructions for performing the
individual tests indicate whether or not the engine control unit
itself also needs to be connected to the test box.
– After installation, the locking plate must be re-fitted on the
control unit.

Audi TT 2007 ➤

– Interrogate and, if necessary, erase fault memory.

♦ Hot air blower -1- from the wiring harness repair set -VAS
1978-
♦ Nozzle attachment -2- from the wiring harness repair set -VAS
1978-
♦ Commercially available vice grip pliers (mole grip) -3-
5051B-
The engine control unit -1- is bolted to the locking plates
-2 and 5-. To make it more difficult to unscrew the shear bolts
-4- for locking plate -2-, their threads have been coated with lock‐
ing fluid.
The protective housing has to be removed before the connectors
can be unplugged from the engine control unit (e.g. to connect
the test box or renew the engine control unit).
Removing
– When renewing engine control unit, select diagnosis object
“Renew engine control unit” in “Guided Functions” ⇒ Vehicle

wiper shafts.

Audi TT 2007 ➤
-2-.
Note
♦ Risk of damage to plenum chamber cover.

♦ Apply a small quantity of soap solution to transition between
windscreen and plenum chamber cover -2-. Then, starting at
edge of windscreen, carefully pull plenum chamber cover up‐
wards off retainer at windscreen.

tition panel.
– Release clips -arrows- and remove engine control unit -J623- .

these bolts, the threads must therefore be heated with the hot-air
blower.

Audi TT 2007 ➤

WARNING
20 ... 30 seconds.

in illustration).
– Unscrew two bolts securing retainers for engine control unit -
J623- .

Audi TT 2007 ➤

connectors.
– Take out old engine control unit -J623- and install new engine
– After installation, the locking plate must be re-fitted on the en‐
The following step must be performed after installing the new en‐
gine control unit:
– Activate engine control unit on vehicle diagnosis and service
information system -VAS 5052- in “Guided Functions” mode,
“J623 - Renew engine control unit, further steps”.

Audi TT 2007 ➤
tions

♦ The engine control unit has a self-diagnosis capability.

Audi TT 2007 ➤

WARNING

erly secured.
secured.
the passenger.
To avoid any risk of injuries to persons and/or damage to the fuel

injection and ignition system, always observe the following safety
precautions.
♦ Do not touch or disconnect ignition wiring when the engine is
leads.
completing the work, interrogate and erase the fault memory.
damaged.

Audi TT 2007 ➤
2.1 Test data

Engine data 2.0 ltr. / turbo FSI engine
Idling speed 640...800 rpm
is not adjustable; controlled by the idling speed
stabilisation
Engine speed limiter (deactivates injectors/closes approx. 6,500 rpm
throttle valve)
Ignition timing is determined by the control unit.
Ignition timing cannot be adjusted. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Ignition system with respect Multi-coil ignition
to the correctness system
of information in thiswith 4 ignition
document. Copyrightcoils (integrated
by AUDI AG.
output stages) connected directly to spark plugs via
spark plug connectors; ignition coils can be pulled out of
cylinder head using puller - T40039 -

❑ Contacts gold-plated
3 - Ignition coil with output
stage -(N70, N127, N291,
N292)-
⇒ page 64
❑ Use puller -T40039- for
removal
4 - Spark plug
❑ 30 Nm
❑ Use spark plug socket
and extension -3122 B-
for removal
let 810
5 - Bolt
❑ 20 Nm
❑ Tightening torque influ‐
ences the function of the
knock sensor
6 - Bolt
❑ 10 Nm
8 - O-ring
❑ Renew O-Ring if dam‐

Audi TT 2007 ➤
aged

with output stages
♦ Puller -T40039-
Removing:
– Unscrew two bolts -1- on connector rail.
– Pull all ignition coils approx. 30 mm out of spark plug

unlessholes
using puller -T40039- . with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi TT 2007 ➤
– Release connectors and unplug all connectors from the igni‐

tion coils at the same time.
Installing:
– Align the ignition coils with the connectors and attach all con‐
nectors onto ignition coils simultaneously.
– Press ignition coils onto spark plugs by hand with uniform
pressure (do not use tool).

Service
Workshop Manual
Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 1.8
ltr., 2.0 ltr. 4-valve turbo with timing chain)
Engine ID
CDA CCZ CCT CES CET
A A A A A
Edition 06.2010

Service
Repair Group


Audi TT 2007 ➤
Direct petrol injection and ignition system (4-cyl. 1.8 ltr., 2.0 ltr. 4-valve turbo with timing chain) - Edition
06.2010
Contents

2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Overviews - fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Overview - fitting locations (engine codes CDAA, CCZA and CCTA) . . . . . . . . . . . . . . . . 8
3.2 Overview - fitting locations (engine codes CESA and CETA) . . . . . . . . . . . . . . . . . . . . . . 19
4 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5 Intake manifold (engine codes CDAA, CCZA and CCTA) . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.2 Fuel rail - exploded view . . . . .Protected . . . . . by
. .copyright.
. . . . . Copying
. . . . . for
. .private
. . . .or.commercial
. . . . . . purposes,
. . . . . .in. part
. . .or.in. whole,
. . . .is. not 37
6 Intake manifold (engine codes CESA and CETA)
with respect . . . .of.information
to the correctness . . . . . .in. this
. . document.
. . . . . by . .AUDI
. . .AG.
. . 39
6.2 Fuel rail - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3 Removing and installing intake manifold with fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.2 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.2 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9.6 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.7 Checking intake manifold change-over function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.8 Checking dual non-return valve of activated charcoal filter solenoid valve 1 N80 . . . . . . 68
10 Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
10.1 Lambda probes - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
10.2 Removing and installing Lambda probe G39 and Lambda probe heater Z19 before catalytic
converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10.3 Removing and installing Lambda probe after catalytic converter G130 and Lambda probe 1
heater after catalytic converter Z29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Contents i
Audi TT 2007 ➤
06.2010

2.1 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.3 Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.4 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
ii Contents
Audi TT 2007 ➤
06.2010

cleanliness

carrying out repairs and fault finding, the event memory must
be interrogated. The vacuum hoses and connections must al‐
so be checked (unmetered air).
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. O-type clips or screw-type clips must not be
used.
damage the Lambda probe.
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
Protected pump is activated
by copyright. for 2or seconds
Copying for private in order
commercial purposes, to or
in part build upispressure
in whole, not
permittedin theauthorised
unless fuel system
by AUDI ⇒ AG.page 2 does
AUDI AG . not guarantee or accept any liability

Audi TT 2007 ➤
06.2010

WARNING

erly secured.
secured.
the passenger.
WARNING

⇒ page 4 .
The connection must be opened immediately after reducing
the pressure; wrap a cloth around the connection and allow the
residual pressure (approx. 6 bar) to dissipate.
Caution


Audi TT 2007 ➤
06.2010
♦ For safety reasons, the battery must be disconnected before

opening the fuel system to prevent the fuel pump from being
activated by the contact switch on the driver's door.
ning.
♦ If engine is to be operated at cranking speed without it starting
(e.g. compression test), unplug connectors from ignition coils
and remove fuse for electric fuel pump.
♦ If the event memory has been erased, you must generate the
♦ If the engine has to be operated at the starting speed without
actually starting (e.g. to test compression pressure), detach
the four connectors from the ignition coils using assembly tool
-T40039- ⇒ page 84 . Also remove fuse for fuel pump control
unit -J538- .
Note

ment (right-side).
♦ Removing the fuse will interrupt the voltage supply “termi‐
nal 30” for the fuel pump control unit -J538- . ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations

start/stop system
WARNING

start/stop system.

tem. When working on the fuel supply/injection system, pay care‐
ful attention to the following basic rules:

Audi TT 2007 ➤
06.2010

opening.
immediately.

opening high-pressure
Protected by copyright. injection
Copying for private or system
Caution
The injection system consists of a high-pressure section (max‐

imum approx. 150 bar) and a low-pressure section (approx. 7
bar).
Prior to opening the high-pressure section (e.g. when removing
the high-pressure pump, fuel rail, injectors, fuel pipes, etc.) the
fuel pressure in the high-pressure section must be reduced.
The procedure is described below.

