1.8l Turbo ATC AWP PDF

2006 Audi TT
ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): ATC, AWP
ENGINE
1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): ATC, AWP
00 GENERAL, TECHNICAL DATA

TECHNICAL DATA
Engine number
Fig. 1: Locating Engine Number

Courtesy of VOLKSWAGEN UNITED STATES, INC.
The engine number ("Engine code" and "Serial number") can be found at the front
at the connection between the engine and transmission.
There is also a sticker on the cylinder head cover showing the engine code and
serial number.
The engine code is also included on the vehicle data plate.

Engine data
Engine code ATC AWP

Manufactured from 01.99 from 05.00
Displacement liters 1.781 1.781
Output kW at RPM 132 @5500 132 @5500
Torque Nm at RPM 235 @1950- 235 @1950-
4700 4700
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2006 Audi TT
Bore mm 81 81
Stroke mm 86.4 86.4
Compression ratio 9.5:1 9.5:1
RON min. 95 unleaded 95 unleaded
Injection/ignition system Motronic Motronic
Knock control Yes Yes
On Board Diagnostic (OBD) Yes Yes
Oxygen sensor control Yes Yes
Catalytic converter Yes Yes
Engine code ATC AWP

Turbocharged Yes Yes
Exhaust gas recirculation system No No
Secondary air system Yes Yes
Camshaft adjustment Yes Yes
Valve timing
At 1 mm valve lift and 0 mm valve clearance
Inlet opens after TDC 18° 18°
Inlet closes after BDC 28° 28°
Exhaust opens before BDC 28° 28°
Exhaust closes before TDC 8° 8°
10 ENGINE - ASSEMBLY
ENGINE, REMOVING AND INSTALLING
Engine, removing and installing
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2006 Audi TT
Fig. 2: Identifying Special Tools - Engine, Removing And Installing (1 Of 3)

Special tools, testers and repair equipment required

V.A.G 1306 Drip tray
T10012 Engine bracket
VW 313 Support clamp
VW 540 Engine and transmission support
3180 Retainer
V.A.G 1202 A Workshop crane
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2024 A Lifting tackle

V.A.G 1331 Torque wrench (5-50 Nm)

V.A.G 1332 Torque wrench (40-200 Nm)
V.A.G 1383 A Engine/transmission jack
V.A.G 1921 Spring-type clip pliers
VW 457 Support rails

3300 A Engine support device
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3283 Pressing-out appliance

VAS 5085 Step ladder
V.A.G 1756 Angle wrench
G 000 100 grease (vehicles with manual transmission)
Bolt M10 X 25/8.8

Bolt M8 X 25/8.8
Engine, removing
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NOTE: The engine is removed from underneath together with

the transmission.
All cable ties which are opened or cut open when
removing the engine must be replaced in the same
position when installing the engine.
Secure all hose connections with hose clamps of the
same type as those installed at the factory.
V.A.G 1921 hose clip pliers are recommended when installing spring-type
clips.
Make sure the connectors are correctly assigned; mark if necessary.
Obtain radio anti-theft code on vehicles with coded radio.

With the ignition switched off, disconnect the battery Ground strap.
Fig. 5: Removing Engine Cover Panel Above Cylinder Head

Remove engine cover from cylinder head cover.
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Fig. 6: Removing Cover In Front Of Intake Manifold

Remove cover in front of intake manifold.
Fig. 7: Disconnecting Air Duct At Bottom Of Right Side Longitudinal Member

Disconnect air duct at bottom of right side longitudinal member (air duct leads
to charge air cooler).
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Fig. 8: Removing Noise Insulation Panels (Center, Left And Right)

Remove sound insulation in the center and on left and right sides (arrows).
Unbolt heat shield for right side drive axle.
Fig. 9: Unbolting Pendulum Support And Left/Right Side Drive Axles From
Transmission Flange
Unbolt pendulum support.

Unbolt left and right side drive axles from transmission flange.
Move left side drive axle toward rear of vehicle and secure in place by tying to
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stabilizer bar.
Remove front exhaust pipe. Refer to Front exhaust pipe, removing and
installing.
NOTE: Do not bend the flexible connection on the front exhaust

pipe more than necessary (not more than 10°).
Fig. 10: Securing Support Rails 457/1 To Subframe With Bolt M8 X 25 And
Engine Support Device 3300A To Support Rails 457/1
Secure support rails 457/1 to subframe with bolt M8 x 25 (-B-). Also secure
engine support device 3300A (-C-) to support rails 457/1 (arrows).
Press engine forward.
NOTE: Make sure not to damage the power steering line.
Fig. 11: Loosening Right Side 12-Point Nut For Drive Axle
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Loosen right side 12-point nut for drive axle. When doing this, vehicle must be
standing on its wheels.
Unbolt wheel.
Fig. 12: Pressing Out Drive Shaft Using Special Tool 3283
Press out drive axle using special tool 3283.
NOTE: Make sure there is enough clearance when pressing out the
axle shaft.
Remove drive axle.

Place drip tray V.A.G 1306 below engine.
Remove cap from coolant expansion tank.
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Fig. 13: Turning Drain Screw On Radiator

Turn drain screw (arrow) on radiator counter-clockwise. If necessary, fit drain

hose to connection.
Fig. 14: Disconnecting Bottom Coolant Hose At Oil Cooler To Drain Off
Remaining Coolant
Disconnect bottom coolant hose from oil cooler (arrow) and allow remaining
coolant to drain.
Fig. 15: Identifying Air Hose, Mass Air Flow Sensor & Bolts
Disconnect air hose -4- from mass air flow sensor.

Disconnect electrical connectors for mass air flow sensor -1-.
Remove bolts -2- and -3- and take off air cleaner housing.
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The air intake hose connection on the turbocharger is removed as follows:
Fig. 16: Identifying Vacuum Hose, Crankcase Breather, Wastegate Bypass

regulator valve & Hose
Disconnect vacuum hose -1- from air recirculation valve.

Disconnect hose from pressure control valve for crankcase breather -2-.
Disconnect electrical connector from Wastegate bypass regulator valve -N75-
(-3-).
Disconnect hose -4- from Wastegate bypass regulator valve -N75-.
Disconnect hose -5- at bulkhead (hose leads from solenoid valve to

turbocharger).
Remove wastegate bypass regulator valve from air intake hose and place it to
one side on engine.
Disconnect hose between EVAP canister and turbocharger on bulkhead.
Pull retainer off turbocharger connection and disconnect air intake hose.
Remove battery.
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Fig. 17: Removing Battery Platform

Remove battery platform (arrows).
Fig. 18: Identifying Battery Ground Cable, Connector & Electrical

Connections
Unbolt Ground wire -1- on engine/transmission flange.

Disconnect wires -3- and -4- from starter.
Disconnect connector -2- and pull out of retainer.
Disengage wires from retainer on starter and move wires to one side.
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Fig. 19: Identifying Electrical Change-Over Valve Connector, Intake Manifold

Brackets & Dipstick Tube
Disconnect connector -1- for electrical change-over valve on underside of

bracket.
Unbolt bracket from intake manifold (-2- and -3-) and disengage dipstick tube -
4-.
Fig. 20: Locating Generator Connections

Disconnect wire -1- from terminal 30/B+ on generator.

Disconnect connector -2- from terminal D+.
Remove cable clip -3-.
Vehicles with air conditioning
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Disconnect connector from a/c compressor.
All models
Fig. 21: Identifying Coolant Hose, Knock Sensor (KS) I -G61-, Engine Speed
Sensor (RPM) -G28-, Knock Sensor (KS) II -G66-, Oil Pressure Switch -F1- &
Vacuum Pipe
Remove coolant hose -1- (complete).

Disconnect wires/connectors as follows:
2 - Knock Sensor (KS) I -G61-

3 - Engine speed sensor (RPM) -G28- (center, gray)
4 - Knock Sensor (KS) II -G66-
6 - Oil pressure switch -F1-
Take Generator wire out of retainer.

Disconnect vacuum pipe -5- from intake manifold.
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Fig. 22: Identifying Hose Clip, Intake Air Temperature (IAT) Sensor -G42 &
Throttle Valve Control Module -J338-
Disconnect connector -1- for Intake air temperature sensor -G42- and
connector -4- for Throttle valve control module -J338- (under throttle valve
control module).
Disconnect air hose -2- from throttle valve control module.
Disconnect vacuum hose -3- (for EVAP canister) from throttle valve control
module.
Fig. 23: Locating Connector At Camshaft Position Sensor G40

Disconnect connector from Camshaft Position (CMP) sensor -G40- (arrow).
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Fig. 24: Identifying Vacuum Pipe, Vacuum Reservoir, Connectors, Support

Bar & Ground Wire
Disconnect vacuum pipe -1- from vacuum reservoir.

Unbolt vacuum reservoir -2- and remove from bracket.
Disconnect connectors -3- from injectors and unclip support bar from fuel rail
at points -4- and -5-.
Unbolt Ground wire -6- between ignition coils 1 and 2.
Disconnect connectors -7- from ignition coils.

Disconnect connector from Engine Coolant Temperature (ECT) sensor -G62-
(on coolant hose flange on left of cylinder head).
Disconnect connector from Speedometer sensor -G22- (on rear of
transmission).
Move lines and hoses clear.
Disconnect the following coolant hoses:
On expansion tank (top and bottom)

On cylinder head (top hose leading to radiator)
On bulkhead (two hoses leading to heat exchanger for heater)
On left of engine block, below cylinder head (hose joined to connection in
upper coolant hose leading to radiator)
On oil cooler (rear hose)

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Disengage wiring harness from retainers and place to one side.
Fig. 25: Pulling Collar (Toward Ball Joint) To Compress Spring, Then
Turning Collar Clockwise To Lock In Position
Mark threaded sections of both selector cables -1- with a permanent marker
pen so that they can be installed in same positions later.
Pull collar in direction of arrow -2- (toward ball joint) to compress spring, then
turn collar clockwise (arrow -3-) to lock in position.
Disengage both threaded sections.
Fig. 26: Unclipping Clutch Slave Cylinder Hose From Selector Cable Support
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Bracket, Removing Bolts & Selector Cable Support Bracket From

Transmission
Unclip clutch slave cylinder hose from selector cable support bracket (arrow).
Remove bolts (arrows), remove selector cable support bracket from
transmission and place to one side.
Fig. 27: Identifying Slave Cylinder

Remove clutch slave cylinder from transmission and place to one side.
NOTE: Do not open the hydraulic system.

Do not depress the clutch.
Disconnect electrical wire from Back-up light switch -F4-.

Disengage wiring harness from retainers and place to one side.
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Fig. 28: Identifying Supply Line And Return Line

Disconnect fuel supply line -1- and fuel return line -2- at connection point by
pressing release tabs.
NOTE: Check the colors of the connectors when connecting the

fuel supply and return lines.
WARNING: The fuel system is under pressure! Before opening

the system place a cloth around the connection,
then release pressure by carefully loosening the
connection.
Fig. 29: Relieving Tension On Poly V-Belt

Loosen ribbed belt by turning tensioning element in direction indicated

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(arrow).
NOTE: Before removing the ribbed belt, mark the direction of

rotation with chalk or a felt pen. If a used belt rotates in the
wrong direction when reinstalled, this can result in
breakage. When installing the belt, ensure it is correctly
seated in the pulleys.
Remove ribbed belt.
Fig. 30: Blocking Tensioner With 3090

The tensioning element can be locked in position with a suitable punch (4.5 mm
diameter, approx. 55 mm long). Connecting rod support 3090 can also be used.
Fig. 31: Identifying Connecting Line Bolts (Left)

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Remove connecting pipe between both left and right crossmembers.
Fig. 32: Right Crossmember

Right crossmember.
Fig. 33: Removing Connector At Starter And Transmission

Remove connector at both starter and transmission.

Remove B+ cable from starter.
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Fig. 34: Removing Cooling Line From Transmission

Remove power steering fluid cooling line from transmission.
Remove cooling line retaining clip at lower left and remove coolant hose.
Open hose clamp at lower left of radiator and completely remove cooling line.
Fig. 35: Removing Pulley From Power Steering Pump

Remove pulley from power steering pump (counterhold with socket wrench).
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Fig. 36: Identifying Spring Clamp, Expansion Hose & Bracket

Place clean container under pump.
Open spring clips -3- from intake hose and remove hose.
Remove flexible hose -4-.
NOTE: For vehicles with pressure switch, remove connector first

and remove switch.
Unbolt pump bolts -1- and -2- from bracket (4x).
Fig. 37: Disconnecting Hoses And Connectors On Secondary Air Pump

Remove connector and hoses at secondary air pump.

Remove secondary air pump.
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Fig. 38: Disconnecting Two Coolant Fan Connectors On Radiator Cowl

Disconnect two coolant fan connectors on radiator cowl (bottom left).
Remove cowl from radiator (4 bolts) together with both fans and remove by
pulling downward.
CAUTION: The air conditioning refrigerant circuit must not be

opened.
Remove retainers for refrigerant hoses.
Fig. 39: Unbolting A/C Compressor & Pressing Sliding Bushing Back Into
Hole
Unbolt A/C compressor, lift clear together with refrigerant hoses (do not
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disconnect) and tie in place on hood lock.
Fig. 40: Locating Engine Carrier Bolts (Engine Side)

Loosen engine/transmission mounting (about two turns only) on engine side.

Do not remove bolts completely.
Fig. 41: Locating Engine Carrier Bolts (Transmission Side)

Loosen engine/transmission mounting (about two turns only) on transmission
side. Do not remove bolts completely.
Raise vehicle.
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Fig. 42: Identifying Engine Bracket T10012 & Engine/Transmission Jack

V.A.G. 1383A
Bolt engine bracket T10012 to cylinder block with securing nut and bolt (M10
x 25/8.8). Tighten to approx. 20 Nm.
Install engine/transmission jack V.A.G 1383A to engine bracket and raise
engine/transmission slightly.
Fig. 43: Locating Engine Carrier Bolts (Engine Side)

Unbolt engine/transmission mounting on engine side. (Use step ladder VAS

5085 or equivalent for access to engine compartment from above.)
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Fig. 44: Locating Engine Carrier Bolts (Transmission Side)

Unbolt engine/transmission mounting on transmission side.
Carefully lower engine/transmission assembly.
NOTE: Check to make sure that all connections between

engine and body have been disconnected.
The engine/transmission assembly must be carefully
guided by a second technician while it is being lowered
so as to avoid damaging the body panels.
Fig. 45: Removing Bolts On Engine/Transmission Flange

Remove bolts -1- to -8- on engine/transmission flange.

Separate engine from transmission.
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Engine, attaching to engine stand
Before performing repair work, attach the engine to support clamp VW 313 with
engine and transmission support VW 540.
Work sequence
Unbolt transmission.
Fig. 46: Attaching Engine Sling 2024 A With Retainer 3180 And Lifting Off
Engine/Transmission Jack V.A.G 1383 A With Workshop Crane V.A.G 1202
A
Engage lifting tackle 2024A with retainer 3180 as shown in illustration and lift
engine off engine/transmission jack V.A.G1383A using workshop crane V.A.G
1202A.
Pulley end:
2nd hole on support bar in position 1
Flywheel end:
3rd hole on support bar in position 5
CAUTION: Always use split pins to secure hooks and retainer

pins.
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Fig. 47: Identifying Engine Fastened Using Holding Fixture VW 540 &
Holding Fixture VW 313
Secure engine to engine/transmission support VW 540 and fit to support

clamp.
Engine, installing
NOTE: When performing repairs, always replace seals and gaskets

as well as self-locking nuts and bolts which have a
specified tightening torque.
Installation is performed in the reverse order. Note the following:

Check whether dowel sleeves for centralizing engine/transmission are in
cylinder block and install if necessary.
Fig. 48: Identifying Intermediate Plate, Sealing Flange And Dowel Sleeves
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Engage intermediate plate on sealing flange, and press onto dowel sleeves
(arrows).
Make sure that clutch plate is properly centered.
Check clutch release bearing for wear. Replace if necessary.

Lightly grease clutch release bearing, release bearing guide sleeve and splines
on input shaft with G 000 100.
Install slave cylinder for hydraulic clutch release mechanism:
Refer to
30 CLUTCH for 5 AND 6 SPD. MANUAL TRANSMISSION 02M, 02Y

ALL WHEEL DRIVE
30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 02J FRONT WHEEL
DRIVE
Fig. 49: Identifying Engine Supports Bolts & Distance Between Engine
Console & Support Arm
Adjust engine mounting so that distance -a- (on right side mounting) is about
13 mm. It should be possible to insert a 12 mm flat metal bar (e.g. special tool
2011) without any difficulty.
To move engine within engine console, first loosen bolts -b- on left and right
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engine supports by about 2 turns each.

Adjusting engine mounting. Refer to Engine mountings, adjusting.
Attach selector cables to transmission and adjust:
Refer to
34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 AND 6

SPD. MANUAL TRANSMISSION 02M, 02Y ALL WHEEL DRIVE
34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD.
MANUAL TRANSMISSION 02J FRONT WHEEL DRIVE
Install power steering pump:
Refer to 48 STEERING
Installing drive axle
Insert drive axle.

Insert outer CV joint as far as possible.
Lower vehicle making sure wheels do not touch ground.
NOTE: Wheel bearings can be damaged.
Depress brake pedal (second technician needed).

Tighten 12-point nut.
NOTE: Tightening torques for 12-point nuts vary.
Refer to 40 FRONT SUSPENSION

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Hole
To facilitate installing air conditioning compressor, knock back threaded

bushes -B- for mounting bolts -A- slightly in direction indicated (arrow).
All vehicles
Install ribbed belt. Refer to Installing ribbed belt.

Install front exhaust pipe. Refer to Front exhaust pipe, removing and
installing.
NOTE: Avoid excessive bending of the de-coupling element (no

more than 10°).
Stress-free alignment of exhaust system. Refer to Exhaust system, aligning stress-

free.
Connect coolant hoses. Refer to Engine cooling system components,
overview.
Connect vacuum hoses. Refer to Charge air pressure control system and
vacuum system connections, diagram.
Fill up with coolant. Refer to Filling.
NOTE: Drained-off coolant may only be used again if the

original cylinder head and cylinder block are re-
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installed.
Do not use coolant that is dirty or contaminated.
Check oil level before starting engine. Refer to Engine oil level, checking.
Electrical connections and routing:
Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations
After connecting battery terminals, enter anti-theft code for radio.
Refer to Radio operating instructions
CAUTION: If a battery charger is used to give the engine an

assisted start, there is a risk that the control modules
in the vehicle will be damaged.
Close power windows in front doors to their top positions using electric
switches.
Operate all power window switches again for at least one second in "close"
direction to activate automatic one-touch function.
Set clock to correct time.
Perform adaptation of throttle valve control module.
Refer to
24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V

TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU
TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC
TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP
TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA
Check DTC memory.

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Refer to
01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO
FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU
FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC
FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP
FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA
NOTE: DTCs will be stored in the memory because connectors

have been disconnected. Therefore, check and erase DTC
memory after installing the engine.
Tightening torques
NOTE: The tightening torques listed on this Article apply only

to lightly greased, oiled, phosphated, or black-finished
nuts and bolts.
Additional lubricant such as engine and transmission
oil may be used, but do not use molybdenum lubricant.
Do not use degreased parts.
Tolerance for tightening torques is ± 15%.
Fig. 51: Removing Bolts On Engine/Transmission Flange

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Engine/transmission mountings (manual transmission)
A: centering sleeves
Item No. Bolt Nm

1 M12 x 55 65
2 M12 x 55 1) 65
3 M12 x 140 1) 65
4 M12 x 140 1) 65
5 M10 x 50 45
6 M10 x 70 45
7 M10 x 50 45
8 M12 x 55 65
1) Bolt with M8 stud
Components Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Screw clamps 2
Except for the following:
Axle shafts to M8 40
transmission
Engine support to engine console 1) 85
Transmission support to transmission console 1) 60 + 90° 2)
Drive plate to torque M10 x 1 85

converter
Pendulum support to transmission 1) 40 + 90° 2)
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Pendulum support to subframe 1) 20 + 90° 2)

Front exhaust pipe to turbocharger 40
A/C compressor to bracket 45
Drive axle heat shield to cylinder block 35
Nuts for clamp 40
1) Stretch bolts - replace
2) 90° is one quarter turn

Engine mountings, adjusting
Unbolt hydraulic fluid reservoir above right side engine mounting and pull to
one side.
Distance -a- between engine console -1- and support arm -2- of right side engine
mounting should be about 13 mm. It should be possible to insert a 12 mm flat iron
bar without difficulty (e.g. special tool 2011).
If the gap is too narrow or too wide, proceed as follows:
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Remove air hose -4- from mass air flow sensor.
Remove bolts -2- and -3- and remove air cleaner housing.
Fig. 54: Setting Up Engine Support 10-222A On Two Wing Panel Flanges And
Set Up With Supports 10-222A/1 And Two Spindles
Set up engine support 10-222A onto fender panel flanges with supports10-
222A/1 and two spindles.
Bolt retainer 3180 to right side lifting eye and engage on hook at end of right
side spindle.
Engage hook at end of left side spindle in left side lifting eye.
Raise engine slightly, taking up weight evenly on both spindles.
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Loosen bolts -b- on left and right side support arms by about two turns each.
Insert an iron bar between engine console and support arm, then move engine
until gap -a- measures 13 mm.
Tighten (by hand) all four bolts -b- on left and right side support arms.
Tighten all four bolts to 85 Nm.
13 ENGINE - CRANKSHAFT, CYLINDER BLOCK
ENGINE, DISASSEMBLING AND ASSEMBLING
Ribbed belt, removing and installing
NOTE: The following illustration shows the belt drive on

vehicles without air conditioning.
Before removing the ribbed belt, mark the direction of
rotation using chalk or a felt marker pen. If the belt
rotates in the wrong direction when it is reinstalled, this
can cause breakage. Ensure that the belt is properly
seated in the pulleys when installing.
Installing air conditioning compressor. Refer to
Installing air conditioning compressor, Fig. 3.
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Fig. 56: Ribbed Belt Remove/Install Components

1 - 25 Nm
2 - Tensioning element for ribbed belt
Turn with open-end wrench to loosen ribbed belt. Refer to Removing ribbed
belt.
3 - Vibration damper
With pulley for ribbed belt

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Can only be installed in one position
4 - 25 Nm
5 - Generator
Removing and installing:
Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

To facilitate positioning of Generator on bracket, knock back threaded
bushings for retaining bolts slightly.
6 - 25 Nm
7 - Bracket
Illustration shows version for vehicles without air conditioning
8 - 45 Nm
9 - 25 Nm
10 - Banjo bolt, 30 Nm
11 - Sealing ring
Replace
12 - Pressure line
13 - Sealing ring
Replace
14 - Power steering pump
Removing and installing:
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Refer to 48 STEERING
To facilitate positioning of pump on bracket, knock back threaded bushings for
retaining bolts slightly.
15 - Pulley
For power steering pump
16 - 25 Nm
17 - 25 Nm
18 - Ribbed belt
Position of ribbed belt on vehicles without air conditioning. See Ribbed belt
on vehicles without air conditioning
Position of ribbed belt on vehicles with air conditioning. See Ribbed belt on
vehicles with air conditioning
A double ribbed belt is installed on engines with an A/C compressor
Mark direction of rotation before removing.
Check for wear.
Do not kink
Removing ribbed belt. Refer to Removing ribbed belt
Installing ribbed belt. Refer to Installing ribbed belt
Ribbed belt on vehicles without air conditioning
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Fig. 57: Ribbed Belt On Vehicles Without Air Conditioning

Ribbed belt on vehicles with air conditioning
Fig. 58: Ribbed Belt On Vehicles With Air Conditioning

NOTE: Engines with an air conditioning compressor have a double

ribbed belt installed.
Installing air conditioning compressor
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Hole
To facilitate positioning of A/C compressor, knock back threaded bushings -B-

for retaining bolts -A- slightly in direction indicated (arrow).
Tighten bolts to 45 Nm.
Removing ribbed belt
NOTE: Before removing the ribbed belt, mark the direction of

rotation using chalk or a felt marker pen. If the belt rotates
in the wrong direction when it is reinstalled, this can cause
breakage. Ensure that the belt is properly seated in the
pulleys when installing.
Fig. 60: Relieving Tension On Poly V-Belt

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To loosen ribbed belt turn tensioning element in direction of arrow.

Remove ribbed belt.
Fig. 61: Blocking Tensioner With 3090

The tensioning element can be locked in position with a suitable punch (4.5 mm
diameter, approx. 55 mm long). Connecting rod support 3090 can also be used.
Installing ribbed belt
NOTE: Before installing the ribbed belt ensure that all accessories
(Generator, air conditioning compressor, power steering
pump) are properly secured.
Install ribbed belt.
Fig. 62: Pulling Out Punch Or Connecting Rod Support 3090

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Loosen tensioning element for ribbed belt. Pull out punch or connecting rod
support 3090 (arrows).
Start engine and check that belt runs properly.
NOTE: Engines with an air conditioning compressor have a double

ribbed belt installed.
Toothed belt, removing and installing
Fig. 63: Identifying Special Tools - Toothed Belt, Removing And Installing
NOTE: Mark the direction of rotation before removing the toothed

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belt. If a used belt rotates in the wrong direction when

reinstalled, this can result in breakage.
1 - Engine support
Removing (removing toothed belt). Refer to Removing toothed belt
2 - 45 Nm
3 - Toothed belt guard, top
To remove belt guard, it may be necessary to unbolt retainer for coolant return
line (for turbocharger).
4 - Toothed belt
Mark direction of rotation before removing
Check for wear
Do not kink
Removing. Refer to Toothed belt, removing and installing
Installing belt and adjusting timing. Refer to Installing toothed belt (setting
camshaft timing)
5 - Idler roller
6 - 27 Nm
7 - 65 Nm
Use counter-hold 3036 to loosen and tighten

8 - Camshaft sprocket
For exhaust camshaft

To remove and install, first remove toothed belt. Refer to Toothed belt,
removing and installing
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Note installation position: camshaft sprocket is installed with smaller side

facing out and TDC marking for cylinder 1 visible
9 - Tensioner
10 - Washer
11 - Tensioner for toothed belt

12 - O-ring
Replace
Lightly coat with coolant G 012 A8 D before installing
13 - Coolant pump
Removing and installing. Refer to Coolant pump, removing and installing
14 - 15 Nm
15 - Crankshaft sprocket
Contact surface between sprocket and crankshaft must be free of oil
16 - 90 Nm + 1/4 turn (90°) further
Replace
Counter-hold with 3099 retainer to loosen and tighten
Place 2 washers between sprocket and retainer when mounting retainer: Refer
to Front sealing flange, removing and installing
17 - 15 Nm
18 - 20 Nm
19 - Toothed belt guard, center
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20 - Toothed belt guard, bottom

21 - 10 Nm
Removing toothed belt
Special tools, testers and workshop equipment required:
Fig. 64: Identifying Support Assembly 10-222A

10-222A Engine support bridge
Fig. 65: Identifying Support Assembly 10-222A/1

10-222A/1 Bracket for engine

Engine in vehicle
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Fig. 66: Disconnecting Air Duct At Bottom Of Right Side Longitudinal

Member
Disconnect air duct at bottom of right-hand longitudinal member (air duct leads
Remove sound insulation panels in center and on right (arrows).

Remove ribbed belt and tensioning element. Refer to Ribbed belt, removing
and installing.
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Fig. 68: Detaching Coolant Expansion Tank And Power Steering Reservoir
Remove coolant expansion tank and power steering reservoir (arrows) and
move to one side with hoses connected.
Disconnect vacuum hose from EVAP canister and from connection on throttle
valve.
Disconnect electrical connectors on coolant expansion tank and EVAP
canister.
Remove toothed belt guard (top).
Fig. 69: Engine Support Bridge 10 - 222 A Install With Bracket For Engine 10
- 222 A/1
Set up engine support bracket 10-222 A with supports 10-222 A/1.

Install retainer 3180 to right lifting eye and attach to engine support bracket 10-
222 A.
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Lift engine slightly with spindle of engine support bracket 10-222 A.
NOTE: Lift coolant expansion tank and power steering reservoir

and tie them in place on the engine support bracket.
Fig. 70: Setting Crankshaft To Markings For TDC Of No. 1 Cylinder

Set crankshaft to markings for TDC of No. 1 cylinder (arrows) by turning

central bolt on crankshaft sprocket in direction of rotation.
Remove vibration damper, making sure not to change TDC position.
Remove center and bottom sections of toothed belt guard.
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Fig. 71: Unbolting Engine Support From Engine Console And Engine Console
From Body
Unbolt engine support from engine console and engine console from body
(arrows).
Unbolt connecting piece between engine console and body.
Take out engine console.
Fig. 72: Removing Engine Bracket Bolts

Remove bolts for engine support (arrows), but do not take out engine support.
NOTE: To remove the bolts for the engine support, raise or lower
the engine slightly as necessary via the spindles on engine
support bracket 10-222A.
Mark direction of rotation of toothed belt with chalk or felt pen.
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Fig. 73: Screwing Stud Into Toothed Belt Tensioning Element & Hex Nut Onto
Stud Using Large Washer
Screw M5 x 55 stud -1- into toothed belt tensioning element. Screw hex nut -2-
onto stud -1- using a large washer -3-.
Only tension piston of tensioning element as far as necessary to secure it with a
locking pin (e.g. from lifting appliance 2024A) -arrow-.
Pull out toothed belt through space between engine support and cylinder block.
Installing toothed belt (setting camshaft timing)
NOTE: The position of the toothed belt must be set as

described below, even after repairs in which the belt is
only taken off the camshaft sprocket.
When turning the camshaft the crankshaft must not be
at TDC (danger of damage valves/piston crown).
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Align camshaft sprocket mark with marking on cylinder head cover.
Place toothed belt on crankshaft sprocket (mark direction of rotation using
chalk or paint).
Install toothed belt guard, lower part.
Install vibration damper (note installation position: hole in vibration damper is
over projection on toothed belt sprocket).
Align vibration damper marking with marking on lower part of toothed belt
guard.
Install toothed belt onto coolant pump, then tensioning roller, and finally
camshaft sprocket.
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Fig. 75: Pulling Out Locking Pin, Loosening Piston Of Toothed Belt
Tensioning Element & Removing Stud
Pull out locking pin (arrow) and loosen piston of toothed belt tensioning
element.
Remove stud -1-.
Turn crankshaft two complete turns in engine direction of rotation, set again to
TDC and check adjustment.
Install engine support and console.
Remove engine support bracket 10-222 A with retainer 3180.
Install toothed belt guard (center and top sections).
Install ribbed belt and tensioning element. Refer to Ribbed belt, removing
and installing.
Install and secure coolant expansion tank and power assisted steering reservoir.
Tightening torques
Component Nm
Bottom section of toothed belt guard to cylinder 10
block
Center section of toothed belt guard to cylinder 10
block
Vibration damper to crankshaft 25
Engine support to cylinder block 45
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Engine support to engine console 1) 60 + 90° 2)

Engine console to body 1) 40 + 90° 2)
Coolant expansion tank to body 10
Power steering reservoir to body 10
Screw clamps 2
1) Stretch bolts - replace
2) 90° is a quarter turn

SEALING FLANGES AND FLYWHEEL, REMOVING AND INSTALLING
Sealing flanges and flywheel, removing and installing
NOTE:
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Fig. 76: Identifying Sealing Flanges And Flywheel/Drive

Plate
For repairs to the clutch:
Refer to
30 CLUTCH for 5 AND 6 SPD. MANUAL TRANSMISSION 02M, 02Y

ALL WHEEL DRIVE
30 CLUTCH for 5 SPEED MANUAL TRANSMISSION 02J (FRONT
WHEEL DRIVE)
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When working on the engine, it should be secured to the engine stand using the
engine bracket VW 540.
1 - 90 Nm + 1/4 turn (90°) further
Replace
Counter-hold with 3099 retainer to loosen and tighten
Place 2 washers between pulley and retainer when mounting retainer: Refer to
Front sealing flange, removing and installing
2 - Crankshaft sprocket

Contact surface between sprocket and crankshaft must be free of oil
Removing and installing toothed belt. Refer to Toothed belt, removing and
installing
3 - 15 Nm
4 - Oil seal
Replacing. Refer to Crankshaft oil seal (pulley end), replacing

5 - Sealing flange, front
Must be located on dowel sleeves

Removing and installing. Refer to Front sealing flange, removing and
installing
6 - Cylinder block
Removing and installing crankshaft. Refer to Crankshaft, removing and
installing
Disassembling and assembling pistons and connecting rods. Refer to Pistons
and connecting rods, disassembling and assembling
7 - 60 Nm + 1/4turn (90°) further

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Turn further can be done in several stages

Replace
8 - Dual mass flywheel/drive plate
Can only be installed in one position (holes are offset)

Removing and installing dual mass flywheel. Refer to Dual mass flywheel,
Removing and installing drive plate. Refer to Drive plate, removing and
installing
9 - Intermediate plate

Do not damage or bend when assembling
Is installed on sealing flange. See Installing intermediate plate
10 - Rear sealing flange with oil seal
With gasket for cylinder block

Replacement sealing flange has oil seal in different position
Remove oil pan in order to remove and install. Refer to Oil pan, removing
and installing.
Clean sealing surface before installing.

Lightly oil sealing lip of oil seal.
When installing, push guide sleeve from repair kit onto crankshaft
Installing intermediate plate
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Fig. 77: Identifying Intermediate Plate, Sealing Flange And Dowel Sleeves
Engage intermediate plate on sealing flange and press onto dowel sleeves
(arrows).
Crankshaft oil seal (pulley end), replacing
Removing
Remove ribbed belt. Refer to Removing ribbed belt.