♦ Specification: between 35 and 45 bar
– The fuse is located in the fuse holder in the luggage compart‐
ment (right-side).

Audi TT 2007 ➤
06.2010
– Remove luggage compartment trim (rear right) ⇒ Rep. Gr.

70 .
– With engine idling, pull out fuse for fuel pump control unit -
J538- ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
– Observe fuel pressure displayed on tester.
fuel by the fuel system pressurisation pump -G6- .
approx. 8 bar.
Note
WARNING
The fuel lines are still filled with fuel, however the fuel is no
longer under high pressure. Wear safety goggles and protec‐
tive clothing when opening the fuel system to avoid possible
injury and skin contact.
Before opening the high-pressure section, wrap a cloth around
the connection.

pair work: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Refit fuse. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Erase event memory and generate readiness code in engine

control unit in “Guided Functions” mode.

Procedure
♦ Cracks

Audi TT 2007 ➤
06.2010

– If an entry is stored in the event memory, check the vacuum
lines leading to the corresponding component and also check
the remaining vacuum lines leading to other components.

Audi TT 2007 ➤
06.2010
2 Technical data
Engine data 1.8 ltr. and 2.0 ltr. turbo FSI engine
Idling speed is not adjustable; con‐ 640 ... 800 rpm
trolled by the idling speed stabili‐
sation
Maximum rpm governed by deac‐ 6500 rpm
tivation of fuel injectors
Fuel Copying
Protected by copyright. pressurefor private or commercial Initial fuel
purposes, pressure
in part or in whole,up to
is not 3.0 to 7.0 bar (identical for all operating
permitted unless authorised by AUDI AG. AUDI AG does high-pressure pump
not guarantee or accept any (gen‐
liability conditions)
with respect to the correctness of information in thiserated
document.by electric
Copyright fuelAG.
by AUDI pump
in fuel tank)
Pressure in high-pressure approx. 40 bar at idling speed
fuel circuit (generated by approx. 150 bar in certain parts of operating
mechanical single-plunger range.
pump) at a coolant temper‐
ature of approx. 85°C.
2. Technical data 7
Audi TT 2007 ➤
06.2010
3 Overviews - fitting locations
3.1 Overview - fitting locations (engine co‐

des CDAA, CCZA and CCTA)
Components A to K are not shown in the overview.

N205-
⇒ page 14
⇒ Rep. Gr. 15
⇒ Rep. Gr. 21
tion valve -N249-
⇒ Rep. Gr. 21
4 - Ignition coils with output Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
stages permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 84
stage -N70-
stage -N127-
stage -N291-
stage -N292-
tion coils from cylinder
head.
❑ Lambda probes - overview ⇒ page 71
❑ Fitting location (engine code CDAA, 1.8 ltr.) ⇒ page 12
❑ Fitting location (engine codes CCZA and CCTA, 2.0 ltr.) ⇒ page 12

Audi TT 2007 ➤
06.2010

❑ Fitting location (engine code CDAA, 1.8 ltr.) ⇒ page 12
❑ Fitting location (engine codes CCZA and CCTA, 2.0 ltr.) ⇒ page 12
9 - Electrical connector for Lambda probe -G39- and Lambda probe heater -Z19-
10 - Air mass meter -G70- and intake air temperature sender 2 -G299-
11 - Radiator outlet coolant temperature sender
Protected-G83-
❑ Fitting location ⇒ page 16 with respect to the correctness of information in this document. Copyright by AUDI AG.
12 - Vacuum unit for air flow control flaps (intake manifold flaps)
❑ 4.5 Nm
❑ From knock sensor 1 -G61- , fitting location ⇒ page 15
❑ From Hall sender -G40- , fitting location ⇒ page 15
❑ For injectors, fitting location ⇒ page 15
❑ After throttle valve module -J338- has been renewed, it must be re-adapted to engine control unit -J623- ,
see vehicle diagnostic, testing and information system -VAS 5051B-
❑ 20 Nm
❑ 27 Nm
24 - Valve for oil pressure control -N428-
3. Overviews - fitting locations 9

Audi TT 2007 ➤
06.2010
25 - Oil pressure switch

❑ Oil pressure switch for reduced oil pressure -F378-
❑ Oil pressure switch -F22-
A - Diagnostic connector
❑ In driver's knee restraint
E - Accelerator position sender -G79- and accelerator position sender 2 -G185-
G - Injectors
❑ Injector, cylinder
Protected 1 -N30-
❑ Injector, cylinder 2authorised
permitted unless -N31- by AUDI AG. AUDI AG does not guarantee or accept any liability
H - Continued coolant circulation pump -V51-
I - Lambda probe after catalytic converter -G130- and Lambda probe heater 1 after catalytic converter -Z29-
J - Electrical connector for Lambda probe after catalytic converter -G130- and Lambda probe 1 heater after
catalytic converter -Z29-
K - Relay and fuse holder in electronics box

Audi TT 2007 ➤
06.2010
Engine control unit -J623-

er 2 -G185-
Fuel pumptocontrol
with respect unitof-J538-
the correctness -2-in this document. Copyright by AUDI AG.
information


Audi TT 2007 ➤
06.2010


High-pressure pump -2-

Note
Illustration shows pump of engine code CDAA, 1.8 ltr.
High-pressure pump -2-

Note
Illustration shows pump of engine codes CCZA and CCTA, 2.0

ltr.

Audi TT 2007 ➤
06.2010
Activated charcoal filter solenoid valve 1 -N80- -1-
Fitting location of knock sensor 1 -G61- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1- Electrical connector for knock sensor 1 -G61-


Fitting location: below intake manifold and coolant pump
Intake manifold flap valve -N316- -2-

Note
Intake manifold flaps are the same as air flow control flaps.
Fuel pressure sender -G247- -1-


Audi TT 2007 ➤
06.2010
Intake manifold flap potentiometer -G336- -1-
Oil pressure switch

1 - Oil pressure switch for reduced oil pressure -F378-
2 - Electrical connector for oil pressure switch for reduced oil
pressure -F378-
4 - Electrical connector for oil pressure switch -F22-
Valve for oil pressure control -N428- -3-
Camshaft control valve 1 -N205- -arrow-


Audi TT 2007 ➤
06.2010
Engine speed sender -G28- -1-
1 - From Hall sender -G40- and intake manifold flap potentiometer
-G336-
2 - From knock sensor 1 -G61-

Fitting location: below intake manifold in coolant pump

Audi TT 2007 ➤
06.2010
Charge pressure sender -G31- -2-

Note
♦ The radiator fan control unit -J293- is integrated into the radi‐
ator fan -V7- .
♦ The fan shown in the illustration on the left is the radiator fan
-V7- .
♦ The fan shown in the illustration on the right is the radiator fan
on right of radiator -V35- .
Electrical connector
1- For Lambda probe -G39- and Lambda probe heater -Z19-

Audi TT 2007 ➤
06.2010
Fitting location of Lambda probe

1- Lambda probe -G39- and Lambda probe heater -Z19-
Electrical connector (behind cover) for Lambda probe after cata‐

lytic converter -G130- and Lambda probe 1 heater after catalytic
converter -Z29-

Note
The arrow in the illustration points in the direction of travel.
Components on turbocharger
2 - Tighten charge pressureProtected
controlby solenoid valve
copyright. Copying for-N75-
private orto 3 Nm purposes, in part or in whole, is not
commercial
3 - Tighten turbocharger air recirculation
with respect to thevalve -N249-
correctness to 7 Nm

Audi TT 2007 ➤
06.2010
Pay attention to installation position of turbocharger air recircula‐

tion valve -N249-


Audi TT 2007 ➤
06.2010
3.2 Overview - fitting locations (engine codes CESA and CETA)

N205-
⇒ page 25
⇒ Rep. Gr. 15
2 -permitted
Charge pressure
unless control
solenoid valve
with respect -N75-

⇒ Rep. Gr. 21
tion valve -N249-
⇒ Rep. Gr. 21
4 - Actuators for camshaft ad‐
justment
❑ Actuator 1 for camshaft
adjustment -F366-
adjustment -F367-
adjustment -F368-
adjustment -F369-
adjustment -F370-
adjustment -F371-
adjustment -F372-
❑ Actuator 8 for camshaft adjustment -F373-
5 - Ignition coils with output stages
❑ Puller -T40039- is required for removing ignition coils from cylinder head.