Remove toothed belt. Refer to Toothed belt, removing and installing.
Remove lower air duct.
Fig. 78: Identifying Counterhold 3099

Remove crankshaft sprocket. To do this counter-hold sprocket with 3099

retainer.
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When installing retainer, place 2 washers between sprocket and retainer.
NOTE: On some engines there is a rib on the oil pan flange which
prevents retainer 3099 from being attached as shown. In
this case proceed as follows:
Remove bolts from retainer, and screw back in from the reverse side.
Knock the fitted pins in the square bars downward until they are flush with the
top surface of the bars.
Bolt the retainer to the crankshaft (fit 2 washers between sprocket and
retainer).
Screw central bolt from sprocket back into crankshaft in order to remove oil
seal.
Remove inner part of oil seal extractor 3203 two turns (approx. 3 mm) out of
outer part and lock with knurled screw.
Fig. 79: Loosening Knurled Screw And Turning Inner Part Against
Crankshaft Until Oil Seal Is Pulled Out
Lubricate threaded head of oil seal extractor, place it in position and exerting
firm pressure screw it as far as possible into oil seal.
Loosen knurled screw and turn inner part against crankshaft until oil seal is
pulled out.
Installing
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Fig. 80: Identifying Guide Sleeve 2080 A Mount Onto Crankshaft Journal
Place guide sleeve from 2080 A onto crankshaft journal.

Slide oil seal over guide sleeve.
Fig. 81: Pressing Seal With Center Bolt Into Sealing Flange Using Seal
Installer 3265
Press oil seal in until flush with press sleeve from 3265, using central bolt -1-
for toothed belt sprocket.
Install crankshaft sprocket and lock in position with retainer 3099.
NOTE: Replace central bolt for toothed belt sprocket.
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Tighten central bolt.

Install toothed belt. Refer to Installing toothed belt (setting camshaft
timing).
Tightening torque
Toothed belt sprocket to crankshaft: 90 Nm + 1/4 turn (90°) further

Dual mass flywheel, removing and installing
Removing
Mark installing position of dual mass flywheel on crankshaft with a permanent

felt-marker.
Fig. 82: Inserting Retainer 3067 In Hole On Cylinder Block

Insert counter-hold tool 3067 in drilling in cylinder block, and engage on

flywheel.
Insertion position for counter-hold tool:

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A: to tighten
B: to loosen
Loosen flywheel bolts.
Installing
Install dual mass flywheel to crankshaft in position marked when removing it.
Install new bolts and tighten.
Tightening torque
Flywheel to crankshaft: 60 Nm + 1/4 turn (90°) further

Drive plate, removing and installing
Removing
Fig. 83: Securing Counter-Hold Tool VW 558 To Drive Plate With Hexagon
Bolt
Secure counter-hold tool VW 558 to drive plate with a hex bolt M8 x 45. Place
two M10 hex nuts -1- between counter-hold tool and drive plate.
Loosen securing bolts on drive plate.
Installing
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Fig. 84: Identifying Drive Plate, Grooved Washer & Bolts

Install drive plate using packing plate with notches -1-.
Insert at least 3 of old securing bolts -3- and tighten to 30 Nm.
Fig. 85: Checking Installation Position Of Drive Plate By Measuring At Three

Points And Calculate Average
Check installation position of drive plate by measuring at three points and

calculate average.
Specification: 19.5-21.1 mm
NOTE: Measurement is taken through the hole in the drive plate to

the machined surface of the cylinder block.
If the distance is too large:

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Fig. 86: Identifying Drive Plate, Grooved Washer & Bolts

Remove drive plate again and install appropriate shim -2-.
Measure distance again.
If specification is achieved:
Install new bolts and tighten.
Tightening torque
Driveplate to crankshaft: 60 Nm + 1/4 turn (90°) further

Front sealing flange, removing and installing
Special tools, testers and auxiliary items required

Electric drill with plastic brush attachment
Silicone sealant D 176 404 A2
Removing
and installing.
Remove toothed belt. Refer to Toothed belt, removing and installing.
Remove lower air duct. Refer to Charge air cooling system components,
removing and installing, item 11.
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Fig. 87: Identifying Counterhold 3099

Remove crankshaft sprocket. To do this counter-hold sprocket with 3099
retainer.
When installing retainer, place 2 washers between sprocket and retainer.
NOTE: On some engines there is a rib on the oil pan flange which
prevents retainer 3099 from being attached as shown. In
this case proceed as follows:
Remove bolts from retainer, and screw back in from the reverse side.
Knock the fitted pins in the square bars downward until they are flush with the
top surface of the bars.
Bolt the retainer to the crankshaft (install 2 washers between sprocket and
retainer).
Drain engine oil.
Remove oil pan. Refer to Oil pan, removing and installing.

Unbolt front sealing flange.
Remove sealing flange. Release flange by tapping lightly with a rubber
hammer if necessary.
Remove sealant remaining on cylinder block with flat scraper.
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Fig. 88: Removing Sealant Remains On Sealing Flange With Rotating Plastic
Brush
Remove sealant remaining on sealing flange (with rotating plastic brush or

similar).
WARNING: Wear eye protection
Clean sealing surfaces; they must be free of oil and grease.

Installing
NOTE: The sealing flange must be installed within 5 minutes after

applying silicone sealant.
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Fig. 89: Cutting Off Tube Nozzle & Applying Silicone Sealing Compound To
Oil Pan Sealing Surface
Cut off nozzle of tube at front marking (nozzle diameter approx. 3 mm).
Sealant should applied in a bead 2 - 3 mm wide (arrows).
NOTE: The bead of sealant must not be thicker than 3 mm,

otherwise excess sealant can enter the oil pan and obstruct
the filter screen in the oil intake line.
Fig. 90: Applying Silicone Sealant Bead To Clean Sealing Surface Of Sealing
Flange
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Apply bead of silicone sealant onto clean sealing surfaces of sealing flange, as
illustrated.
Install sealing flange immediately, and tighten all bolts lightly.
NOTE:
Fig. 91: Identifying Guide Sleeve 2080 A Mount Onto

Crankshaft Journal
To install sealing flange with the oil seal already installed,

use guide sleeve from 2080A.
Tighten bolts on sealing flange in diagonal sequence.

Install oil sump. Refer to Installing.
NOTE: After installing, the sealant must be allowed to dry for about
30 minutes before filling with engine oil.
Install crankshaft sprocket.
NOTE: Replace central bolt for sprocket.
Install toothed belt (adjust valve timing). Refer to Installing toothed belt
(setting camshaft timing).
and installing.
Tightening torques
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Sealing flange to cylinder block: 15 Nm

Toothed belt sprocket to crankshaft: 90 Nm + 1/4 turn (90°) further
Chain sprocket, removing and installing
Removing
Remove front sealing flange. Refer to Front sealing flange, removing and
installing.
Remove chain tensioner, oil pump sprocket and chain.
Fig. 92: Pulling Off Chain Sprocket From Crankshaft

Pull chain sprocket off crankshaft with puller -2-. Use suitable washer -1- to
protect end of crankshaft.
Installing
Heat chain sprocket to 220° C in oven.
WARNING: Wear protective gloves.
NOTE: Installation position: wide collar on sprocket facing toward

engine.
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Fig. 93: Installing Chain Sprocket Onto Crankshaft Up To Limit Stop Using
Press Tube 30-100
Using pliers, locate sprocket on end of crankshaft and push onto seat on
crankshaft with drift sleeve 30-100.
CRANKSHAFT, REMOVING AND INSTALLING
Crankshaft, removing and installing
NOTE: When working on the engine it should be secured to the

engine stand with engine bracket VW 540.
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Fig. 94: Crankshaft, Assembly Overview

1 - Oil pump
Removing and installing. Refer to Lubrication system components,
2 - 15 Nm
3 - Chain sprocket
For oil pump drive

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Removing and installing. Refer to Chain sprocket, removing and installing
4 - Bearing caps 1, 2, 4 and 5
For bearing cap without oil groove

For cylinder block with oil groove
Do not interchange used bearing shells (mark)
5 - 65 Nm + 1/4 turn (90°) further
Replace
Tighten to 65 Nm to measure crankshaft radial play
6 - Bearing cap
Bearing cap 1: pulley end
Bearing cap 3 with recesses for thrust washers
Bearing shell retaining lugs (cylinder block/bearing cap) must be on same side
7 - Bearing shell 3
For bearing cap without oil groove
For cylinder block with oil groove
8 - Sensor wheel
For Engine speed (RPM) sensor -G28-

Always replace sensor wheel if securing bolts have been unscrewed
Can only be installed in one position (holes are offset)
9 - 10 Nm + 1/4 turn (90°) further
Replace
10 - Thrust washer
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For bearing cap and cylinder block, bearing 3

Note installation arrangement
11 - Crankshaft
Axial clearance, New: 0.07 - 0.21 mm; Wear limit: 0.30 mm

Check radial clearance with Plastigage ™ , New: 0.01 - 0.04 mm; Wear limit:
0.15 mm
Do not rotate crankshaft when checking radial clearance
Crankshaft dimensions. Refer to Crankshaft dimensions
Crankshaft dimensions
Honing Main journal diameter (mm) Connecting rod journal

dimension diameter (mm)
-0.022 -0.022
Basic 54.00 47.80
dimension
-0.042 -0.042
-0.022 -0.022
1st 53.75 47.55
undersize
-0.042 -0.042
-0.022 -0.022
2nd 53.50 47.30
undersize
-0.042 -0.042
-0.022 -0.022
3rd 53.25 47.05
undersize
-0.042 -0.042
PISTONS AND CONNECTING RODS, DISASSEMBLING AND ASSEMBLING
Pistons and connecting rods, disassembling and assembling

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NOTE: When working on the engine it should be secured to engine

stand with engine bracket VW 540.
Fig. 95: Pistons And Connecting Rods, Assembly Overview

1 - Piston ring
Offset gaps by 120°

Remove and install with piston ring pliers
"TOP" faces toward piston crown
Checking ring gap. See Checking piston ring gap
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Checking ring to groove clearance. See Checking ring to groove clearance
2 - Piston
Checking. See Checking piston

Mark installation position in relation to connecting rod and cylinder number
with a permanent felt marker.
Arrow on piston crown points to pulley end
Install using piston ring clamp
Piston and cylinder dimensions. Refer to Piston and cylinder, dimensions
3 - Connecting rod
Only replace as a set

Mark cylinder number -B-.
Installation position: Marks -A- must be aligned and facing belt pulley side
With hole for lubricating piston pin
4 - Connecting rod bearing cap
Mark cylinder number -B-.

Installation position: Marks -A- must be aligned and facing belt pulley side
5 - 30 Nm + 1/4 turn (90°) further

Replace
Oil threads and contact surface
To measure radial clearance tighten to 30 Nm, but not further
6 - Pressure relief valve, 27 Nm
Opens at 2.5-3.2 bar

Do not apply sealant when installing
7 - Oil spray jet

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For piston cooling
8 - Bearing shell
Note installation position

Ensure retaining lugs fit tightly in recesses
Axial clearance, New: 0.10 - 0.35 mm; Wear limit: 0.40 mm
Check radial clearance with Plastigage, New: 0.01 - 0.05 mm; Wear limit: 0.12
mm
Do not rotate crankshaft when checking radial clearance
With hole for lubricating piston pin
9 - Cylinder block
Checking cylinder bores. See Checking cylinder bores
Piston and cylinder dimensions. Refer to Piston and cylinder, dimensions
10 - Connecting rod bolt
Replace together with item - 5 under Pistons and connecting rods,

disassembling and assembling
11 - Circlip
12 - Piston pin
If difficult to move, heat piston to approx. 60° C.

Remove and install with drift VW 222a
Checking piston ring gap
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Fig. 96: Checking Piston Ring Gap

Push ring squarely from above down to approx. 15 mm from bottom end of
cylinder. To do this use a piston without rings.
Piston ring Gap

New Wear limit
Compression rings mm 0.15 - 0.40 0.80
Oil scraper ring mm 0.25 - 0.50 1.00
Checking ring to groove clearance
Fig. 97: Checking Ring To Groove Clearance

Clean groove before checking clearance.
Piston ring Clearance

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New Wear limit

Compression rings mm 0.02 - 0.07 0.12
Oil scraper ring mm 0.02 - 0.06 0.12
Checking piston
Fig. 98: Checking Piston

Measure pistons approx. 10 mm from lower edge of skirt, at 90° to piston pin
axis.
Permissible deviation from nominal dimension: max. 0.04 mm
Checking cylinder bores
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Fig. 99: Checking Cylinder Bores

Use internal dial indicator (50-100 mm).
Take measurements at 3 positions in both lateral direction -A- and longitudinal

direction -B-.
Permissible deviation from nominal dimension: max. 0.10 mm
NOTE: Measuring the cylinder bores must not be done when the
cylinder block is mounted on a repair stand with adapter
bracket VW 540, as incorrect measurements would then be
possible.
Piston and cylinder, dimensions
Honing dimension Piston diameter Cylinder bore

Basic dimension mm 80.985 81.01
Oversize mm 81.485 81.51
15 ENGINE - CYLINDER HEAD, VALVETRAIN
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CYLINDER HEAD, REMOVING AND INSTALLING
Cylinder head, removing and installing
NOTE: Always replace cylinder head bolts when assembling.

Replace self-locking nuts.
Always replace bolts that are tightened to a specified
angle.
Always replace sealing rings and gaskets when
assembling.
When installing an exchange cylinder head with the
camshafts fitted, the contact surfaces between valve
lifter and cam running surface must be oiled after
installation of the cylinder head.
The plastic protectors fitted to protect the open valves
must only be removed immediately before installing the
cylinder head.
When installing a new cylinder head or cylinder head
gasket, drain off all the old coolant and re-fill with new
coolant.
Cylinder heads which have cracks between the valve
seats or between valve seat inserts and the spark plug
thread can be used further without reducing service life,
provided the cracks do not exceed a maximum of 0.3
mm in width, or when no more than the first 4 turns of
the spark plug threads are cracked.
Removing and installing toothed belt. Refer to Toothed belt, removing and
installing.
Checking cylinder compression. Refer to Compression, checking.
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Fig. 100: Cylinder Head, Removing And Installing - Overview

1 - Cylinder head
If replaced, replace coolant completely.

Removing cylinder head. Refer to Cylinder head, removing
Installing cylinder head. Refer to Cylinder head, installing
Checking for distortion. See Checking cylinder head for distortion
Reworking limit. See Cylinder head reworking limit
2 - Oil deflector
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Note installation position: above intake camshaft between No. 1 and No. 2
cylinders
3 - Cylinder head bolt
Replace
Note sequence when loosening. Refer to Cylinder head, removing
Note sequence when tightening. Refer to Cylinder head, installing
4 - Cylinder head cover gasket

Replace if damaged or leaking
Before installing gasket, apply sealant D 454 300 02 to sides of sealing

surfaces:
Between double bearing cap and cylinder head. See Sealing transition points
between double bearing cap and cylinder head
Between hydraulic chain tensioner and cylinder head. See Sealing points for
hydraulic chain tensioner/cylinder head
5 - Cylinder head cover

6 - Gasket
For ignition coil

Replace if damaged
7 - Ignition coil
Checking
Refer to

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8 - 10 Nm
9 - Filler cap
10 - Seal
Replace if damaged
11 - 10 Nm
12 - Intake manifold gasket
Replace
13 - Cylinder head gasket
Removing cylinder head. Refer to Cylinder head, removing

Position: Part No. toward cylinder head
If replaced, replace coolant completely.
Checking cylinder head for distortion
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Fig. 101: Checking Cylinder Head For Distortion

Use knife-edge straightedge and feeler gauge to measure at several points.
Max. permissible distortion: 0.1 mm

Cylinder head reworking limit
Fig. 102: Cylinder Head Reworking Limit

Reworking cylinder head (shaving) is only permitted down to minimum dimension

-a-.
Minimum dimension -a- = 139.25 mm

Sealing transition points between double bearing cap and cylinder head
Fig. 103: Sealing Transition Points Between Double Bearing Cap And Cylinder
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Head
Carefully apply a thin coat of sealant D 454 300 02 to both edges of sealing
surfaces between double bearing cap and cylinder head (arrows) using a small
screwdriver.
Sealing points for hydraulic chain tensioner/cylinder head
Fig. 104: Sealing Points For Hydraulic Chain Tensioner/Cylinder Head

Carefully apply a thin coat of sealant D 454 300 02 to both edges of sealing
surfaces between hydraulic chain tensioner and cylinder head (arrows) using a
small screwdriver.
Intake manifold, removing and installing
Removing
NOTE: All cable ties which are released or cut open when
removing must be fitted in the same position when
installing.

With ignition switched off, disconnect battery Ground strap.
Remove engine cover.
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Fig. 105: Identifying Hose Clip, Intake Air Temperature (IAT) Sensor -G42 &
Throttle Valve Control Module -J338-
Disconnect connector -1- for Intake Air Temperature (IAT) sensor -G42- and
connector -4- for Throttle valve control module -J338- (located under throttle
valve control module).
Disconnect air hose -2- from throttle valve control module.
Disconnect vacuum hose -3- from throttle valve control module (hose leads to
EVAP canister).

Disconnect connector off Camshaft Position (CMP) sensor -G40- (arrow).
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Fig. 107: Disconnecting Connectors For Injectors And Unclip Support Bar
From Fuel Rail
Disconnect connectors -1- for injectors and unclip support bar from fuel rail -2-
.
Fig. 108: Identifying Electrical Change-Over Valve Connector, Intake

Manifold Brackets & Dipstick Tube
Disconnect connector -1- for electrical change-over valve on underside of
bracket.
Unbolt bracket from intake manifold (-2- and -3-) and disengage dipstick tube -
4-.
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Fig. 109: Identifying Supply Line And Return Line

Press release tabs and pull fuel supply line -1- and fuel return line -2- off
connections.
WARNING: Fuel system is under pressure! Before opening the

system place a cloth around the connection. Then
release pressure by carefully loosening the
connection.
Disconnect crankcase breather hose from T-piece.

Unbolt intake manifold support from intake manifold.
Pull out oil dipstick.
Unbolt intake manifold at flange and remove.
Installing
Installation is performed in the reverse order of removal. Note the following:

After connecting battery terminals, enter anti-theft code for radio.
Close power windows in front doors to their top positions using electrical
switches.
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Perform adaptation of throttle valve control module:
Refer to

Check DTC memory:
Refer to


Cylinder head, removing
Engine in vehicle
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NOTE: Secure all hose connections with the correct hose clips
(same as original equipment)
All cable ties which are opened or cut open when removing must be replaced
in the same position when installing.

With ignition switched off disconnect battery Ground strap.
Drain cooling system. Refer to Draining.
Remove intake manifold. Refer to Intake manifold, removing and installing.
Disconnect coolant line from thermostat housing only. Refer to Coolant line,
removing and installing.
Unbolt coolant line flange from cylinder head (left) and place it to one side.
Disconnect connectors on ignition coils.
Unclip/release all lines and hoses on cylinder head and move clear.
Fig. 110: Identifying Upper Air Line Air Hose & Oil Return Line
Disconnect air hose -1- from upper air line.

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Unbolt retainer for oil return line -2-.
Fig. 111: Identifying Upper Air Line Hose, Heat Shield Bolts & Upper Air
Line Bolts
Release hose -4- from upper air line (hose leads to turbocharger).
Remove bolts -1- and -5- for heat shield on back of cylinder head.
Remove bolts -2- and -3- for upper air line.
Remove upper air line and heat shield.
Unbolt turbocharger from exhaust manifold.
and installing.
Remove toothed belt guard (upper). Refer to Toothed belt, removing and
installing.
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Remove bolts (left arrows) and remove coolant expansion tank together with
hoses.
Remove bolt (right arrow) and remove power steering reservoir. Do not
disconnect hoses.
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Fig. 114: Screwing Stud Into Toothed Belt Tensioning Element & Hex Nut
Onto Stud Using Large Washer
Screw M5 x 55 stud -1- into toothed belt tensioning element.

Screw hex nut -2- onto stud -1- using large washer -3-.
Tension pressure piston of tensioning element only until it can be secured with
a locking pin (e.g. from lifting appliance 2024 A) -arrow-.
NOTE: If it is not possible to insert the locking pin, carefully

tension the pressure piston of the tensioning element just
enough to allow the toothed belt to be removed.
Take toothed belt off camshaft sprocket.

Unbolt ignition coils.
Remove cylinder head cover. Refer to Cylinder head, removing and
installing.
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Fig. 115: Cylinder Head Bolts Loosening Sequence

Maintain sequence when loosening and tightening cylinder head bolts.

Remove cylinder head.
Cylinder head, installing
NOTE: Always replace cylinder head bolts when assembling.

Replace self-locking nuts.
Always replace bolts that are tightened to a specified
angle.
If repairing, carefully remove any remains of gasket
material from the cylinder head and cylinder block.
Make sure that no long scores or scratches are made
on the surfaces.
Carefully remove any remaining emery and abrasive
material.
Remove new cylinder head gasket from packaging, just
before installation.
Handle gasket extremely carefully. Damaging the
silicone layer 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 head.
Ensure fuel hoses are tight.
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Before positioning cylinder head, set crankshaft and camshaft to TDC of No. 1
cylinder.
Fig. 117: Identifying Turbocharger Bracket Bolts

Remove bolts -1- and -2- on turbocharger bracket (about 2 full turns each) to
avoid stressing when installing cylinder head.
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Fig. 118: Identifying Cylinder Block Centering Pins

Place cylinder head gasket in position.
NOTE: Note position of centralizing pins in cylinder block (arrows).
Check installation position of cylinder head gasket.
Part No. should be legible from intake side.
Place cylinder head in position.

Insert cylinder head bolts and tighten by hand.
Fig. 119: Cylinder Head Bolt Tightening Sequence

Tighten cylinder head bolts in two stages in sequence shown as follows:
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Stage 1: 40 Nm
Stage 2: additional 1/2 turn (180°) using rigid wrench (in two 1/4 turns (90°) if
necessary).
NOTE: It is not necessary to re-tighten cylinder head bolts after

repairs have been performed.
Install turbocharger with new gasket and bolt bracket to cylinder block. Refer
to Installing.
NOTE: Follow all instructions for removing and installing toothed

belt. Refer to Toothed belt, removing and installing.
Install cylinder head cover. Refer to Cylinder head, removing and installing.
Installing ribbed belt and tensioning element. Refer to Ribbed belt, removing
and installing.
After connecting battery terminals, enter anti-theft code for radio
switches.
Perform adaptation of throttle valve control module:
Refer to

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Check DTC memory:

Refer to


Electrical connections and routing:

Compression, checking
Requirements
Engine oil temperature not less than 30° C
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Pull connector from Camshaft Position (CMP) sensor -G40- (arrow).
With ignition switched off, disconnect connectors from ignition coils.
Unbolt ignition coils.
Remove spark plugs with spark plug spanner 3122B.
Fully open throttle valve.
Check compressions with compression tester V.A.G 1381 or V.A.G 1763.
NOTE: Using the compression tester:
Refer to Operating instructions
Operate starter until tester shows no further pressure increase.
Compression pressure
New (bar) Wear limit (bar) Permissible difference

between cylinders (bar)
10.0 - 13.0 7.0 max. 3.0
Install spark plugs and ignition coils.

Check DTC memory:
Refer to
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Tightening torque
Component ft lb Nm
Ignition coils to cylinder 7 10
head
Spark plugs to cylinder 22 30
head
Vacuum reservoir to 22 30
cylinder head
VALVE GEAR, SERVICING
Valve gear, servicing
NOTE: Cylinder heads which have cracks between the valve

seats or between valve seat inserts and the spark plug
thread can be used further without reducing service life,
provided the cracks do not exceed a maximum of 0.3
mm in width, or when no more than the first 4 turns of
the spark plug threads are cracked.
After installing new lifters wait for approx. 30 minutes
before starting engine. Hydraulic valve compensation
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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 contact when the starter is operated.
Fig. 121: Valve Gear, Servicing Remove/Install Components

1 - 65 Nm
Use counter-hold 3036 to loosen and tighten

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2 - Camshaft sprocket
Note installation position: camshaft sprocket is installed with smaller side
facing out and TDC marking for cylinder 1 visible
3 - Oil seal

Replacing. Refer to Camshaft oil seals, replacing
4 - Cylinder head
Removing. Refer to Cylinder head, removing
Checking cylinder head for distortion. Refer to Fig. 1 under Checking
cylinder head for distortion
Reworking cylinder head. Refer to Fig. 2 under Cylinder head reworking
limit
Checking valve guides, grinding-in valve seats. Refer to Valve guides,
checking
Installing. Refer to Cylinder head, installing

Sealing connections. Refer to Fig. 3 under Sealing transition points between
double bearing cap and cylinder head and Fig. 4 under Sealing points for
hydraulic chain tensioner/cylinder head
5 - Valve guide
Checking. Refer to Valve guides, checking
Replacing. Refer to Valve guides, replacing
6 - Valve stem seal
Replacing. Refer to Valve stem seals, replacing
7 - Valve springs
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Removing and installing. Refer to Valve stem seals, replacing
8 - Valve spring plate
9 - Valve keepers
10 - Hydraulic valve lifter
Do not interchange
Oil contact surface
Store with cam contact surface downward
Before installing check camshaft axial clearance. Refer to Camshaft axial
clearance, checking.
Checking. Refer to Hydraulic valve lifters, checking

Removing and installing. Refer to Valve stem seals, replacing
11 - Intake camshaft
Valve timing. Refer to Engine data
Checking axial clearance. Refer to Camshaft axial clearance, checking
Removing and installing camshafts. Refer to Camshafts and hydraulic chain
tensioner, removing and installing
Check radial clearance with Plastigage ™ (valve lifters not installed) Wear
limit: 0.1 mm; Run-out max: 0.01 mm
12 - Bearing cap/intake camshaft

Installation sequence. Refer to Camshafts and hydraulic chain tensioner,
13 - Double bearing cap

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Seal connections between double bearing cap and cylinder head. Refer to Fig.
3 under Sealing transition points between double bearing cap and cylinder
head
Coat sealing surface lightly with D 454 300 02 before installation. Refer to
Camshafts and hydraulic chain tensioner, removing and installing.
14 - Exhaust camshaft
Valve timing. Refer to Engine data, Engine data

Checking axial clearance. Refer to Camshaft axial clearance, checking
Removing and installing camshafts. Refer to Camshafts and hydraulic chain
tensioner, removing and installing
Check radial clearance with Plastigage ™ (valve lifter not installed) Wear
limit: 0.1 mm; Run-out max: 0.01 mm
15 - Bearing cap/exhaust camshaft

Installation sequence. Refer to Camshafts and hydraulic chain tensioner,
16 - 10 Nm
17 - 10 Nm
18 - Drive chain
Check for wear

Before removing, mark running direction (installation position). Refer to
Camshafts and hydraulic chain tensioner, removing and installing.
19 - Hydraulic chain tensioner
Before removing, lock in position with retainer V.A.G 3366

Removing and installing. Refer to Camshafts and hydraulic chain tensioner,
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Seal connections between hydraulic chain tensioner and cylinder head. Refer to
Fig. 4 under Sealing points for hydraulic chain tensioner/cylinder head.
20 - Metal/rubber gasket
Replace. Refer to Camshafts and hydraulic chain tensioner, removing and

installing
21 - Gasket
Replace
22 - Exhaust valve
With sodium filling

Note instructions on scrapping valves with a sodium filling. Refer to Valve
dimensions
Do not rework; only grinding-in is permitted
Valve dimensions. See Valve dimensions
Checking valve guides, grinding in valve seats. Refer to Valve guides,

checking
23 - Intake valve
Do not rework; only grinding-in is permitted
Valve dimensions. See Valve dimensions
Checking valve guides, grinding in valve seats. Refer to Valve guides,
checking
24 - Oil seal
For intake camshaft

Replacing. Refer to Camshaft oil seals, replacing
25 - Hall sensor rotor

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Note installation position: locate notch in camshaft
26 - Washer
With conical taper

27 - 25 Nm
28 - Camshaft Position (CMP) sensor -G40-
29 - 10 Nm
Valve dimensions
Fig. 122: Identifying Valve Dimensions

NOTE: Intake and exhaust valves must not be reworked. Only

grinding-in is permitted.
Dimension Intake valve Exhaust valve

Diameter-a- mm 26.80 - 27.00 29.80 - 30.00
Diameter mm 5.95 - 5.97 5.94 - 5.95
Length -c- mm 104.84 - 105.34 103.64 - 104.14
Angle - a - Angle° 45 45
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CAUTION: Worn exhaust valves with sodium filling must not be

disposed of until they have been treated as follows:
The valves must be sawn into two sections with a

metal saw at a point between the center of the
shaft and the valve head. They must not come
into contact with water when this is done.
Throw the valves into a bucket of water (not more
than ten at time). Then step back because a
chemical reaction occurs when the sodium filling
burns. After this treatment the valves can be
disposed of in the normal way.
Camshaft axial clearance, checking
Perform measurement with valve lifters removed and with bearing cap at chain
sprocket end and double bearing cap at camshaft sprocket end installed.
Attach dial indicator with universal dial indicator holder VW 387 to cylinder
head.
Fig. 123: Camshaft Axial Clearance, Checking - Intake Camshaft

Intake camshaft
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Fig. 124: Camshaft Axial Clearance, Checking - Exhaust Camshaft

Exhaust camshaft
Wear limit for intake and exhaust camshaft (axial play): no more than 0.20 mm
Camshaft oil seals, replacing
Replacing exhaust camshaft oil seal
Removing
Remove sound insulation in center and on right side.
and installing.
Remove upper toothed belt guard. Refer to Toothed belt, removing and
installing.
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Disconnect vacuum hose from EVAP canister and from throttle valve
connection.
Unbolt coolant expansion tank and power steering reservoir, but do not
disconnect hoses.
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Screw hex nut -2- with a large washer -3- onto stud -1-.
Tension pressure piston of tensioning element just enough so that it can be
secured with a suitable locking pin (e.g. from lifting appliance 2024 A).


Loosen camshaft sprocket (counter-hold with 3036).
Pull off camshaft sprocket.
Fig. 127: Camshaft Gear Retaining Bolt Installed Into Camshaft To Stop
To guide oil seal extractor, screw securing bolt for camshaft sprocket (arrow)
into camshaft as far as it will go (by hand).
outer part and lock in position with knurled screw.
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Fig. 128: Loosening Knurled Screw And Turning Inner Part Of Extractor
Against Camshaft Until Oil Seal Has Been Extracted
Lubricate threaded head of oil seal extractor 2085, place it in position, and
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.
Installing
Fig. 129: Installing Guide Sleeve 3241/2 Onto Camshaft Journal

Install guide sleeve 3241/2 onto camshaft journal.

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Fig. 130: Pressing Oil Seal In Onto Stop With Press Sleeve 3241/1
Press oil seal in onto stop with press sleeve 3241/1. To do this use bolt 3241/5.
Fig. 131: Checking Camshaft Sprocket Installation Position

Install camshaft sprocket.

Check installation position.
Narrow web of camshaft sprocket faces outward (arrows) and marking for No. 1
cylinder TDC is visible.
Install securing bolt for camshaft sprocket (use counter-hold tool 3036).
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Align vibration damper marking with marking on lower part of toothed belt
guard.
NOTE: If a piston is at TDC the valves could strike the piston when
turning the camshaft. To avoid damage to valves and
pistons the pistons must not be at TDC.
Install toothed belt onto camshaft sprocket.
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Fig. 133: Pulling Out Locking Pin, Loosening Piston Of Toothed Belt
Tensioning Element & Removing Stud
Pull out locking pin (arrow) and loosen piston of toothed belt tensioning
element.
Remove stud -1-.
Turn crankshaft two complete turns in engine direction of rotation, set again to
TDC and check adjustment.
Install upper toothed belt guard.
Installing ribbed belt and tensioning element. Refer to Ribbed belt, removing
and installing.
Tightening torques
Component Nm
Camshaft sprocket to camshaft 65
Ribbed belt tensioner to bracket 25
Replacing intake camshaft oil seal

Removing
Remove ribbed belt. Refer to Removing ribbed belt.

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Disconnect connector from Camshaft Position (CMP) -G40- (arrow).
Remove toothed belt guard (upper section). Refer to Toothed belt, removing
and installing.
Remove CMP sensor housing.
Remove sensor rotor and washer.
Fig. 135: Adapter 2085/1 Threaded In Camshaft

To guide oil seal extractor, screw bolt 2085/1 by hand into camshaft as far as it
will go.
outer part and lock in position with knurled screw.
Fig. 136: Screwing Threaded Head Of Seal Extractor With Forced Pressure
Into Oil Seal
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Lubricate threaded head of oil seal extractor 2085, place it in position and,
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.
Installing
Fig. 137: Installing Guide Sleeve 3241/2 Onto Camshaft Journal

Install guide sleeve 3241/2 onto camshaft journal.
Fig. 138: Pressing In Gasket Up To Stop Using Thrust Sleeve 3241/1 And Bolt
3241/3
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Press oil seal in onto stop with press sleeve 3241/1. To do this use bolt 3241/3.
Install notch in Hall sensor rotor into intake camshaft.
Install washer (conical taper facing outward).
Install CMP sensor housing.
Install toothed belt guard (upper section).

Plug in connector for CMP sensor.
Tightening torques
Component Nm
Hall sensor rotor to camshaft 25
Hall sensor housing to cylinder head 10
Camshafts and hydraulic chain tensioner, removing and installing
Cylinder head installed

Special tools, testers and auxiliary items
Fig. 139: Identifying Counter-Hold Tool 3036

Counter-hold tool 3036

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Fig. 140: Identifying Retainer For Chain Tensioner 3366

Retainer for chain tensioner 3366
Fig. 141: Identifying Puller T40001

Puller T40001
Removing
Remove ribbed belt and tensioning element for ribbed belt. Refer to Removing
ribbed belt.
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Remove engine cover panel above cylinder head.
Remove toothed belt guard (upper section). Refer to Toothed belt, removing
and installing.