Audi TT 2007 ➤
06.2010
10 - Electrical connector for Lambda probe -G39- and Lambda probe heater -Z19-
with respect ⇒ page of
to the correctness 24information in this document. Copyright by AUDI AG.
❑ 4.5 Nm
❑ From knock sensor 1 -G61- , fitting location ⇒ page 27
❑ From Hall sender -G40- , fitting location ⇒ page 27
❑ For injectors, fitting location ⇒ page 15
❑ After throttle valve module -J338- has been renewed, it must be re-adapted to engine control unit -J623-
using a vehicle diagnostic tester
❑ 20 Nm
❑ 27 Nm
24 - Intake manifold pressure sender -G71-
25 - Oil pressure switch
❑ Oil pressure switch for reduced oil pressure -F378-

Audi TT 2007 ➤
06.2010
❑ Oil pressure switch -F22-

27 - Valve for oil pressure control -N428-
A - Diagnostic connector
❑ In driver's knee restraint
E - Accelerator position sender -G79- and accelerator position sender 2 -G185-
G - Injectors

H - Continued coolant circulation pump -V51-
I - Exhaust flap 1 valve -N321-
J - Lambda probe after catalytic converter -G130- and Lambda probe heater 1 after catalytic converter -Z29-
K - Electrical connector for Lambda probe after catalytic converter -G130- and Lambda probe 1 heater after
catalytic converter -Z29-

Audi TT 2007 ➤
06.2010
Engine control unit -J623-

er 2 -G185-
Fuel pump control unit -J538- -2-


Audi TT 2007 ➤
06.2010


High-pressure pump
Activated charcoal filter solenoidpermitted
valveunless
1 -N80- -1- by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised

Audi TT 2007 ➤
06.2010

1- Electrical connector for knock sensor 1 -G61-
Fitting location: below intake manifold and coolant pump
Intake manifold flap valve -N316-

Note
Intake manifold flaps are the same as air flow control flaps.
Intake manifold pressure sender -G71- -1- and fuel pressure

sender -G247- -2-
1- Intake manifold pressure sender -G71-
2- Fuel pressure sender -G247-
Intake manifold pressure sender -G71- -1-

Audi TT 2007 ➤
06.2010
Intake manifold flap potentiometer -G336- -1-
Oil pressure switch

1 - Oil pressure switch for reduced oil pressure -F378-
2 - Electrical connector for oil pressure switch for reduced oil
pressure -F378-
4 - Electrical connector for oil pressure switch -F22-
Valve for oil pressure control -N428- -3-
Camshaft control valve 1 -N205- -arrow-

Audi TT 2007 ➤
06.2010
Ignition coils
1 - Ignition coil 1 with output stage -N70-
5 - Actuator 2 for camshaft adjustment -F367- (for cylinder No. 1)
10 - Actuator 5 for camshaft adjustment -F370- (for cylinder No.
3)
4)
4)
Engine speed sender -G28- -1-

Audi TT 2007 ➤
06.2010
1 - From Hall sender -G40- and intake manifold flap potentiometer
-G336-
2 - From knock sensor 1 -G61-

Fitting location: below intake manifold in coolant pump
Charge pressure sender -G31- -2-

Audi TT 2007 ➤
06.2010

Note
♦ The radiator fan control unit -J293- is integrated into the radi‐
ator fan -V7- .
♦ The fan shown in the illustration on the left is the radiator fan
-V7- .
♦ The fan shown in the illustration on the right is the radiator fan
on right of radiator -V35- .
Electrical connector Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1- For Lambda probe -G39- and Lambda probe heater -Z19-to the correctness of information in this document. Copyright by AUDI AG.
with respect

1- Lambda probe -G39- and Lambda probe heater -Z19-
Electrical connector (behind cover) for Lambda probe after cata‐

lytic converter -G130- and Lambda probe 1 heater after catalytic
converter -Z29-

Audi TT 2007 ➤
06.2010

Note
Components on turbocharger
3 - Tighten turbocharger air recirculation valve -N249- to 7 Nm
Pay attention to installation position of turbocharger air recircula‐

tion valve -N249-


Audi TT 2007 ➤
06.2010
Exhaust flap 1 valve -N321- -1-

Audi TT 2007 ➤
06.2010
4 Air cleaner
2 - Air hose
❑ To turbocharger
❑ Check air intake hose
for dirt and leaves
❑ 1.5 Nm
⇒ page 65
4 - Bolts Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For air cleaner (top sec‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
tion)
❑ 1.5 Nm
5 - Bolts
tion)
❑ 1.5 Nm
❑ Clean any salt residue,
leaves and dirt out of air
cleaner (top section)
7 - Filter element
⇒ page 32
Booklet 810
8 - Bolt
section)
9 - Snow screen
❑ Not installed in all vehicles
❑ Clean any salt residue, leaves and dirt out of air cleaner (bottom section)
❑ Clean connection
❑ Clean water drain hose
13 - Flutter valve
❑ To lock carrier
4. Air cleaner 31
Audi TT 2007 ➤
06.2010
❑ Clean any leaves and dirt out of intake air duct

panel
Removing
– Carefully pull off engine cover panel. Do not jerk the cover
panel away, and do not try to pull on one side only.
Installing
– Press engine cover panel back carefully into its retainers.

ment
Removing
Note
Disregard items 1 to 3.
Installing
Note

♦ The air cleaner housing must be clean.
pressed air.
– Check for dirt in air intake hose from air duct.

Audi TT 2007 ➤
06.2010
Note

quence.

housing
Removing
– Remove air duct leading from lock carrier to air cleaner hous‐
ing -2 and 3-.
– Slacken bolt -1-.

– Carefully lift air cleaner (bottom section).
Installing
4. Air cleaner 33
Audi TT 2007 ➤
06.2010
Note

hose.
quence.