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installing.

Screw hex nut -2- onto stud -1- using large washer -3-.
Only tension piston of tensioning element as far as necessary to secure it with a
locking pin (e. g. from lifting appliance 2024 A) -arrow-.


Loosen camshaft sprocket (using 3036).
Remove camshaft sprocket using puller T40001.
Remove CMP sensor housing.
Remove rotor for CMP sensor.
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Fig. 145: Securing Camshaft Adjuster Or Chain Tensioner Using Bracket For
Chain Adjustment 3366
Secure hydraulic chain tensioner with retainer for chain tensioner 3366.
NOTE: If the retainer for chain tensioner is tightened excessively,

this can damage the hydraulic chain tensioner.
Fig. 146: Checking Position Of Camshafts To Each Other

Recheck TDC position of camshafts.
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Marks on camshafts must be in line with arrows on bearing caps.

Clean chain and camshaft sprockets opposite two arrows on bearing caps and
mark installation position with colored marks.
Fig. 147: Checking Distance Between Markings Consists Of 16 Rollers Of

Drive Chain
The distance between the two arrows (and thus between the colored markings)
is 16 rollers on the chain.
The notch on the exhaust camshaft is offset slightly toward the inside in
relation to chain roller -1-.
NOTE: Do not mark chain with a center punch or by making a

notch or similar.
Fig. 148: Identifying Bearing Cap Positions

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First remove bearing caps 3 and 5 on intake and exhaust camshafts.
Remove double bearing cap.
Remove both bearing caps next to intake and exhaust camshaft chain
sprockets.
Remove securing bolts of hydraulic chain tensioner.
Loosen bearing caps 2 and 4 of intake and exhaust camshafts alternately and
diagonally, and remove.
Remove intake and exhaust camshafts with hydraulic chain tensioner.
Installing
Fig. 149: Sealant Application Area Identified By Hatched Surface

Replace rubber/metal gasket for hydraulic chain tensioner and apply a thin coat
of sealant D 454 300 A2 to shaded area.
Install drive chain on camshaft sprockets as follows:
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Fig. 150: Installing Chain So That Colored Markings Are In Line

When the old chain is being re-installed, Install the chain so that the colored
markings are in line (arrows).
Fig. 151: First And Sixteenth Drive Chain Rollers Installed On Chain Gears
When a new chain is being installed, the distance between the notches -A- and
-B- on the camshafts must be 16 rollers on the chain. The illustration shows the
exact positions of the 1st and 16th rollers on the sprockets.
Notch -A- is offset slightly toward the inside in relation to chain roller -1-.
Insert hydraulic chain tensioner into chain.

Locate camshafts together with chain and hydraulic chain tensioner on cylinder
head.
Oil running surfaces of both camshafts.
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NOTE: Dowel sleeves for bearing caps and hydraulic chain

tensioner must be located in cylinder head.
When installing bearing caps ensure that the
identification mark is readable from the intake side of
cylinder head.
Tighten mountings of hydraulic chain tensioner (watch position of dowel

sleeves).
Fig. 152: Identifying Bearing Cap Positions

Tighten bearing caps 2 and 4 of intake and exhaust camshafts in stages and in
diagonal sequence (watch position of dowel sleeves).
Install bearing caps next to chain sprockets on intake and exhaust camshafts.
Check correct setting of camshafts:
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Fig. 153: Checking Position Of Camshafts To Each Other

The two markings on the camshafts must be in line with the two arrows on the
bearing caps (arrows).
Fig. 154: First And Sixteenth Drive Chain Rollers Installed On Chain Gears
The distance between the two arrows on the bearing caps (or between the
colored markings) is 16 rollers on the chain.
The notch on the exhaust camshaft is offset slightly toward the inside in
relation to chain roller -1-.
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Remove holder for chain tensioner 3366.
Fig. 155: Identifying Double Bearing Cap Sealant Application Area

Apply a thin coat of sealant D 454 300 A2 to shaded area on double bearing
cap and install bearing cap (watch position of dowel sleeves).
Install remaining bearing caps (watch position of dowel sleeves).

Install new intake and exhaust camshaft oil seals. Refer to Camshaft oil seals,
replacing.
Fig. 156: Identifying Camshaft Gear Thin Rib Toward Outside And TDC
Marking Visible
Install camshaft sprocket.
Check installation position: Narrow web of camshaft sprocket faces outward

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(arrows) and marking for No.1 cylinder TDC is visible from front.
Install securing bolt for camshaft sprocket (hold in place with retainer 3036).
Install camshaft position sensor.
Install cylinder head cover. Refer to Cylinder head, removing and installing.


Align marking on vibration damper with marking on lower part of toothed belt
guard.
NOTE: The crankshaft must not be at TDC when the camshaft is

rotated, otherwise valves can contact pistons and cause
damage.
Install ribbed belt and ribbed belt tensioning element. Refer to Installing
ribbed belt.
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NOTE: Follow all instructions for removing and installing

toothed belt. Refer to Toothed belt, removing and
installing.
Wait about 30 minutes after installing the camshafts
before starting the engine. The hydraulic valve
compensating elements must settle (otherwise the
valves will strike the pistons).
Hydraulic valve lifters, checking
NOTE: Replace malfunctioning lifters (they cannot be adjusted

or repaired).
Irregular valve noises when starting the engine is
normal.
Start engine and run until coolant fan has switched on once.
Increase engine speed to about 2500 rpm for 2 minutes (perform road test if
necessary).
NOTE: If the irregular valve noises stop but reoccurs repeatedly

during short journeys, a new oil retention valve must be
installed. The oil retention valve is located in the oil filter
bracket. Refer to Lubrication system components, Part II.
If the hydraulic lifters are still noisy, locate malfunctioning lifters as follows:

installing.
Rotate crankshaft clockwise by turning central securing bolt on crankshaft
toothed belt sprocket until cams of lifter to be checked are pointing upward.
Determine play between cam and valve lifter.
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Fig. 158: Pressing Valve Lifter Down With Wooden Or Plastic Wedge
Press lifter down with a wooden or plastic wedge. If a 0.20 mm feeler gauge
can be inserted between camshaft and lifter, replace lifter.
Replacing lifter. Refer to Camshafts and hydraulic chain tensioner, removing

and installing.
NOTE: After installing new lifters the engine must not be

started for approx. 30 minutes (otherwise valves will
strike pistons).
Valve stem seals, replacing
Cylinder head installed
Removing
Remove camshafts. Refer to Camshafts and hydraulic chain tensioner,

Remove valve lifters and place them down with contact surface facing
downward. When doing this ensure that lifters are not interchanged.
Remove spark plugs with spark plug spanner 3122B.
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Set piston of appropriate cylinder to bottom dead center (BDC).
Screw pressure hose VW 653/3 into spark plug thread.
Fig. 159: Identifying Intake And Exhaust Valves Installation Position

The intake and exhaust valves are fitted at different angles in the cylinder head.
Valve spring compressor 3362 can be set accordingly to two different positions:
1 - Upper position for center intake valve

2 - Lower position for the two outer intake valves and the two exhaust valves
3 - Threaded holes on each side to take two M6 x 25 bolts for securing spring
compressor to cylinder head
Fig. 160: Mounting Fitting Tool 3362 On Cylinder Head With Fitting Tool
Securing Bolts
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Mount fitting tool 3362 on cylinder head with fitting tool securing bolts.
NOTE: To install assembly tool 2036 on the exhaust side the studs
at the back of the exhaust side have to be unscrewed.
Set correct position for valve concerned.

Connect pressure hose to compressed air supply.
Air pressure: at least 6 bar
Press valve springs down with threaded spindle and thrust piece 3362/1 and
remove.
NOTE: Tight keepers can be loosened by tapping lightly on the

valve spring plate.
Fig. 161: Removing Valve Stem Seals Using Valve Stem Removal Tool 3364
Pull off valve stem seals with extractor 3364.
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Installing
Fig. 162: Placing Plastic Sleeve On Valve Stem & Placing Valve Stem Seal In
The Tool 3365
To prevent damage to new valve stem seals, place plastic sleeve -A- on valve
stem.
Lightly oil sealing lip of valve stem seal.
Place valve stem seal -B- in the tool 3365 and push carefully onto valve guide.
NOTE: When replacing intake and exhaust valves, lightly oil valve
stems before installing.
Install camshafts. Refer to Camshafts and hydraulic chain tensioner,

NOTE: After installing new lifters wait for approx. 30 minutes

before starting engine. Hydraulic valve compensation
elements have to settle (otherwise valves will strike
pistons).
Valve guides, checking
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Fig. 163: Identifying Special Tool - VW 387 Installed

Insert valve into valve guide until end of valve stem is flush with end of guide.
Due to slight difference in stem diameters, ensure that only an intake valve is
used in intake guide and an exhaust valve in exhaust guide.
Measure amount of sideways play.
Wear limit
Intake valve guide Exhaust valve guide

0.80 mm 0.80 mm
NOTE: If the wear limit is exceeded, repeat the measurement

with new valves. If the wear limit is again exceeded,
replace the valve guide.
If the valve is to be replaced as part of a repair, use a
new valve for the measurement.
Grinding in valve seats
Grind in valve seats only as far as necessary to achieve a good seating pattern.
Valve guides, replacing
Special tools, testers, measuring instruments and auxiliary items required
Drift 3360
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Support 3361
Hand reamer 3363 and cutting fluid
Press tool VW 411
Removing
First check whether valve seat insert rings and, if necessary, cylinder head
sealing surface can be reworked. If not, then valve guide should not be
replaced.
Fig. 164: Inserting Locating Pins For Cylinder Head Bolt Holes In
Appropriate Holes
Set up the support as follows:

Insert locating pins for cylinder head bolt drillings -A- in holes 2 and 3.
Insert pin -B- in appropriate hole (marked according to valve angle).
Outer intake valves: 21.5 Angle°
Central intake valve: 15 Angle°
Exhaust valves: 20 Angle°
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Fig. 165: Pressing Out Worn Valve Guides Using Drift 3360
Press out worn valve guides as follows using drift 3360:
Valve guides without shoulder from camshaft side

Valve guides with shoulder (repair version) from combustion chamber side
Installing
NOTE: When the shoulder on guide makes contact, the pressure

must not exceed 10 kN (approx. 1.0 t), otherwise the
shoulder may break off.
Coat new valve guides with oil and press with drift 3360 into cold cylinder
head from camshaft side until shoulder makes contact.
Ream guides out with hand reamer 3363 using plenty of cutting fluid.
Rework valve seats. Refer to Valve seats, reworking.
Replace valve stem seals. Refer to Valve stem seals, replacing.
Valve seats, reworking
Special tools, testers, measuring instruments and auxiliary items required
Depth gauge
Valve seat refacing tool
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NOTE: When repairing engines with leaking valves, it is not

sufficient to reface the valve seats and replace the
valves. The valve guides must also be checked for
wear. This is particularly important on high mileage
engines. Refer to Valve guides, checking.
Only rework the valve seats as far as is necessary to
ensure a good seating pattern.
Before starting to rework the valve seats, calculate the
maximum permissible reworking dimension.
If the maximum reworking dimension is exceeded, the
hydraulic lifters will not work properly and the cylinder
head will have to be replaced.
Calculating maximum permissible reworking dimension
Insert valve and press firmly against valve seat.
NOTE: If the valve is to be replaced as part of a repair, use a new

valve for the calculation.
Measure distance between end of valve stem and central axis of camshaft
(central axis of camshaft is level with top of cylinder head.)
Calculate max. permissible reworking dimension from measured distance and
minimum dimension.
Minimum dimensions
Outer intake valves Central intake valve Exhaust valves
34.0 mm 33.7 mm 34.4 mm
Measured distance minus minimum dimension = max. permissible reworking

dimension.
Example (for outer intake valve):

Measured distance 34.4 mm
- Minimum dimension - 34.0 mm
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= Max. permissible reworking dimension = 0.4 mm

1)
1) The maximum permissible reworking dimension is shown in the illustration

under Reworking valve seats as dimension "b."
NOTE: If the maximum permissible reworking dimension is 0 mm

or less than 0 mm, repeat the measurement with a new
valve. If the measured result is again 0 mm or less than 0
mm, replace the cylinder head.
Reworking valve seats
Fig. 166: Intake/Exhaust Valve Seat Measurements

Intake valve seat

a = 26.2 mm diameter
b = Max. permissible
reworking dimension 1)
c = 1.5-1.8 mm
Z = Bottom surface of
cylinder head
a = 45° valve seat angle
ß = 30° upper correction
angle
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gamma = 60° lower correction

angle
Exhaust valve seat

a = 29.0 mm diameter
b = Max. permissible
reworking dimension 1)
c = Approx. 1.8 mm
Z = Bottom surface of
cylinder head
a = 45° valve seat angle
ß = 30° upper correction
angle
gamma = 60° lower correction
angle
1) Calculating maximum permissible reworking dimension. Refer to Calculating

maximum permissible reworking dimension.
17 ENGINE - LUBRICATION
LUBRICATION SYSTEM COMPONENTS, REMOVING AND INSTALLING
Lubrication system components, removing and installing
NOTE: If large quantities of metal shavings or particles are

found in the engine oil when repairing the engine,
carefully clean the oil passages and replace the oil
cooler and all the oil spray jets in order to prevent
further damage occurring later.
The oil level must not be above the "Max." mark,
otherwise there is a risk that the catalytic converter may
be damaged.
Checking oil pressure and oil pressure switch. Refer to
Oil pressure and oil pressure switch, checking
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Viscosity grades and oil specifications. Refer to Engine

oil.
Checking engine oil level. Refer to Engine oil level,
checking.
Oil system capacity with filter change: 4.8 qts. (4.5
liters)
Oil system capacity without filter change: 4.2 qts. (4.0
liters)
Lubrication system components, Part I
Fig. 167: Lubrication System Components, Removing And Installing Overview

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- Part I
1 - Oil pump
With pressure relief valve (12 bar)

Removing and installing. Refer to Oil pump, removing and installing
Before installing, check that both dowel sleeves for centering oil
pump/cylinder block are fitted.
Replace pump if there is scoring on moving surfaces and gear teeth
Tightening torque for oil pump cover to oil pump housing: 10 Nm
2 - Chain sprocket for oil pump

Note correct position
Sprocket can only be fitted on oil pump shaft in one position
3 - 25 Nm
4 - Drive chain for oil pump
Mark running direction before removing.

Check for wear.
5 - Sealing flange
Apply silicone sealant D 176 404 A2 before installing. Refer to Installing.
Replacing crankshaft oil seal on pulley end. Refer to Crankshaft oil seal
(pulley end), replacing
6 - 15 Nm
7 - Chain tensioner
Tighten to 15 Nm
Do not disassemble
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Note installed position

Pre-tension spring and engage before installing
If spring is broken replace entire chain tensioner.
8 - Chain sprocket
Removing and installing. Refer to Chain sprocket, removing and installing
9 - Dowel sleeves
10 - 15 Nm
11 - Suction line
Clean strainer if soiled.
12 - O-ring
Replace
13 - Baffle plate
Only install with oil pump installed

14 - 15 Nm
15 - 15 Nm
16 - Oil pan
Apply silicone sealant D 176 404 A2 when installing. Refer to Installing
17 - Seal
Replace
18 - Oil drain plug, 30 Nm
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Lubrication system components, Part II
Fig. 168: Lubrication System Components, Removing And Installing Overview

- Part II
1 - Plug, 40 Nm
2 - Seal
Replace
3 - Spring
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For pressure relief valve, approx. 4 bar
4 - Piston
For pressure relief valve, approx. 4 bar
5 - Gasket
Replace
6 - Oil retention valve
Tightening torque: 8 Nm
Built into oil filter bracket
7 - O-ring
Replace
Slide on until flush with collar on line - Lubrication system components,
Part II
8 - Line
9 - Retaining clip
10 - Screw plug, 15 Nm
11 - Seal
If seal is leaking, cut open and replace.
12 - 20 Nm
13 - Oil supply line
To turbocharger
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15 - Seals
Replace
16 - Oil pressure switch -F1-, 1.4 bar, 25 Nm
Black insulation
Checking. Refer to Oil pressure and oil pressure switch, checking
17 - Seal
If seal is leaking, cut open and replace.
18 - 15 Nm + 1/4 turn (90°) further
Replace
19 - Gasket
Replace
Engage in projections on oil cooler
20 - Oil filter
Loosen with oil filter wrench 3417
Tighten to 20 Nm
Observe installation instructions on oil filter
Observe change intervals
21 - 25 Nm
22 - Oil cooler
See note. Refer to Lubrication system components, removing and installing

Ensure clearance to adjacent components
Coolant hose connection diagram. Refer to Engine cooling system
components, overview
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23 - Oil filter bracket

With pressure relief valve (approx. 4 bar)
Oil pan, removing and installing
Electric drill with plastic brush attachment

Silicone sealant D 176 404 A2
Removing
Fig. 169: Locating Center Sound Insulation Fasteners

Remove center sound insulation panel (arrows).