Audi TT 2007 ➤
06.2010
5 Intake manifold (engine codes

CDAA, CCZA and CCTA)

ature sender -G42-
❑ 5 Nm
sender -G42-
enoid valve 1 -N80-
❑ With dual non-return
valve; checking
⇒ page 68
4 - Intake manifold
⇒ page 42
5 - Vacuum unit for air flow
control flaps (intake manifold
flaps)
6 - Bolts for high-pressure
pump Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 10 Nm (engine code permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
CDAA, 1.8 ltr.) with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 20 Nm (engine codes
CCZA and CCTA, 2.0
ltr.)
7 - Connecting piece for fuel
supply pipe
❑ From fuel tank
valve -N276-
lating valve -N276-
(fitted in fuel tank) supplies fuel to the mechanical high-pressure pump
❑ When installing the high-pressure fuel pump, it is essential to ensure that no dirt enters the fuel system.
10 - Roller tappet
❑ May remain lodged in exhauster pump when high-pressure pump is removed; it can be taken out
❑ Renew
❑ 25 Nm
12 - High-pressure fuel pipe
5. Intake manifold (engine codes CDAA, CCZA and CCTA) 35

Audi TT 2007 ➤
06.2010
❑ 20 Nm
14 - Injectors
❑ Renew O-ring and teflon ring
❑ 20 Nm
❑ 10 Nm
18 - Bolts for throttle valve module -J338-
❑ 5 Nm
20 - Seal
❑ Renew

Audi TT 2007 ➤
06.2010
1 - Injector
seal): always renew
❑ Renew O-rings
tion position.
⇒ page 53
2 - Support ring
3 - Fuel rail
⇒ page 42
❑ Tighten to 8 Nm
lating valve -N276-
high-pressure fuel
not be under pressure
when installing the high-
pressure pump; proce‐
dure for reducing fuel
pressure ⇒ page 4
of tension when with instal‐
led.
5 - Roller tappet
7 - Bolts for high-pressure pump
❑ 10 Nm (engine code CDAA, 1.8 ltr.)
❑ 20 Nm (engine codes CCZA and CCTA, 2.0 ltr.)
8 - Connecting piece for fuel supply pipe
❑ Renew
❑ 25 Nm
9 - Union nut for fuel supply pipe
❑ 20 Nm
10 - Air flow control flaps (intake manifold flaps)
11 - Gasket
❑ Renew
5. Intake manifold (engine codes CDAA, CCZA and CCTA) 37

Audi TT 2007 ➤
06.2010
13 - Vacuum unit for air flow control flaps (port separator plates)
❑ 7 Nm
15 - Bolts for intake manifold
❑ 9 Nm
❑ Intake manifold flap potentiometer -G336- must be re-adapted to engine control unit -J623- if it has been
renewed. Use vehicle diagnostic tester to do so.
❑ 27 Nm
❑ Lubricate threads lightly with clean engine oil

Audi TT 2007 ➤
06.2010
6 Intake manifold (engine codes CESA

and CETA)

ature sender -G42-
❑ 5 Nm
sender -G42-
enoid valve 1 -N80-
❑ With dual non-return
valve; checking
⇒ page 68
4 - Intake manifold
⇒ page 42
5 - Vacuum unit for air flow
control flaps (intake manifold
flaps)
6 - Bolts for high-pressure
pump
❑ 20 Nm
7 - Connecting piece for fuel
supply pipe
❑ From fuel tank
valve -N276-
lating valve -N276-
ical high-pressure pumpProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ When installing the permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
high-pressure fuel pump, with it isrespect
essential to ensure
to the correctness that noin this
of information dirtdocument.
entersCopyright
the fuelby system.
AUDI AG.
10 - Roller tappet
❑ May remain lodged in exhauster pump when high-pressure pump is removed; it can be taken out
❑ Renew
❑ 25 Nm
12 - High-pressure fuel pipe
❑ 20 Nm
6. Intake manifold (engine codes CESA and CETA) 39

Audi TT 2007 ➤
06.2010

14 - Injectors
❑ Renew O-ring and teflon ring
❑ 20 Nm
❑ 10 Nm
18 - Bolts for throttle valve module -J338-
❑ 5 Nm
electric throttle -G188- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ After throttle valve module -J338- has been
with respect renewed,
to the correctness it mustinbe
of information thisre-adapted to engine
document. Copyright control unit -J623-
by AUDI AG.
20 - Seal
❑ Renew
22 - Bolts for intake manifold pressure sender -G71-
❑ 5 Nm

Audi TT 2007 ➤
06.2010
1 - Injector
seal): always renew
❑ Renew O-rings
tion position.
⇒ page 53
2 - Support ring
3 - Roller tappet
valve -N276-
lating valve -N276-
high-pressure fuel
not be under pressure
when installing the high-
pressure pump; proce‐
dure for reducing fuel
pressure ⇒ page 4
led.
⇒ page 50
❑ 20 Nm
7 - Bolts
❑ 9 Nm
8 - Connecting piece for fuel unless
permitted supply pipe by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
❑ Renew
❑ 25 Nm
9 - Union nut for fuel supply pipe
❑ 20 Nm
10 - Bolts
❑ 9 Nm

Audi TT 2007 ➤
06.2010
❑ 7 Nm
❑ Tighten to 5 Nm
❑ Tighten to 5 Nm
❑ Intake manifold flap potentiometer -G336-
permitted unless authorised must
by AUDI AG.be re-adapted
AUDI to engine
AG does not guarantee control
or accept unit -J623- if it has been
any liability
renewed. Use vehicle diagnostic tester to do so.
17 - Gasket
❑ Renew
18 - Air flow control flaps (intake manifold flaps)
❑ 27 Nm
❑ Lubricate threads lightly with clean engine oil
20 - Fuel rail
❑ Tighten to 8 Nm

with fuel rail
After the fuel rail has been removed or renewed, intake manifold
flap potentiometer -G336- must be adapted to engine control unit
-J623- . Use vehicle diagnostic tester to do so.

Audi TT 2007 ➤
06.2010
♦ Socket Torx T30 -T10347-
♦ Oil filter tool -3417-

Removing
Note
♦ The combustion chamber (teflon) ring seal and the O-ring

must always be renewed.
♦ Intake manifold - exploded view ⇒ page 35
♦ Fuel rail - exploded view ⇒ page 37
WARNING

⇒ page 4 .
– Disconnect negative terminal from battery.

– Clean joint between intake manifold and cylinder head.

Audi TT 2007 ➤
06.2010

– Unclip air duct at the bottom by releasing clips -arrows-.
– Detach air duct at bottom together with air hose.
– Disconnect vacuum line -arrow- leading to activated charcoal

filter.
– Unplug following electrical connectors:
3 - Throttle valve module -J338- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Unplug electrical connector -1- at Hall sender -G40- .


Audi TT 2007 ➤
06.2010
– Release hose clips -2- on air pipe.

– Unscrew bolts -1 and 4- and remove air hose from throttle
valve module -J338- downwards.
– Pull out air hose.
– Disconnect vacuum line -1- at position marked -2- and remove

crankcase breather hose -3-.
– Unclip fuel supply hose from intake manifold.
Note
♦ The fuel system must not be under pressure.

♦ Use a clean cloth to catch escaping fuel.
– Release spring-type clip -1- and detach permitted

fuel supply hose from
high-pressure pump. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Unscrew union nut for high-pressure fuel pipe -2- at high-pres‐

sure pump.
Note
Seal off open connections with clean caps. It is essential to ensure

that no dirt enters the fuel system.
– Disconnect vacuum line -arrow- at intake manifold flap valve -

N316- .

Audi TT 2007 ➤
06.2010
– Remove two bolts -arrows- for coolant line from intake mani‐
fold.
Note
On vehicles with engine codes CESA and CETA, also unplug

electrical connector at intake manifold pressure sender -G71- .
– Unplug electrical connector at fuel pressure sender -G247-

-1-.
– Unplug electrical connectors -1- and -3- and detach connec‐

tors from retainer towards one side.
– Slightly loosen securing nut -1- and remove bolt -2-.

Audi TT 2007 ➤
06.2010
– Loosen oil filter -arrow- with oil filter tool -3417- and remove oil
filter.
– Open cable retainer -arrow- and move wiring clear.

– Unscrew bolts from intake manifold using socket Torx T30 -
T10347- .
Note
To remove the bolts that cannot be accessed if you do not have

socket Torx T30 -T10347- , the throttle valve module -J338- must
be removed.
– Carefully pull intake manifold and fuel rail slightly away from
cylinder head.
– Unplug electrical connector -1- from intake manifold flap po‐

tentiometer -G336- and then detach intake manifold.
Note
♦ The injectors can remain in the fuel rail.

♦ Block off intake ports with a clean cloth.
– Disconnect intake manifold from fuel rail ⇒ page 47 .