Drain engine oil.
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Fig. 170: Removing Oil Return Line From Oil Pan

Remove bracket -2- for oil return line.

Remove oil return line from oil pan.
Remove oil pan.
NOTE: Use special tool 3185 to loosen and tighten oil pan screws.
Remove using 3249 hex ball socket.
Remove oil pan (if necessary, loosen pan by lightly tapping with rubber
mallet).
Remove sealant remaining on cylinder block with flat scraper.
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Fig. 171: Removing Sealant Residue From Oil Pan With A Rotating Brush
Remove remaining sealant from oil pan (with rotating plastic brush or similar).
WARNING: Wear eye protection.
Clean sealing surfaces: they must be free of oil and grease.

Installing
NOTE: The oil pan must be installed within 5 minutes after

applying the silicone sealant D 176 404 A2.
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Fig. 172: Cutting Off Tube Nozzle & Applying Silicone Sealing Compound To
Oil Pan Sealing Surface
Cut off nozzle on tube at front marking (nozzle diameter approx. 3 mm).
Thickness of sealant bead: 2-3 mm
NOTE: The bead of sealant must not be thicker than 3 mm,

otherwise excess sealant will enter the oil pan and obstruct
the strainer in the oil intake line.
Fig. 173: Identifying Clean Sealing Surfaces Sealant Application Areas

Apply silicone sealant to clean sealing surface on oil pan as illustrated.

Illustration shows position of sealant bead on cylinder block.
NOTE: Apply sealant bead with particular care around rear sealing
flange (arrows).
Install oil pan immediately and bolt to cylinder block. Start by tightening all
bolts by hand.
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Tighten 3 bolts securing oil pan to transmission.

Tighten bolts securing oil pan to cylinder block in two stages in diagonal
sequence.
Tightening torques
Component ft lb Nm
Oil pan to cylinder block 11 15
Oil pan to transmission 33 45
NOTE: When installing the oil pan with the engine out of the
vehicle, ensure that the oil pan is flush with the cylinder
block at the flywheel end.
After installing the oil pan, wait for about 30 minutes for
the sealant to dry before putting in engine oil.
Oil pump, removing and installing
Removing
Fig. 174: Detaching Oil Pump

Loosen bolts (arrows).

Remove oil pump but leave chain sprocket in place.
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Installing
Insert dowel sleeves at top of oil pump.
Chain sprocket can only be installed in one position on oil pump shaft.
Install oil pan. Refer to Installing.
Tightening torques
Component ft lb Nm
Chain sprocket to 18 25
oil pump shaft
Oil pump to 11 15
cylinder block
Oil pressure and oil pressure switch, checking
Function of dynamic oil pressure warning system
Checking warning lamp
The oil pressure warning lamp lights up when the ignition is switched on
("Terminal 15 on") with the engine not running (this does not apply to vehicles with
auto-check system).
Conditions for activation of warning

Engine not running; oil pressure switch closed.
Coolant temperature above 60° C, engine speed above 1500 rpm and oil
pressure switch open.
When engine speed is above 5000 rpm an active oil pressure warning is not
cancelled, irrespective of the condition of the oil pressure switch.
If the power supply to the control unit is OK (Terminal 15) and the oil pressure
switch is open for longer than 0.5 seconds at engine speeds above 1500 rpm,
this condition is stored in the memory. If this condition occurs three times with
"Terminal 15 on," the warning will also become active or remain active at
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engine speeds below 1300 rpm.

Requirements
Oil level OK
Oil pressure warning lamp -K3- must come on when ignition is switched on
In vehicles with auto-check system the "OK" display must appear (call up
symbol)
Engine oil temperature approx. 80° C (coolant fan must have cut in once)
Checking oil pressure switch
Disconnect wire from oil pressure switch.
Fig. 175: Removing Oil Pressure Switch And Screwing In Oil Pressure Tester
V.A.G 1342
Remove oil pressure switch and screw in oil pressure tester V.A.G 1342.
Screw oil pressure switch -2- intoV.A.G 1342.
Connect brown wire -1- of tester to Ground (-).
Connect LED voltage tester V.A.G 1527 to oil pressure switch and positive
side of battery (+).
LED voltage tester should not light up.
If the LED voltage tester lights up:

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Replace oil pressure switch.

Start engine.
LED voltage tester should light up at 1.2-1.6 bar.
If the LED voltage tester does not light up:
Replace oil pressure switch.
NOTE: The oil pressure switch may reach its switching point while
the engine is being turned over by the starter. It is therefore
important to watch the tester and the LED voltage tester
while starting the engine.
Checking oil pressure

Disconnect wire from oil pressure switch.
Fig. 176: Removing Oil Pressure Switch And Screwing In Oil Pressure Tester
V.A.G 1342
Remove oil pressure switch and screw in oil pressure tester V.A.G 1342.
Screw oil pressure switch -2- intoV.A.G 1342.
Start engine (engine oil temperature at least 80° C).
Oil pressure at idling speed: at least 1.0 bar

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Oil pressure at 3000 rpm: between 3.5 and 4.5 bar
If the specifications are not obtained:
Replace oil filter bracket with pressure relief valve (Refer to Lubrication
system components, Part II) or replace oil pump (Refer to Oil pump,
removing and installing).
Engine oil
A high-quality multigrade oil is put in at the factory. This oil may be used all year
round, except in extremely cold climates.
Viscosity grades and oil specifications
Fig. 177: Viscosity Grades And Oil Specifications

Select the viscosity grade of the oil according to the chart. The oil does not need
changing for brief variations of temperature outside the temperature ranges shown.
The specifications listed here must appear on the container - either singly or
together with other specifications.
A - High lubricity multigrade oils, specification VW 500 001
B - Multigrade oils, specification VW 501 011

- Multigrade oils, specification API-SJ or API-SL2
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1) The date given after the VW specification must be not earlier than 10.91.
2) Only use these grades of oil if the approved grades are not available.
Different types of oil may be mixed if necessary when topping up.

Engine oil level, checking
Conditions
Check the oil level only when the engine is warm (oil temperature above 60°
C)
Vehicle must be standing on level ground when checking the oil level. Wait a
few minutes after switching off the engine to allow the oil to flow back into the
oil pan
Work sequence
Pull out dipstick, wipe off with a clean cloth and insert again as far as it will
go.
Pull out dipstick again and read oil level.
Fig. 178: Markings On Oil Dipstick

Markings on oil dipstick:

a - Do not top up oil.
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b - Oil can be topped up. Oil level may rise as far as area -a- after topping up.
c - Oil must be topped up. It is sufficient if oil level is somewhere in area -b-
(grooved area on dipstick) after topping up.
NOTE: The oil level must not be above the max. marking on the
dipstick.
19 ENGINE - COOLING SYSTEM

ENGINE COOLING SYSTEM COMPONENTS, REMOVING AND INSTALLING
Engine cooling system components, removing and installing
NOTE: When the engine is warm the cooling system is under

pressure. If necessary release pressure before
commencing repair work.
Secure all hose connections with hose clamps of the
same type as those installed at the factory.
V.A.G 1921 hose clip pliers are recommended when installing spring-type
clips.
Replace all gaskets and seals.
The arrow markings on the coolant lines and on the ends of the hoses must be
aligned with each other.
Draining and filling cooling system. Refer to Draining.
Anti-freeze concentration. Refer to Filling.

Coolant hose connection diagram. Refer to Engine cooling system
components, overview.
Checking cooling system for leaks with V.A.G 1274 and 1274/8. Refer to
Cooling system, checking for leaks.
Removing coolant pump. Refer to Coolant pump, removing and installing.
Removing coolant thermostat. Refer to Coolant thermostat, checking,

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Engine cooling system components, overview
Fig. 179: Engine Cooling System Components, Overview

1 - Radiator
After replacing replace entire coolant
2 - Oil cooler
Removing and installing. Refer to Lubrication system components, Part II,
item 22
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3 - Coolant pump, coolant thermostat

Removing and installing coolant pump. Refer to Coolant pump, removing
and installing
Check for ease of movement.
Removing and installing coolant thermostat. Refer to Coolant thermostat,
checking, removing and installing
Testing, operating data. Refer to Checking coolant thermostat
4 - Cylinder block
5 - Expansion tank
Checking filler cap. Refer to Checking pressure relief valve in filler cap
6 - Turbocharger
7 - Intake manifold
8 - Heating system heat exchanger
9 - Transmission oil cooler
For ATF in automatic transmission

Engine cooling system, draining and filling
Draining
NOTE: Collect drained coolant in a clean container for re-use

or disposal.
Coolant must only be mixed with clean drinking water.
WARNING: Hot steam can escape when the cap on the

expansion tank is opened. Cover the cap with a
cloth, and open it carefully.
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Remove center sound insulation panel.
Place drip tray V.A.G 1306 below engine.
Fig. 181: Turning Drain Screw On Radiator

Turn drain screw (arrow) on radiator counter-clockwise (install an extension

hose to connection if necessary).
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Fig. 182: Disconnecting Bottom Coolant Hose At Oil Cooler To Drain Off
Remaining Coolant
Also disconnect bottom coolant hose from oil cooler (arrow), and drain
remaining coolant.
Filling
NOTE: Only use coolant additive G 012 A8 D which meets

specification TL VW 774 D (identifiable by red color).
CAUTION: Do not use G 011 A8 C. The two different coolant

additives G 011 A8 C and G 012 A8 D must not be
mixed together. Otherwise this can result in serious
damage to the engine.
If the fluid in the expansion tank is brown it means G 012 A8 D has been
mixed with another type of coolant. In this case, flush out the cooling system
and put in fresh coolant. To flush the system, fill it with clean drinking water
and run the engine for about 2 minutes. This should remove very nearly all of
the old coolant.
G 012 A8 D and coolant additives marked "meeting specification TL VW 774
D" prevent frost and corrosion damage, stop scaling, and at the same time raise
the boiling point of coolant. For these reasons the cooling system must be filled
all year round with the correct anti-freeze and anti-corrosion additive.
Because of its high boiling point, the cooling improves engine reliability under
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heavy loads, particularly in countries with tropical climates.

Frost protection is required down to about -25° C (or to about -35° C in
countries with arctic climates).
The coolant concentration must not be reduced by adding water even in

warmer seasons and in warmer countries. The anti-freeze ratio must be at least
40%.
If greater frost protection is required in very cold climates, the amount of G
012 A8 D can be increased, but only up to 60% (this gives frost protection to
about -40° C), as otherwise frost protection is reduced again and cooling
effectiveness is also reduced.
If the radiator, heat exchanger, cylinder head or cylinder head gasket are
replaced, do not re-use old coolant.
Recommended mixture ratios:
Frost protection Anti-freeze Quantity of G 012 Quantity of

to concentration water1)
A8 D 1)
-25° C 40 % 2.0 ltr. 3.0 ltr.
-35° C 50 % 2.5 ltr. 2.5 ltr.
1) Coolant quantity: 5.0 liters (may vary depending upon the vehicle equipment)
NOTE: Use clean drinking water in addition to coolant to top off

cooling system.
Screw in coolant drain plug.
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Fig. 183: Identifying Expansion Tank

Top up coolant to max. mark on expansion tank.
Start engine and run at approx. 1500 rpm for max. 2 minutes and at same time
fill with coolant up to overflow hole on expansion tank.
Install expansion tank cap.
Run engine until coolant fan cuts in.
Stop engine.
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, coolant level must be between the min. and max.
marks

Coolant pump, removing and installing
NOTE: Always replace seals and gaskets.
Removing
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Fig. 185: Disconnecting Air Duct At Bottom Of Right Side Longitudinal

Member
Disconnect air duct at bottom of right side longitudinal member (air duct leads
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Remove center and right side sections of sound insulation (arrows).
and installing.
Disconnect vacuum hose from EVAP canister and from throttle valve
connection.
Remove coolant expansion tank (left arrows) together with hoses.
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Unbolt power steering reservoir (right arrow). Do not disconnect hoses.

Remove toothed belt guards (upper and center). Refer to Toothed belt,


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Screw M5 x 55 stud -1- into toothed belt tensioning element. Screw hex nut -2-
onto stud -1- using large washer -3-.
Tension pressure piston of tensioning element only until it can be secured with
a locking pin (e.g. from lifting appliance 2024 A) -arrow-.

Remove toothed belt from camshaft sprocket.
NOTE: The vibration damper and bottom toothed belt guard do

not have to be removed.
The toothed belt should be left in position on the
crankshaft sprocket.
Cover toothed belt with a cloth to protect it from
coolant before removing coolant pump.
Remove lower air duct (Refer to Charge air cooling system components,
removing and installing, item 11).
All models
Fig. 190: Identifying Coolant Pump & Securing Bolts

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Remove coolant pump securing bolts -1- and remove coolant pump -2-.
Installing
Installation is performed in the reverse order, noting the following:
Clean and smooth down sealing surface for O-ring as required.

Moisten new O-ring with coolant G 012 A8 D.
Install coolant pump. Installation position: plug in housing faces downward.
NOTE: Follow all the instructions on removing and installing the

toothed belt. Refer to Toothed belt, removing and installing.
and installing.
Fill with coolant. Refer to Filling.
Tightening torque
Component ft lb Nm
Coolant pump to cylinder 11 15
block
Coolant thermostat, checking, removing and installing
Removing
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opened.
Unbolt front engine cover support from intake manifold.

Remove retainers for refrigerant hoses.
Hole
Unbolt A/C compressor, lift clear together with refrigerant hoses (do not
disconnect) and tie in place on hood lock.
All vehicles
Fig. 192: Identifying Elbow Connection, Bolts, O-Ring & Thermostat

Disconnect coolant hose from connection -3-.

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Remove bolts -4- and remove connection, O-ring -2- and coolant thermostat -
1-.
Installing
Clean and smooth down sealing surface for O-ring as required.

Insert coolant thermostat.
Installation position: bowed metal strip on thermostat must be vertical.

Moisten new O ring with coolant G 012 A8 D.
Tighten bolts.
Tightening torque
Connection to cylinder block: 15 Nm
Checking coolant thermostat
Heat thermostat in water bath.
Starts to open Fully open Opening travel

approx. 87° C approx. 102° C 1) at least 7 mm
1) Cannot be tested
Coolant line, removing and installing
Removing

Remove intake manifold. Refer to Intake manifold, removing and installing.
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Disconnect air duct -4- from mass air flow sensor.
Remove bolts -2- and -3- and take off air cleaner housing.
Remove air intake hose from connection on turbocharger as follows:

Disconnect vacuum hose -1- from air recirculation valve.

Disconnect hose from pressure control valve for crankcase breather -2-.
Disconnect electrical connector from Wastegate bypass regulator valve -3- -
N75.
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Disconnect hose -5- at bulkhead (hose leads from solenoid valve to

turbocharger).
Take solenoid charge pressure control valve out of air intake hose and place it
to one side on engine.
Pull retainer off turbocharger connection and remove air intake hose.
Disconnect coolant hose from coolant line (hose leads to heat exchanger for
heater).
Vehicles with automatic transmission
Fig. 195: Identifying Transmission Electrical Connections

Disconnect connectors:
1 - for solenoid valves (10-pin connector)
2 - for Vehicle speed sensor (VSS) -G68-

All vehicles
Unbolt coolant line retainer from coolant line flange on left of cylinder head.
Disconnect hose (leading to oil cooler) from coolant line.
Remove crankcase breather line.
Unbolt coolant line retainer from cylinder block.
Disconnect hose (leading to coolant expansion tank) from coolant line (right).
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Unbolt coolant line retainer from tensioning element for ribbed belt.
Pull tapered collar off oil dipstick tube.
Disconnect wires/connectors as follows:
Knock Sensor (KS) 1 -G61-

Engine speed (RPM) sensor -G28- (middle, gray)
Knock sensor (KS) 2 -G66-
Take connectors out of retainer.

Remove oil line leading to turbocharger and unbolt retainer for oil line (both
are attached to oil filter bracket).
Unbolt retainer for connectors.
Unbolt knock sensors 1 and 2.
Unbolt left side coolant line flange from cylinder head.
Remove coolant line.
Installing
Before installing, clean and smooth down sealing surface for O-ring as
required.
Fig. 196: Identifying O-Ring & Coolant Pipe

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Moisten new O-ring -1- with G 012 A8 D and slide onto coolant line -2-.
Push coolant line into opening in cylinder block.
switches.
Check DTC memory:
Refer to


have been unplugged. Therefore, check and erase DTC
Tightening torques
Component ft lb Nm
Coolant line bracket to cylinder block 7 10
Coolant line bracket to oil filter 15 20
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bracket
Coolant line bracket to coolant line 7 10
flange
Radiator, removing and installing
NOTE: Always replace gaskets and seals.

Removing


Remove sound insulation (arrows).