Installing
– Fit intake manifold onto studs (left and right) on cylinder head.
Note
Make sure that injectors are installed correctly.

sequence. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Tightening torque: intake manifold - exploded view
⇒ page 35
• Tightening torque: fuel rail - exploded view ⇒ page 37
6.3.1 Removing and installing fuel rail
Note
Intake manifold must be removed; removing intake manifold

⇒ page 42 .

Audi TT 2007 ➤
06.2010
– Release hose clip -1-.

– Remove hoses from activated charcoal filter.
– Disconnect fuel pipe at fuel rail.
– Unscrew two bolts -arrows- on fuel rail.
– Detach fuel rail from intake manifold.
Installing
– Always renew both connecting piecesCopying
Protected by copyright. for fuel supply
for private pipe. purposes, in part or in whole, is not
or commercial
– Connect fuel pipe. with respect to the correctness of information in this document. Copyright by AUDI AG.

sequence.
– Re-connect electrical connectors.

Audi TT 2007 ➤
06.2010
WARNING

to ⇒ page 4
1 - Roller tappet
❑ May possibly remain
lodged in exhauster
pump when high-pres‐
sure pump is removed
2 - O-ring
❑ Renew
❑ An electric fuel by
Protected pump
(fitted in fuel tank)
permitted sup‐
plies fuel towith
therespect
mechan‐

high-pressure fuel
not be under pressure;
procedure for reducing
fuel pressure ⇒ page 4
led.
⇒ page 50
valve -N276-
5 - Aperture in exhauster pump
for high-pressure pump
6 - Injectors
❑ Renew O-ring and teflon
ring
tion position.
8 - Camshaft control valve 1 -N205-
❑ 20 Nm (engine codes CCZA, CCTA, CESA, CETA, 2.0 ltr.)
Audi TT 2007 ➤
06.2010
10 - Connecting piece for fuel supply pipe from fuel tank

❑ Renew
❑ Connecting piece: 25 Nm
❑ 40 Nm (engine codes CCZA, CCTA, CESA, CETA, 2.0 ltr.)
❑ Tightening torque for union nut for fuel supply pipe: 20 Nm (engine code CDAA, 1.8 ltr.)
❑ Tightening torque for union nut for fuel supply pipe: 20 Nm (engine codes CCZA, CCTA, CESA, CETA,
2.0 ltr.)
❑ Fuel supply pipe must be free of tension when installed (make sure all parts are clean)

pump
Removing
Note
♦ The high-pressure pump must only be removed when the en‐

gine is cold.
♦ Use a cloth to catch escaping fuel.
♦ The O-ring must always be renewed.
♦ Always ensure that the high-pressure fuel pipes are free of
tension when tightening the connections.
WARNING

to ⇒ page 4

– Detach electrical connector at fuel pressure regulating valve -
N276- -1-.
Note
Illustration shows pump of 2.0 ltr. engine.

Audi TT 2007 ➤
06.2010
– Disconnect both fuel lines -arrows-.
– Remove 2 bolts -arrows-.

– Carefully pull out high-pressure fuel pump. It is possible that
the roller tappet may remain lodged in the exhauster pump.
Installing
– Renew O-ring for high-pressure pump.
– Fit roller tappet in exhauster pump (check roller tappet for
damage first).
Note
♦ The roller tappet must be positioned at the lowest point when

installing the high-pressure pump.
♦ If the old high-pressure pump is re-installed, or if a used pump
is installed, the connecting piece for the fuel supply pipe (high-
pressure section of the system) must be renewed. Refer to
high-pressure pump - exploded view (item 11) ⇒ page 49 .
– Turn crankshaft until roller tappet is positioned at lowest point.

– Fit high-pressure pump in exhauster pump.
– Tighten bolts hand-tight.
– Renew connecting piece at high-pressure pump.
• Tightening torque: refer to exploded view of high-pressure
pump ⇒ page 49 .
– Protected
Now by tighten bolts
copyright. infordiagonal
Copying sequence
private or commercial to specified
purposes, torque,
refer unless
permitted to high-pressure
authorised by AUDIpump
AG. AUDI - exploded view ⇒orpage
AG does not guarantee 49liability
accept any .
– Tighten union nut on fuel supply pipe hand-tight. Align so that
parts are free of tension.
• Tightening torque for fuel supply pipe (union nut): intake mani‐
fold - exploded view ⇒ page 35 .
Audi TT 2007 ➤
06.2010
– Re-attach electrical connector for fuel pressure regulating

valve -N276- -1-.
– Put back fuse if it has been removed.
Note

Audi TT 2007 ➤
06.2010
8 Injectors

♦ Tool kit with puller -T10133-
Note
Special tool T10133/2 (puller) has been modified and now has the
designation puller T10133/2 A . If you have not
withyet received
respect the of information in this document. Copyright by AUDI AG.
to the correctness
new tool you can make the modification yourself.
Modifying special tool T10133/2 (puller) to make it equivalent to

puller T10133/2 A
– File out a semi-circular recess as shown in the illustration. The
recess allows the tool to be pushed further onto the injector so
the contact surface is increased.
– For identification purposes, mark the modified tool with the
letter “A” after the tool number.

♦ Round file, approx. 6 mm
Removing
– Remove intake manifold and fuel rail ⇒ page 42 .
Removing injectors (from fuel rail)
Carefully pull injectors out of fuel rail.
8. Injectors 53
Audi TT 2007 ➤
06.2010
Removing injectors (from cylinder head)

Injector (old version)
2 - Support ring is replaced by intermediate ring; see next illus‐
tration ⇒ page 54
3 - Injector
installation)
Injector (new version)

1 - Renew intermediate ring
2 - Retainer
4 - Injector
installation) with respect to the correctness of information in this document. Copyright by AUDI AG.
– Cover open inlet ports with a clean cloth.
– Unplug electrical connector at injector that is to be removed.

– Then attach removal tool -T10133/16- and pull out injector by
turning bolt -1-.
Note

to reinstalling the injector ⇒ page 54 .
8.1.1 Renewing combustion chamber ring

seal (teflon ring seal)
Note

to reinstalling the injector.
– Carefully remove old teflon ring using suitable tools (e.g. cut
open ring using razor blade, or prise open ring with small
screwdriver and then pull off forwards). It is important to en‐

Audi TT 2007 ➤
06.2010
sure that the groove and the continuous ridge in the bottom of
the groove are not damaged.
Note
The injector must be renewed if the groove is damaged.
– Before new teflon ring is fitted, any combustion residue must

be removed from ring groove and injector stem using a clean
cloth.
Note
The illustration shows an injector with “offset connector”. This can

be ignored since it is not relevant when replacing the combustion
chamber ring seal.
– Fit assembly cone -T10133/5- with new teflon ring -1- onto in‐
jector -2-.
– Use assembly sleeve -T10133/6- to press teflon ring further

onto assembly cone -T10133/5- until it seats in groove. Do not
use any lubricants during this procedure.
Note
The teflon ring is widened as it is pushed onto the injector. The
teflon ring must therefore be compressed again after it has been

fitted. This is done in two steps. The procedure is described be‐

low.
Step 1 of teflon ring seal calibration (adaption) is done with cali‐

bration sleeve -T10133/7- .
– Fit spacer sleeve -T10133/11- onto body of injector.
– Push calibration sleeve -T10133/7- over teflon ring until it
makes contact with spacer sleeve -T10133/11- by pressing
lightly and turning approx. 180°.
8. Injectors 55
Audi TT 2007 ➤
06.2010

opposite direction.
Use calibration sleeve -T10133/8- for step 2 of the calibration of
the teflon ring.
– Push calibration sleeve -T10133/8- over teflon ring until it
makes contact with spacer sleeve -T10133/11- by pressing
lightly and turning approx. 180°.

opposite direction.
The teflon ring is now installed in the correct position.
– The teflon ring must not be lubricated.
– Fit new O-ring on injector. Lubricate O-ring lightly with clean
engine oil before installing.
– Use supplied nylon brush -T10133/4- to thoroughly clean

holes for injectors in cylinder head prior to installing injectors.
♦ The teflon seal on the injector must not be oiled or greased.

♦ Make sure there is no cleaning fluid or oil in the cylinder head
– 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.

Audi TT 2007 ➤
06.2010
Note
♦ It should be possible to insert injector easily. If necessary wait

until the combustion chamber ring seal has contracted suffi‐
ciently.
♦ Note correct installation position and ensure that injectors are
properly seated in cylinder head.
♦ If the injector cannot be pushed in by hand, use puller -
T10133/2A- -2- with striker -T10133/3- to insert injector.

sequence.
Important: the following points must always be observed:
• Coat O-rings of high-pressure injectors with clean engine oil
to facilitate insertion into fuel rail.
• Renew all seals.
• Fuel rail must be positioned on injectors and pressed in evenly.
• Install intake manifold with fuel rail ⇒ page 42Protected
8.2 Cleaning injectors

♦ Ultrasonic cleaning unit -VAS 6418-
♦ Mounting plate for injection modules -VAS 6418/1-
♦ For cleaning fluid refer to electronic parts catalogue.
Cleaning
Note
Observe safety precautions and operating instructions for ultra‐

sonic unit.
– Ultrasonic unit must be filled with cleaning fluid.
Note
Ultrasonic unit must be filled with cleaning fluid up to top edge of

apertures (see detail in illustration).
– Insert injectors -1- all the way into mounting plate for injection
modules -VAS 6418/1- -2-.
8. Injectors 57
Audi TT 2007 ➤
06.2010
– Immerse injectors together with mounting plate for injection

modules -VAS 6418/1- into cleaning fluid.
– Set rotary knob -4- to a temperature of 50°C.
– Select a cleaning time of 30 minutes with rotary knob -5-.
– Switch on ultrasonic unit with button -3-.
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 (teflon

ring seal) for each injector ⇒ page 54 .
– Then re-install injectors ⇒ page 53 .

Audi TT 2007 ➤
06.2010

⇒ “9.1 Removing and installing fuel pressure sender G247 ”, page
59
⇒ “9.2 Checking fuel pressure sender G247 ”, page 60
⇒ “9.3 Checking fuel pressure and residual pressure (up to high-
pressure pump)”, page 62
⇒ “9.4 Removing and installing air mass meter G70 ”, page 65
⇒ “9.5 Removing and installing throttle valve module J338 ”, page
65
⇒ “9.6 Cleaning throttle valve module J338 ”, page 66
⇒ “9.7 Checking intake manifold change-over function”,
page 67
⇒ “9.8 Checking dual non-return valve of activated charcoal filter
solenoid valve 1 N80 ”, page 68

sender -G247-
♦ Double hexagon socket 1/2", 27 mm -VAS 5301/7- or com‐

mercially available socket (27 mm)
Removing
– Pull off top engine cover panel carefully.

Audi TT 2007 ➤
06.2010
WARNING

⇒ page 4 .
– Detach coolant pipe from intake manifold -arrows-.
– Release connector on fuel pressure sender -G247- using as‐

sembly tool -T10118- .
– Unscrew fuel pressure sender -G247- using double hexagon
socket, 1/2", 27 mm -VAS 5301/7- .
Installing:
– Make sure that connecting piece is tightened to specified tor‐
que before installing fuel pressure sender -G247- .
• Tightening torque for connecting piece:
permitted unless Fuelby rail
authorised AUDI-AG. exploded
view ⇒ page 37 with respect to the correctness of information in this document. Copyright by AUDI AG.
• Tightening torque for fuel pressure sender -G247- : Fuel rail -

exploded view ⇒ page 37
9.2 Checking fuel pressure sender -G247-

♦ Pressure sensor tester -VAS 6394-
♦ Adapter -VAS 6394/2-
♦ Test instrument adapter -VAS 5570-
♦ Vehicle diagnostic tester
Procedure
WARNING

⇒ page 4 .
– Remove fuel pressure sender -G247- ⇒ page 59 .

Audi TT 2007 ➤
06.2010
– Screw in adapter -VAS 6394/2- in place of fuel pressure send‐

er -G247- and tighten adapter with the same torque as that
specified for fuel pressure sender -G247- .
• Tightening torque: fuel rail - exploded view ⇒ page 37
– Unscrew plug -2- on pressure sensor tester -VAS 6394- and

screw in the removed fuel pressure sender -G247- . Tighten
to torque normally specified for fuel pressure sender.
– Use test instrument adapter -VAS 5570- to make electrical

connection between vehicle and fuel pressure sender -G247- .
Display zone 3 shows the actual pressure value being transmitted
to the engine control unit by the fuel pressure sender -G247- .
– Switch on pressure sensor tester -VAS 6394- by pressing but‐

ton -A- once briefly.
You can press and hold button -A- for 2 seconds to switch on the
illumination for 20 seconds.
Pressure sensor tester -VAS 6394- should indicate 0 bar. If this

is not the case, press button -C- once briefly to zero the tester.

Audi TT 2007 ➤
06.2010
– Connect pressure line of pressure sensor tester -VAS 6394-

to adapter -VAS 6394/2- .
– Start engine.
– Compare the pressure indicated by pressure sensor tester -
VAS 6394/1- with the actual pressure value on the vehicle
diagnostic tester .
• The pressure readings must not deviate by more than 5 bar.
– If the deviation is more than 5 bar, test a new fuel pressure
sender -G247- .
WARNING

⇒ page 4 .
– Screw a new fuel pressure
permitted sender by
unless authorised -G247-
AUDI AG.intoAUDIthe pressure
gauge -VAS 6394/1- .
– Repeat the test with the new fuel pressure sender -G247- and
compare the two pressure values.
If the two values still do not agree:
– Check the electrical connection between the fuel pressure
sender -G247- and the engine control unit; refer to ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
If the values agree:
– Install the new fuel pressure sender -G247- ⇒ page 59 .
9.3 Checking fuel pressure and residual

pressure (up to high-pressure pump)

Test conditions:
• Fuel filter OK.
• Fuel pump control unit -J538- OK (check)

Audi TT 2007 ➤
06.2010
• Ignition off.
Checking fuel pressure
Before removing pressure gauge, release fuel pressure by open‐
ing cut-off valve. Hold a container under the connection.
WARNING
♦ The pressure in the high-pressure part of the injection

system must be reduced to a residual pressure prior to
opening the system ⇒ page 4 .
♦ A clean cloth must then be wrapped around the connec‐
tion and the residual pressure dissipated by carefully loos‐
– Push down protective sleeve -1- and disconnect fuel supply

pipe.
– First press hose connector -2- downwards -arrow A-, then
press release tabs -arrow B-.
– Pull off hose connector, keeping release tabs depressed.
– Screw connector -V.A.G 1318/23- and adapter set -V.A.G

1318/17A- onto K-Jetronic pressure tester -V.A.G 1318- .
– Fit adapter set -V.A.G 1318/17-1A- onto disconnected fuel
supply pipe.
1318- .

Audi TT 2007 ➤
06.2010
– Run test hose into measuring glass -arrow-.
– Close cut-off valve on K-Jetronic pressure testerpermitted
-V.A.Gunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1318- . with respect to the correctness of information in this document. Copyright by AUDI AG.
• Lever is at right angle to direction of flow -arrow-.