Drain cooling system. Refer to Draining
Release clamps and disconnect coolant hoses from connections on radiator (top
and bottom).
Remove front bumper (cover section only):
Refer to 63 BUMPERS
NOTE: Only remove the cover section for the front bumper.
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Fig. 198: Identifying Radiator Fan Cowl Connectors, Coolant Fan Control
(FC) Thermal Switch -F18- Connectors & Radiator Cowl
Disconnect connectors -1- on radiator cowl.

Disconnect connector -2- from Coolant Fan Control (FC) Thermal Switch -
F18-.
Unbolt radiator cowl -3- together with coolant fans (4 bolts) and pull
downward to remove.
Vehicles without air conditioning
Fig. 199: Removing Securing Bolts On Radiator

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Remove 4 securing bolts (arrows) on radiator.
Lower radiator out of vehicle.
Fig. 200: Removing Four Securing Bolts For Condenser & Radiator
Remove four securing bolts -1- for condenser.

Remove four securing bolts -2- for radiator.

opened.
NOTE: To prevent damage to the condenser and refrigerant

lines/hoses, ensure that the lines and hoses are not
stretched, kinked or bent.
Unbolt Coolant Fan Control (FC) control module -J293- from left side
longitudinal member (in front of battery).
Carefully lower radiator between engine and condenser and remove from
below.
Installing

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Fig. 201: Installing Mounts And On Radiator

Install mountings -3- and -4- on radiator as illustrated.
Install radiator securing bolts (help of a 2nd technician is required).
Install front bumper:
Refer to 63 BUMPERS
Replace O-rings in coolant hose connections.

switches.
Check DTC memory:
Refer to

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Tightening torques
Components ft lb Nm
Radiator cowl to radiator 7 10
Thermal switch to 26 35
radiator
Radiator to lock carrier 7 10
Condenser to radiator 7 10
Control module to 7 10
longitudinal member
Cooling system, checking for leaks
Requirement
Engine at operating temperature

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Fig. 202: Positioning Cooling System Tester V.A.G 1274 With Adapter V.A.G
1274/8 On Expansion Tank
Install tester V.A.G 1274 with adapter V.A.G 1274/8 onto expansion tank.
Using hand pump on tester, build up a pressure of approx. 1.0 bar.
If this pressure drops:
Locate leak and repair malfunction.

Checking pressure relief valve in filler cap
Screw filler cap onto tester with adapter V.A.G 1274/9.
Fig. 203: Checking Pressure Relief Valve In Filler Cap

Attach hand pump and build up pressure.

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Pressure relief valve should open at a pressure of 1.4 - 1.6 bar.

21 TURBOCHARGER, G-CHARGER
CHARGE AIR PRESSURE SYSTEM WITH TURBOCHARGER
Charge air pressure system with turbocharger
NOTE: Observe rules for cleanliness. Refer to Rules for

cleanliness.
When performing repairs, replace seals, gaskets, self-
locking nuts and bolts which have a specified
tightening torque.
Secure all hose connections with the correct hose clips
(same as original equipment).
Before performing checks or repair work, make sure that all lines and hoses are
securely connected and that there are no leaks.
Scan Tool (ST) and test equipment safety precautions
WARNING: Due to weight, size and need for manual

operation of test instruments while vehicle is
driven on public roads, instrument must be used
only with a Driver operating the vehicle and an
Instrument Operator operating the test
equipment.
Do not use Instrument with Driver only. Always
use two persons to conduct test.
Do not place Instrument on lap of Driver or front
seat passenger because emergency stop may
dislodge Instrument and cause airbag
deployment with risk of injury to Instrument
Operator.
Model specific WARNINGS! continued. Refer to Scan Tool (ST) and test
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equipment safety precautions.
WARNING: Use of Instrument in Audi TT Coupe:
Place Instrument in rear seating area and secure

by available safety belt.
Instrument Operator must be seated in the other
rear seating position, after sliding front
passenger seat and moving the seat back as far
forward as possible. Do not activate the seat
back release lever.
Instrument Operator must wear safety belt.
Use of Instrument in Audi TT Roadster:
Use only Instrument V.A.G 1551 Scan Tool (ST).

DO NOT USE VAS 5051.
Before test, deactivate passenger's airbag using
key operated switch in glove compartment or via
OBD program. Refer to
01 ON BOARD DIAGNOSTIC (OBD) for 1.8
LITER 4-CYL. 5V TURBO FUEL INJECTION &
IGNITION, ENGINE CODE(S): AMU
IGNITION, ENGINE CODE(S): ATC
IGNITION, ENGINE CODE(S): AWP
IGNITION, ENGINE CODE(S): BEA
; Repair Group 01, Function 10 (Adaptation).
Instrument Operator must be seated on
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passenger seat with safety belt worn.

Place Instrument in foot well in front of
passenger seat in a manner allowing the
Operator to use the Instrument in a safe manner.
After completion of test, re-activate front

passenger airbag.
Charge air pressure control system and vacuum system connections, diagram
Fig. 204: Charge Air Pressure Control System And Vacuum System
Connections, Diagram
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1 - From fuel tank

2 - Evaporative Emission (EVAP) canister
With EVAP canister purge regulator valve -N80-
3 - Non-return valve for EVAP canister
Between EVAP canister and intake line upstream of turbocharger

Install with light and dark sides in positions shown in illustration. Arrow points
in direction of flow.
4 - Turbocharger
Checking charge air pressure. Refer to Turbocharger and charge air

pressure regulating valve, checking
5 - Pressure unit for charge air pressure control
6 - Charge air pressure bypass valve
Checking. Refer to Charge air pressure bypass valve, testing

7 - Brake servo
8 - Non-return valve
Between brake servo and intake manifold
9 - Wastegate bypass regulator valve -N75-
10 - Mass Air Flow (MAF) sensor-G70-
11 - Air cleaner
12 - Crankcase breather pressure regulating valve

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13 - Vacuum reservoir
Bolted to cylinder head cover
14 - Fuel pressure regulator
15 - Intake manifold
With Intake Air Temperature (IAT) sensor -G42-
17 - Recirculating valve for turbocharger -N249-
Checking. Refer to Recirculating valve for turbocharger -N249-, checking
18 - Secondary Air Injection (AIR) solenoid valve -N112-
19 - Crankcase breather
20 - Secondary Air Injection (AIR) pump motor -V101-
21 - Throttle valve control module-J338-

22 - Charge air cooler
With Charge air pressure sensor -G31-

Between EVAP canister and intake manifold

Charge air pressure bypass valve, testing
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2006 Audi TT
NOTE: The charge air pressure bypass valve is located

upstream of the turbocharger. It is opened by vacuum
from the electrically operated Recirculating valve for
turbocharger -N249- when the engine is on overrun,
under part load, or when idling. This disperses the
pressurized air (charge air pressure) upstream of the
throttle valve, and thus keeps the turbocharger rotating
at a higher speed.
Check the charge air pressure bypass valve if the
engine is not producing full power, or jerking when the
throttle is opened and closed.
Fig. 205: Hand Vacuum Pump V.A.G 1390

V.A.G 1390 Vacuum pump

Work sequence
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Fig. 206: Connecting Vacuum Pump V.A.G 1390 To Charge Air Pressure
Bypass Valve
Connect vacuum pump V.A.G 1390 to charge air pressure bypass valve.
Operate vacuum pump.
Charge air pressure bypass valve should open (arrow).
Operate air vent valve on vacuum pump after about 30 seconds.
Charge air pressure bypass valve should close (arrow).
If the charge air pressure bypass valve does not open and close as specified, or if the
valve plate does not seal properly when the valve is closed:
Replace charge air pressure bypass valve. Secure connections on valve with
screw-type clips.
Recirculating valve for turbocharger -N249-, checking
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Fig. 207: Identifying Special Tools - Recirculating Valve For Turbocharger -

N249-, Checking
Special tools, testers and other equipment required
V.A.G 1526 A Multimeter

V.A.G 1527 B Voltage tester
V.A.G 1594 A Connector test kit
V.A.G 1598/31 Test box
VAS 5051 Vehicle diagnosis, testing and information system with VAS 5051/1
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Adapter
or
V.A.G 1551 Scan Tool with V.A.G 1551/3 A Adapter
NOTE: The Recirculating valve for turbocharger -N249 and its

wiring are monitored by the engine control module.
Connect vehicle diagnostic, testing and information system VAS 5051 (or scan
tool V.A.G 1551) and select "Engine Electronics" control module by entering
address word 01. Engine must be running at idling speed.
Refer to
Check DTC memory of engine control module:
Refer to
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If the display shows a malfunction relating to Recirculating valve for turbocharger -

N249-:
Disconnect hoses from valve but leave electrical connector connected.

Install an auxiliary hose to one of connections on valve.
Start output diagnostic test mode and activate Recirculating valve for
turbocharger -N249-:
Refer to

Output Diagnostic Test Mode -->

Air recirc. valve for turbocharger -N249
Indicated on display
Valve should click and open and close (test by blowing into auxiliary hose).
If the valve does not click:
Check internal resistance of valve.
If the valve does not open and close properly:

Replace Recirculating valve for turbocharger -N249-.
Checking internal resistance
Disconnect connector from valve.

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Fig. 208: Connecting Multimeter To Valve (Resistance Measurement Range)

Connect multimeter to valve (resistance measurement range).
Specification: 27 - 30 ohms
If the specification is not obtained:
Replace Recirculating valve for turbocharger -N249-.
If the specification is obtained:
Check voltage supply.

Checking voltage supply
NOTE: The recirculating valve for turbocharger receives its power

supply via the fuel pump relay.
Requirement
Fuse for recirculating valve must be OK
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Fig. 209: 2-Pin Electrical Harness Connector & Terminals

Connect voltage tester V.A.G 1527 B as follows:
Connector terminal Measure against

1 Engine ground (GND)
Operate starter briefly.

LED should light up.
If the LED does not light up:
Check for open circuit in wiring from terminal 1 to fuel pump relay via fuse:

Repair any open circuits.
If the wiring is OK:
Check fuel pump relay.
Refer to

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If the LED lights up:
Check activation.
Checking activation

Connect voltage tester V.A.G 1527 B to terminal 1 (positive) and terminal 2 of
connector.
Start output diagnostic test mode and activate Recirculating valve for
turbocharger -N249-:
Refer to

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LED must flash.
If the LED lamp does not flash or lights up continuously:
Connect test box V.A.G 1598/31 to wiring harness for engine control module.
Do not connect engine control module itself.
Refer to

Check for open circuit and short to positive or Ground (GND) in following
wiring connection:
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Connector terminal Test box V.A.G 1598/31 terminal

2 105
Repair short circuit or open circuit if necessary.

Replace engine control module:
Refer to

Turbocharger and charge air pressure regulating valve, checking
Fig. 212: Identifying Turbocharger Tester V.A.G 1397A

V.A.G 1397 A Turbocharger tester

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Fig. 213: VAS 5051 Vehicle Diagnosis, Testing & Information System
Adapter
or
Scan tool V.A.G 1551 with V.A.G 1551/3 A Adapter

Requirements
All hoses and lines must be securely installed and free of leaks
DTC memory has been checked
Refer to

Output diagnostic test mode has been performed
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Refer to
Vehicle diagnosis, testing and information system VAS 5051 or scan tool
V.A.G 1551 must be connected
Work sequence
WARNING: To avoid any risk of accident, observe the safety

precautions when using test instruments while road
testing the vehicle. Refer to Scan Tool (ST) and test
equipment safety precautions
Fig. 214: Connecting T-Piece And Measuring Hose Of Turbocharger Tester

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V.A.G 1397 A To Intake Manifold

Connect T-piece and measuring hose of turbocharger tester V.A.G 1397 A to

intake manifold (front).
Route measuring hose under rear edge of hood and into passenger
compartment via right side window.
Fig. 215: Identifying Turbocharger Tester V.A.G 1397 A

Switch on turbocharger tester and set measuring range selector switch to

position -I- (absolute pressure).
Connect measuring hose to connection -I-.
NOTE: Hose connections must be completely airtight,

otherwise measurements will not be correct.
Ensure that measuring hose is not pinched at hood or
side window.
Pressing memory key M on turbocharger tester will
store the last measured value until memory key M is
pressed again or the tester is switched off.
The decimal point in the display flashes to indicate that
the value is being stored.
If the battery voltage of the turbocharger tester drops
below the minimum level, an arrow will appear at the
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top left of the display.

Before performing the test, drive the vehicle at a brisk
speed for at least 3 km (without stopping, e.g. at traffic
lights etc.).
A second technician is required to note the readings on
the tester when the vehicle is moving.
Rapid data transfer HELP

Select function XX
Enter "08" to select function "Read Measured Value Block" and confirm entry
with -Q- button.
Read Measured Value Block Q

Enter display group number XXX
Enter "004" to select display group 004 and confirm entry with -Q- button.
Read Measured Value Block 4 -->

1234
Do not proceed with the test until the intake air temperature shown in display zone
4 is between 20 and 50° C. If necessary, run the engine until the required
temperature is reached.
Press -C- button.
Read Measured Value Block Q

Enter display group number XXX
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Enter "115" to select display group 115 and confirm entry with -Q- button.
Read Measured Value Block 115 -->

1234
Indicated on display (1-4 = display zones)
Accelerate vehicle from 2000 rpm at wide open throttle in third gear, and
watch rev counter.
When engine speed reaches 3000 rpm, press "PRINT" button on VAS 5051 (or
V.A.G 1551) and at same time press memory button "M" on V.A.G 1397 A.
NOTE: The charge air pressure should be measured using

turbocharger tester V.A.G 1397/A. Vehicle diagnosis, testing
and information system VAS 5051 (or scan tool V.A.G 1551)
is used to check whether the charge air pressure is being
registered by the control module.

Specification for V.A.G 1397 A: 1.700 - 1.900 bar
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Specification for VAS 5051 or V.A.G 1551: display zone 4 1700-1900 mbar
If the specification is not obtained or is exceeded:
Refer to

Malfunctions in charge air pressure control function
Malfunction Charge air pressure Possible cause

Charge air pressure too Measured value less Wastegate bypass
low than 1.700 bar or regulator valve -
1700 mbar N75- malfunctioning
Malfunction in
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wiring to charge air

pressure control
valve
Charge air pressure

control valve in
turbocharger is
sticking in the
"open" position
Leak between
turbocharger and
intake manifold
Charge air pressure

control valve
malfunctioning
Turbocharger
malfunctioning
Charge air pressure too Measured value Pressure unit for
high 1) more than 1.900 bar charge air pressure
or 1900 mbar control valve
malfunctioning
Leak in hose to
pressure unit for
charge air pressure
control (via -N75-)
Charge air pressure
control valve in
turbocharger is
sticking in the
"closed" position
1) If the charge air pressure is too high the fuel supply will be interrupted in order to
protect the engine, resulting in the misfiring at high engine speeds.
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CHARGE PRESSURE LEAK TEST WITH V.A.G 1687
Intake system, checking for leaks using V.A.G 1687 Diagnostic Tool
Diagnostic trouble codes (DTCs) related to fuel trim, charge pressure or mass air
flow (MAF) may be caused by:
Leaking (worn/torn) intake hoses during charge conditions

Incorrectly torqued or improperly placed clamps on intake hoses etc. causing
leaks during charge conditions
Fig. 218: Checking Charge Air Pressure System Using V.A.G 1687 Charge Air
System Tester
Check the charge air pressure system using the V.A.G 1687 Charge air system
tester.
Special tool V.A.G 1687 Charge air system tester preliminary set-up
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Fig. 219: Special Tool V.A.G 1687 Charge Air System Tester Preliminary Set-
Up
Back off pressure regulator knob -2- of V.A.G 1687 fully to protect gauge
when shop air supply is applied to assembly.
Close valve -3- before gauge.
Close valve -4- after gauge.
The shop air supply line will later be attached to the inlet of V.A.G 1687.
Remove female fitting from tester (arrow) and install an appropriate "male" air
fitting that will connect to your shop air supply line (see WARNING! under
Special tool V.A.G 1687/1 pressure adapter, installing (1.8L Turbo)).
CAUTION: Use only approved air fittings to adapt shop air

supply line to V.A.G 1687 tester.
Special tool V.A.G 1687/1 pressure adapter, installing (1.8L Turbo)
Separate intake hose from Mass Air Flow (MAF) sensor assembly.
Fig. 220: Special Tool V.A.G 1687/1 Pressure Adapter, Installing (1.8L Turbo)
Insert V.A.G 1687/1 pressure adapter in intake hose (black arrow) using
existing clamp (as shown).
Remove crankcase ventilation tube from intake hose at (white arrow).
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NOTE: To help find small leaks, BEFORE pressurizing the

system fill system with smoke using special tool
KLI9210 and adapter KLI9210/50 as described on. Refer
to Special tool KLI9210 (Evaporative system leak
detector), connecting to 1.8L Turbo.
An ultrasonic detector may also be used to detect
extremely small leaks where smoke may not be visible.
Special tool KLI9210 (Evaporative system leak detector), connecting to 1.8L Turbo
Install optional fitting KLI9210/50 on hose of special tool KLI9210.
Fig. 221: Special Tool KLI9210 (Evaporative System Leak Detector),

Connecting To 1.8L Turbo
Connect KLI9210 to V.A.G 1687/1 adapter (KLI9210 is shown attached to
V.A.G 1687/1 at (arrow) on 1.8L Turbo).
Special tool KLI9210 (Evaporative system leak detector), preliminary set-up
Connect smoke generator leads to vehicle battery.
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Fig. 222: Special Tool KLI9210 (Evaporative System Leak Detector),

Preliminary Set-Up
Turn valve to test (black arrow).
Press smoke generator button to fill system with smoke (see instructions
printed on tester).
With system filled with smoke:
Remove smoke generator hose and connect V.A.G 1687 quickly to prevent
smoke from leaking out. Refer to Special tool KLI9210 (Evaporative system
leak detector), preliminary set-up.
Special tool V.A.G 1687, connecting to pressure adapter V.A.G 1687/1 (1.8L Turbo)
For illustrations purposes V.A.G 1687 is shown lying in the engine compartment. In
practice the tool should be hung from the hood.
Connect V.A.G 1687 quickly to prevent smoke from leaking out.
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Fig. 223: Special Tool V.A.G 1687, Connecting To Pressure Adapter V.A.G
1687/1 (1.8L Turbo)
V.A.G 1687 is shown connected to V.A.G 1687/1 (black arrow)
Shop air supply will be connected to V.A.G 1687 at (white arrow)

Perform pressure test. Refer to Performing pressure test.
Performing pressure test
Fig. 224: Special Tool V.A.G 1687 Charge Air System Tester Preliminary Set-
Up
With outlet hose -1- of V.A.G 1687 connected to air pressure adapter:
Attach shop air supply line to previously installed male fitting. Refer to Intake
system, checking for leaks using V.A.G 1687 Diagnostic Tool.
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Open valve -3- between regulator valve and gauge.