– Then select “Final control diagnosis”.
– The fuel pump should start running.
Note
This function actuates the fuel pump.
– Read off fuel pressure on K-Jetronic pressure tester -V.A.G

1318- .
• Specification: approx. 5 bar (3 ... 6 bar).
– End this function when fuel pressure stops rising on K-Jetronic
pressure tester -V.A.G 1318- .
– Check delivery rate of fuel pump ⇒ Fuel supply system, petrol
engines; Rep. Gr. 20 .
– Check system for leaks and check residual pressure by watch‐
ing the drop in pressure on the K-Jetronic pressure tester -
V.A.G 1318- .
• After 10 minutes pressure should still be at least 3 bar.
and fuel supply pipe for leaks.
♦ Renew fuel filter with integrated fuel pressure regulator ⇒ Fuel
supply system, petrol engines; Rep. Gr. 20 . Then repeat the
test.
♦ If fuel filter is OK, renew fuel pump ⇒ Fuel supply system,
petrol engines; Rep. Gr. 20 .
Assembly is carried out in the reverse order; note the following:
– The ignition must be switched off.

Audi TT 2007 ➤
06.2010
Note
Before removing pressure gauge, release fuel pressure by open‐

ing cut-off valve. Hold a container -arrow- under the connection.
– Re-attach fuel supply pipe (make sure that all parts are clean).
Note

-G70-
Removing
Installing
important to observe the following
Protected bynotes and
copyright. instructions.
Note
♦ Use a silicone-free lubricant when installing the air hose.
⇒ page 32
quence.

module -J338-
Removing

Audi TT 2007 ➤
06.2010
– Unscrew bolts and clips -arrows- and remove charge air pipe
and hose from below.
– Unplug electrical connector -1- from throttle valve module -
J338- .
– Remove the four bolts -arrows- from throttle valve module -

J338- and detach throttle valve module -J338- .
Installing
– Clean sealing surface for seal.
– Renew seal.
• Tightening torques: intake manifold - exploded view
⇒ page 35 .
– After throttle valve module -J338- has been renewed, it must
be re-adapted to engine control unit -J623- using a vehicle di‐
agnostic tester.
9.6 Cleaning throttle valve module -J338-
Note
♦ The throttle valve module must be adapted if a new engine

control unit -J623- is installed.
Take care
♦ Protected not toCopying
by copyright. scratch the throttle
for private valve
or commercial housing
purposes, in part when clean‐
or in whole, is not
ing it.
– Remove throttle valve module -J338- ⇒ page 65 .

– Open throttle valve by hand and block it in the open position
with a suitable object (e.g. plastic or wooden wedge) -arrow-.
WARNING
Acetone is highly flammable. Please observe all accident pre‐

vention 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 possible injury and skin contact.

Audi TT 2007 ➤
06.2010
– Clean throttle valve housing, especially around the points

-arrows- where the throttle valve closes, using commercially
available acetone (DIN 53247) and a small brush.
– Wipe out throttle valve housing with a lint-free cloth.
– Allow acetone to evaporate completely and re-install throttle
valve module after cleaning.
– Erase learnt values and adapt engine control unit -J623- to
throttle valve module using a vehicle diagnostic tester.
9.7 Checking intake manifold change-over

function
Only perform this test if there is a loss of engine torque (poor
flexibility or lack of pulling power).
Test condition:
♦ Intake manifold flap valve -N316- has been checked with a
vehicle diagnostic tester.
Perform the following steps if the intake manifold flap valve -
N316- is OK.
– Carefully pull off engine cover panel.
– Have a second mechanic rev up engine quickly (short burst of
throttle) and observe vacuum unit for intake manifold change-
over.
• The vacuum unit should pick up -arrow-.
If the change-over does not operate as described:
– Check vacuum system for leaks.
– Check that change-over mechanism moves freely by operat‐
ing linkage manually.
– Check proper connection of vacuum lines.
– Check vacuum hoses for porosity.

Audi TT 2007 ➤
06.2010
– Disconnect vacuum hose -1- leading to vacuum unit for intake

manifold flap valve -N316- at intake manifold flap valve -N316-
-2-.
– Move adjuster ring -1- on hand vacuum pump -VAS 6213- to

position -A- to select "vacuum".
– Connect hand vacuum pump -VAS 6213- to vacuum unit for

intake manifold flap valve -N316- .
– Operate the hand vacuum pump -VAS 6213- several times.
The vacuum unit should move -arrows-.
– If vacuum unit does not move, renew vacuum unit.
9.8 Checking dual non-return valve of acti‐

vated charcoal filter solenoid valve 1 -
N80-

Audi TT 2007 ➤
06.2010

Test condition:
• Activated charcoal filter solenoid valve 1 -N80- has been
checked with a vehicle diagnostic tester and is OK.
– Carefully pull off engine cover panel.
– Unplug connector -1- and detach breather hose -3- from acti‐
vated charcoal filter solenoid valve 1 -N80- -2-.
– Move adjuster ring -1- on hand vacuum pump -VAS 6213- to

position -A- to select "vacuum".

Audi TT 2007 ➤
06.2010
– Connect hand vacuum pump -VAS 6213- to activated charcoal

filter solenoid valve 1 -N80- .
– Connect contacts of activated charcoal filter solenoid valve 1
-N80- -1- to battery using test leads. This will open activated
charcoal filter solenoid valve 1 -N80- .
Then immediately operate hand vacuum pump -VAS 6213- sev‐
eral times.
• Vacuum should build up.
– Again disconnect battery to cut off current supply.
If vacuum does not build up:
– Renew dual non-return valve -1-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Dual non-return valve, activated charcoal filter solenoid valve 1 -
N80- and plastic hoses are combined as one unit and can only be
renewed together.

Audi TT 2007 ➤
06.2010
10 Lambda probes
10.1 Lambda probes - overview
Electrical connector -1- for Lambda probe -G39- and Lambda
probe heater -Z19-
Lambda probe -G39- and Lambda probe heater -Z19- -1-
Electrical connector for Lambda probe after catalytic converter -

G130- and Lambda probe 1 heater after catalytic converter -Z29-
(behind cover)
10. Lambda probes 71

Audi TT 2007 ➤
06.2010
Lambda probe after catalytic converter -G130- and Lambda probe

1 heater after catalytic converter -Z29- -1-
Note
body.
slots on the Lambda probe body. High-temperature paste ⇒
Parts catalogue
Removing and installing Lambda probe -G39- and Lambda probe

heater -Z19- before catalytic converter
⇒ “10.2 Removing and installing Lambda probe G39 and Lambda
probe heater Z19 before catalytic converter”, page 72 .
Removing and installing Lambda probe after catalytic converter -
G130- and Lambda probe 1 heater after catalytic converter -Z29-
⇒ “10.3 Removing and installing Lambda probe after catalytic
converter G130 and Lambda probe 1 heater after catalytic con‐
verter Z29 ”, page 73

-G39- and Lambda probe heater -Z19-
before catalytic converter

Audi TT 2007 ➤
06.2010
Removing
Lambda probe heater -Z19- .

Installing
Note

body.
Parts catalogue
• Tightening torque: Lambda probe - overview ⇒ page 71

after catalytic converter -G130- and
Lambda probe 1 heater after catalytic
converter -Z29-
Removing
– Remove right-side cover from underbody.
10. Lambda probes 73

Audi TT 2007 ➤
06.2010
– Unplug electrical connector for Lambda probe after catalytic

converter -G130- and Lambda probe 1 heater after catalytic
converter -Z29- .
– Unscrew Lambda probe after catalytic converter -G130- -1-

using tool from Lambda probe open ring spanner set -3337- .
Installing
Note

body.
Parts catalogue
• Tightening torque: Lambda probe - overview ⇒ page 71

Audi TT 2007 ➤
06.2010

box -V.A.G 1598/42-
♦ Test box -V.A.G 1598/42- with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi TT 2007 ➤
06.2010
Note
finding andunless
Fitting locations.

adapter cable -V.A.G 1598/39-2- must be connected to con‐

ning).
WARNING

The engine control unit has to be removed before multi-pin con‐

nectors can be unplugged from engine control unit ⇒ page 77 .
the control unit.

Audi TT 2007 ➤
06.2010
Note
Not every engine control unit is bolted to a protective housing.


♦ Small, commercially available vice grip pliers -3-
Note
♦ Not every engine control unit is bolted to a protective housing.

♦ The engine control unit -1- is bolted to the protective housing
fluid.
tors can be unplugged from the engine control unit (e.g. to
connect the test box or renew the engine control unit).
Removing
– When renewing engine control unit, select diagnosis object
“Replace engine control unit” in “Guided Functions”.

– Loosen wiper arms from wiper shafts by tilting them slightly.


wiper shafts.
Note


Audi TT 2007 ➤
06.2010
-2-.
Note
♦ Risk of damage to plenum chamber cover.

♦ Apply a small quantity of soap solution to transition between
windscreen and plenum chamber cover -2-. Then, starting at
edge of windscreen, carefully pull plenum chamber cover up‐
wards off retainer at windscreen.

partition panel.
– Release clips -arrows- and remove engine control unit -J623- .

Perform the following work steps if a protective housing is fitted:

air blower.

Audi TT 2007 ➤
06.2010

WARNING
20 ... 30 seconds.

in illustration).
– Unscrew two bolts securing retainers for engine control unit -
J623- .

Audi TT 2007 ➤
06.2010

connectors.
– Take out old engine control unit -J623- and connect new en‐
– After installation, the locking plate must be re-fitted on the en‐
After installing a new engine control unit, the following operation
must be performed: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Activate engine control unit viawitha respect
vehicle diagnostic
to the correctness of tester inin this document. Copyright by AUDI AG.
information
“Guided Functions” mode, “Replace engine control unit”.

Audi TT 2007 ➤
06.2010
tions

♦ The engine control unit has a self-diagnosis capability.
unit. The event memory must then be interrogated and, if nec‐

Audi TT 2007 ➤
06.2010

WARNING

erly secured.
secured.
the passenger.
Caution

connecting the battery: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

♦ Do not touch or disconnect ignition wiring when the engine is
leads.
completing the work, interrogate and erase the event memory.

Audi TT 2007 ➤
06.2010
2.1 Test data

Engine data 1.8 ltr. and 2.0 ltr. turbo FSI engine
Idling speed 640...800 rpm
is not adjustable; controlled by the idling speed
stabilisation
Engine speed limiter (deactivates injectors/closes approx. 6,500 rpm
throttle valve)
Ignition timing is determined by the control unit.
Ignition timing cannot be adjusted.
Ignition system Multi-coil ignition system with 4 ignition coils (integrated
output stages) connected directly to spark plugs via
spark plug connectors; ignition coils can be pulled out of
cylinder head using puller - T40039 -

3 - Ignition coil with output
stage -(N70, N127, N291,
N292)-
⇒ page 84
❑ Use puller -T40039- for
removal
4 - Spark plug
❑ 30 Nm
❑ Use spark plug socket
and extension -3122 B-
for removal
❑ Removing and
with respect to installing
let 810
5 - Bolt
❑ 20 Nm
❑ Tightening torque influ‐
ences the function of the
knock sensor
6 - Bolt
❑ 10 Nm
8 - O-ring
❑ Renew O-Ring if dam‐

Audi TT 2007 ➤
06.2010
aged

with output stages
♦ Puller -T40039-
Removing
– Unscrew two bolts on connector rail.
– Pull all ignition coils approx. 30 mm out of spark plug holes
using puller -T40039- .
The following step is only required on vehicles with engine codes
CESA and CETA.
– Release electrical connectors -5 to 12- at all camshaft adjust‐

ment actuators.

Audi TT 2007 ➤
06.2010
– Release connectors and unplug all connectors from the igni‐

tion coils at the same time.
Installing
– Align the ignition coils with the connectors and attach all con‐
nectors onto ignition coils simultaneously.
– Press ignition coils onto spark plugs by hand with uniform
pressure (do not use tool).
2.4 Removing and installing knock sensor 1

-G61-
Removing
– Unplug electrical connector -2- at knock sensor 1 -G61- .
– Remove coolant pump with thermostat ⇒ Engine, mechanics;
Rep. Gr. 19 .
Note
Knock sensor 1 -G61- is located below the intake manifold and

behind the coolant pump.
– Unscrew knock sensor 1 -G61- .


• Tightening torque: refer to exploded view of ignition system

⇒ page 83 .

sender -G28-
♦ Socket (4 mm) -T10370-

Audi TT 2007 ➤
06.2010
Removing
– Remove air pipe -1-.
Note
The air duct -item 2- does not have to be removed.

Audi TT 2007 ➤
06.2010
– Release hose clip -2- on air pipe.

– Unscrew bolts -1 and 4- and remove air hose from throttle
valve module -J338- downwards.
– Disconnect air hose -1- from charge air cooler and remove air
pipe downwards.
– Unplug electrical connector -1- at engine speed sender -G28- .

– Unscrew securing bolt for engine speed sender -G28- .
Installing
• Tightening torque: refer to overview of fitting locations
⇒ page 8 .

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Copyright © 2010 Audi AG, Ingolstadt A005TT02320

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Working on the fuel system

Risk of injury - fuel system operates under pressure.

Observe the following points to prevent personal injuries and

To prevent damage to the electronic components when dis‐

Disconnect battery ⇒ Electrical system; Rep. Gr. 27 .

1.2 Using testers and measuring instru‐

Accidents can be caused if the driver is distracted by test

1.3 Working on vehicles with start/stop sys‐

Risk of injury due to automatic engine start on vehicles with

1.4 Removing and installing components

1.5 Removing and installing fuel tank

2 Rep. Gr.00 - Technical data

2 General repair instructions

2.1 Rules for cleanliness when working on

2.2 Test conditions

• Fuel tank at least 1/4 full.

2. General repair instructions 3

4 Rep. Gr.00 - Technical data

20 – Fuel supply system

1.1 Fuel tank with attached components - exploded view

1. Fuel tank with attached components - vehicles with four-wheel drive 5

Earth connection for fuel filler neck and protective plate

Risk of explosion caused by electrostatic discharge.

1.2 Draining fuel tank

♦ Fuel extractor -VAS 5190-

6 Rep. Gr.20 - Fuel supply system

– Remove filler cap from fuel filler neck.

♦ The procedure when using a fuel extractor without shaft end

– Drain fuel tank as much as possible through fuel filler neck.

All vehicles (continued):

1. Fuel tank with attached components - vehicles with four-wheel drive 7

– Unplug electrical connector -1- at flange.

– Carefully pull fuel gauge sender 2 -G169- -item 1- with suction-

1.3 Removing and installing fuel tank with

8 Rep. Gr.20 - Fuel supply system

Risk of accident caused by weight of fuel tank

– Drain fuel tank ⇒ page 6 .

– Remove back panel trim (right and left) ⇒ Rep. Gr. 70 .

– Unplug electrical connector -arrow- at flange.

1. Fuel tank with attached components - vehicles with four-wheel drive 9

– Unplug electrical connector -1- at flange.

– Clean area around fuel filler neck.

– Remove rear right wheel housing liner ⇒ Rep. Gr. 66 .

10 Rep. Gr.20 - Fuel supply system

All vehicles (continued):

Risk of damage to flexible joints in front exhaust pipe

– Separate exhaust system at clamp -arrows-.

– Secure front section of exhaust system with a chain. To do so,

A second person will be required for detaching rear section of

– Disengage rear silencer at the rubber mountings and remove

1. Fuel tank with attached components - vehicles with four-wheel drive 11

Risk of accident caused by weight of fuel tank

– First remove bolts -2, 5, 6-.

– Secure fuel tank by first tightening bolts at points -1, 3, 4, 7-,

12 Rep. Gr.20 - Fuel supply system

Risk of explosion caused by electrostatic discharge.

– Attach electrical wire for ABS speed sensor to bracket on fuel

1. Fuel tank with attached components - vehicles with four-wheel drive 13