Adjust test pressure up to 0.5 bar by turning regulator valve -2-. (see
CAUTION below)
CAUTION: DO NOT pressurize the system above 0.5 bar!

Doing so may force oil into the intake system
which can damage the engine.
Slowly open outlet valve -4- (after gauge) to test hose connections.
Observe pressure gauge for a drop in pressure.
NOTE: Some pressure will be lost past the throttle plate.
Readjust test pressure to 0.5 bar (Refer to CAUTION listed under Performing
pressure test) by turning regulator valve -2-.
Listen for any very large intake leaks.
If smoke generator was used to fill the system with smoke:
Inspect intake system connections for smoke at leaks.
NOTE: An ultrasonic detector may also be used to detect

extremely small leaks where smoke may not be visible.
Repair any leaks found.

Remove tester.
Remove plug from crankcase ventilation hose.
Remove air pressure adapter.
With VAS 5051 diagnostic tool connected:
Erase DTC memory.
If smoke generator was not used to fill the system with smoke:
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Apply soapy water solution or equivalent to intake system connections.
NOTE: An ultrasonic detector may also be used to detect

extremely small leaks.
Inspect intake system connections for leaks.

Repair any leaks found.
Remove tester.
Remove plug from crankcase ventilation hose.
Remove air pressure adapter.
With VAS 5051 diagnostic tool connected:
Erase DTC memory.

Wastegate bypass regulator valve -N75-, checking
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Fig. 225: Identifying Special Tools - Wastegate Bypass regulator valve -N75-,
Checking

V.A.G 1527 B Voltage tester
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Adapter
or
NOTE: Wastegate bypass regulator valve -N75- and its wiring are
monitored by the engine control module.
Connect vehicle diagnosis, testing and information system VAS 5051 (or scan
address word 01. Engine must be running at idling speed:
Refer to

Refer to
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If the display shows a malfunction relating to Wastegate bypass regulator valve -

N75-:
Disconnect hoses from valve but leave electrical connector connected.

Install an auxiliary hose to one of connections on valve.
Start output diagnostic test mode and activate Wastegate bypass regulator
valve -N75-:
Refer to

Output Diagnostic Test Mode -->

Wastegate bypass regulator valve -N75
Valve should click and open and close (test by blowing into auxiliary hose).
If the valve does not click:
Check internal resistance of valve.
If the valve does not open and close properly:

Replace Wastegate bypass regulator valve -N75-.
Checking internal resistance

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Fig. 226: Connecting Multimeter To Valve (Resistance Measurement Range)

Connect multimeter to valve (resistance measurement range).
Specification: 25-35 ohms
Replace Wastegate bypass regulator valve -N75-.


Connect voltage tester V.A.G 1527 B as follows:
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1 Engine ground (GND)
Operate starter briefly.
LED should light up.
If the LED does not light up:
Check for open circuit in wiring from terminal 1 to fuel pump relay via fuse:

Repair any open circuits.

Check fuel pump relay:
Refer to
If the LED lights up:
Check activation.
Checking activation
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Connect voltage tester V.A.G 1527 B to terminal 1 (positive) and terminal 2 of
connector.
Start Output Diagnostic Test Mode (DTM) and activate Wastegate bypass
regulator valve -N75-:
Refer to

LED should flash.
If the LED lamp does not flash or lights up continuously:

Connect test box V.A.G 1598/31 to wiring harness for engine control module.
Do not connect engine control module itself.
Refer to
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2006 Audi TT


Check for open circuit and short to positive or ground (GND) in following
wiring connections:

2 104
Replace engine control module:
Refer to

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Charge air pressure sensor -G31-, checking
Fig. 230: Identifying Special Tools - Charge Air Pressure Sensor -G31-,
Checking
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Adapter
or
NOTE: Charge air pressure sensor -G31- and its wiring are
monitored by the engine control module.
Connect vehicle diagnosis, testing and information system VAS 5051 (or scan
address word 01. Engine must be running at idling speed.
Refer to
Refer to

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2006 Audi TT

If the display shows a malfunction relating to charge air pressure control valve -
G31-:
Check voltage supply.
Disconnect connector on charge air pressure sensor.
Fig. 231: Identifying Connector Terminals 1 And 4

Connect multimeter (voltage measurement range) between terminals 1 and 3
on connector.
Switch ignition on.
Specification: approx. 5 V
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Fig. 232: Connecting Test Box V.A.G 1598/31 To Wiring Harness For Engine
Control Module
Connect test box V.A.G 1598/31 to wiring harness for engine control module
and also to engine control module itself (-1-).
Refer to

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wiring connections:

1 108
3 98

Check signal wire. Refer to Checking signal wire.

Checking signal wire
Plug in connector on charge air pressure sensor.

Connect multimeter (voltage measurement range) between sockets 101 and 108
on test box.
Start engine and run at idling speed.
Specification: approx. 1.90 V
Increase engine speed by operating throttle quickly.

Specification: 2.00-3.00 V
If the specifications are not obtained:
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wiring connections:

4 101
Replace Charge air pressure sensor -G31-.

Rules for cleanliness
When working on the exhaust gas turbocharger, pay careful attention to the
following "5 rules:"
Thoroughly clean all unions and the adjacent areas before disconnecting.
Place parts that have been removed on a clean surface and cover. Do not use
fluffy cloths!
If the repair cannot be carried out immediately, carefully cover or seal any
components that have been opened.
Only install clean components: only unpack replacement parts immediately
prior to installation. Do not use parts that have been stored loose (e.g. in tool
boxes etc.).
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When the system is open, do not work with compressed air if this can be
avoided. Do not move vehicle unless absolutely necessary.
Turbocharger, assembly overview
Part I
Fig. 235: Turbocharger, Assembly Overview - Part I

NOTE: Replace all gaskets and seals.
1 - Front exhaust pipe
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2 - 40 Nm
Replace
3 - Spacer sleeve
4 - Gasket
Replace
5 - 10 Nm
Install with locking fluid D 000 600 A2
6 - Pressure unit
For charge air pressure regulating valve
7 - Securing clip
8 - Turbocharger
9 - O-ring
Replace
10 - 10 Nm
11 - Connection
12 - Gasket
Replace
13 - 20 Nm
14 - Heat shield
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15 - 10 Nm
17 - Oil supply line
From oil filter bracket. Refer to Lubrication system components, Part II,
item - 23
18 - 30 Nm
Replace
Coat threads and bolt head seating surface with G 000 500
19 - Exhaust manifold
20 - Gasket
Replace
21 - 20 Nm
23 - 25 Nm
Replace
25 - Coolant return line
26 - 25 Nm
27 - Spacer sleeve
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29 - 10 Nm
30 - Coolant supply hose/line
32 - Bracket
33 - 30 Nm
Use only genuine bolts
Refer to Parts catalog
34 - 25 Nm
35 - Gasket
Replace
36 - Gasket
Replace
37 - 10 Nm
38 - Oil return line
To oil pan
39 - 10 Nm
40 - 10 Nm
Install with locking fluid D 000 600 A2
Part II
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Fig. 236: Turbocharger, Assembly Overview - Part II

1 - To charge air pressure control valve

2 - Locking clip
3 - O-ring
Replace
4 - Air intake hose
To connection on turbocharger
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5 - Wastegate bypass regulator valve -N75-

6 - Charge air pressure bypass valve
7 - Hose
To Recirculating valve for turbocharger -N249-
8 - Pressure regulating valve
For crankcase breather
9 - Hose
Between charge air pressure bypass valve and upper air line
10 - To crankcase breather
11 - Upper air line

12 - 25 Nm
13 - 25 Nm
14 - To throttle valve housing
Install with light and dark sides in positions shown in illustration

16 - To EVAP canister purge regulator valve -N80-
17 - Hose
Install with light and dark sides in positions shown in illustration
19 - Coolant line
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20 - To connection on turbocharger
21 - To pressure unit for charge air pressure control valve
Turbocharger, removing and installing
Removing
NOTE: The turbocharger is removed from below after taking out

the exhaust manifold.
Remove engine cover (complete).


Unbolt heat shield for right drive axle.
Remove right drive axle:
Refer to 40 FRONT SUSPENSION
Remove front exhaust pipe. Refer to Exhaust system, vehicles with front
wheel drive.
NOTE: Do not bend the flexible connection (de-coupling element)

in the exhaust system more than 10° , otherwise it may be
damaged.
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Drain engine oil.

Remove air hose -1- between upper air line and lower air line.
Unbolt bracket -2- for upper air line.
Remove oil return line -3-.
Fig. 239: Identifying Turbocharger Bracket, Coolant Return Line, Coolant

Supply Line & Bolts
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Loosen bolted connection -3- for turbocharger bracket by a few turns.

Remove turbocharger bracket from cylinder block (bolts -1- and -2-).
Unbolt bracket for coolant return line (bolt -4-).
Unbolt coolant supply line from cylinder block (bolt -5-).
Disconnect hose from pressure unit for charge air pressure control valve (on
turbocharger).
Fig. 240: Air Intake From Connection On Turbocharger Hose Removal

Components
Air intake hose is removed from connection on turbocharger as follows:
Remove pressure control valve -8- (for crankcase breather) from hose.
Disconnect connector -6- from Wastegate bypass regulator valve -N75-.
Disconnect hose -2- from upper air line (hose leads to -N75-).
Disconnect hose -1- from air line.

Disconnect vacuum line -4- from recirculating valve for turbocharger.
Disconnect air intake hose -7- from air cleaner.
Pull locking clip out of turbocharger connection and take off air intake hose.
Disconnect hose -3- from non-return valve (hose leads to turbocharger).

Disconnect coolant return hose from Y connection on right next to cylinder
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head (hose leads to turbocharger).
Fig. 241: Identifying Upper Air Line Bolts, Heat Shield Bolts & Upper Air
Line Hose
Disconnect hose -3- from upper air line (hose leads to turbocharger).
Remove bolts -1- and -4- for heat shield on back of cylinder head.
Remove bolts -2- and -5- on upper air line.
Fig. 242: Removing Exhaust Manifold Nuts

Unbolt turbocharger -1- from exhaust manifold -2-.

Remove gasket. Turbocharger will drop down slightly.
Remove all nuts (arrows) on exhaust manifold (nuts can be reached from
above).
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Remove washers and take off exhaust manifold.
Fig. 243: Unbolting Retainer Piece For Oil Supply Line From Turbocharger
Unbolt retainer piece for oil supply line from turbocharger (arrow).
Bolt turbocharger bracket back onto cylinder block.
Fig. 244: Removing/Installing Coolant Return Pipe & Oil Supply Pipe
Unbolt oil supply line (bolt -2-) and coolant return line (bolt -1-) from
turbocharger.
Remove spacer sleeve from connection for coolant return line.
Disconnect coolant return line.
Unbolt turbocharger bracket from cylinder block and remove turbocharger.
Installing
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NOTE: Fill the turbocharger with engine oil via the oil supply
connection.
Bolt turbocharger bracket onto turbocharger but do not tighten bolts.

Position turbocharger against engine from below, then tighten bolts by hand to
secure bracket to cylinder block.
Fig. 245: Removing/Installing Coolant Return Pipe & Oil Supply Pipe
Tighten bolts for oil supply line -2-.
Banjo bolt: 30 Nm
Bolt for retainer piece: 10 Nm
Install coolant return line -1- with spacer sleeve and bolt it to turbocharger (35
Nm).
Unbolt turbocharger bracket from cylinder block again.
Install exhaust manifold (25 Nm).
Bolt turbocharger to exhaust manifold.
The remaining installation steps are performed in the reverse sequence. Note the
following points:
Install heat shield sleeves on hoses around turbocharger.

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Fill with engine oil.
NOTE: After installing the turbocharger, run the engine for

approx.1 minute at idling speed; do not rev up immediately.
This ensures that the turbocharger is properly lubricated.
Tightening torques
Components Nm
Oil return line to oil pan 10
Oil return line to turbocharger 10
Coolant supply line to cylinder block 35
Turbocharger bracket to turbocharger 30
Turbocharger bracket to cylinder block 25
Oil supply line to turbocharger 30
Oil supply line retainer piece to 10
turbocharger
Coolant return line to turbocharger 35
Turbocharger to exhaust manifold 30
Exhaust manifold to cylinder head 25
Drive axle heat shield to cylinder 35
block
Nuts for clamp 40
Charge air cooling system components, removing and installing
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Fig. 246: Charge Air Cooling System Components, Removing And Installing
NOTE: All hose connections must be secured with hose clips

(same as original parts).
Before carrying out tests or repair work, make sure that all lines and hoses are
securely connected and that there are no leaks.
1 - Air ducting
2 - Charge air cooler (intercooler)
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Removing and installing. Refer to Charge air cooler (intercooler), removing

and installing
3 - Charge air pressure sensor -G31-
4 - 10 Nm
5 - Rubber grommet
With sleeve
6 - 10 Nm
7 - Hose
Between intake manifold and charge air cooler (intercooler)

8 - Rubber grommet
With sleeve
9 - Hose
Between upper air line and lower air line
10 - 10 Nm
11 - Lower air line
12 - 10 Nm
13 - Bracket
14 - Rubber grommet
With sleeve
15 - Hose
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16 - 10 Nm
Charge air cooler (intercooler), removing and installing


Remove front bumper:
Refer to 63 BUMPERS
Remove right side headlight:
Refer to 94 LIGHTS, SWITCHES - EXTERIOR
Remove EVAP canister:

Refer to
20 - FUEL PUMP, FUEL SUPPLY, EVAPORATIVE EMISSIONS for 1.8

LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE
CODE(S): BEA
20 - FUEL SUPPLY for 3.2 LITER V6 4V GENERIC SCAN TOOL,
ENGINE CODE: BHE
Disconnect air hose from top of charge air cooler.
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Fig. 248: Removing Bolts For Charge Air Cooler

Remove 2 bolts (arrows) for charge air cooler.

Unclip cowl from charge air cooler.
Fig. 249: Disconnecting Air Hose From Bottom Of Charge Air Cooler &
Removing Lower Securing Bolt For Charge Air Cooler
Disconnect air hose -2- from bottom of charge air cooler.

Remove lower securing bolt -1- for charge air cooler.
Take out charge air cooler from underneath.
Installation is performed in the reverse order. Note the following:
Adjust headlights:
Refer to 01 MAINTENANCE ; Headlights (halogen), adjusting
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or
Refer to 01 MAINTENANCE ; Headlights (gas charged Xenon), adjusting
26 EXHAUST SYSTEM, EMISSION CONTROLS
EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLING
Exhaust system components, removing and installing
NOTE: Always replace seals and gaskets, self-locking nuts and

clamps.
After working on the exhaust system ensure that the
system is not under stress, and that it has sufficient
clearance from the bodywork. If necessary, loosen
clamp and align silencers and exhaust pipe so that
sufficient clearance is maintained to the bodywork at all
points and the mountings are evenly loaded.
Loosen and tighten clamping plates for heat shields
with a screwdriver. Tightening torque: 2 Nm
De-coupling element on front exhaust pipe may only be
bent slightly (not more than 10°).
If droning noises can be heard after aligning the
exhaust system, adjust the engine mountings. Refer to
Engine mountings, adjusting.
Exhaust system, vehicles with front wheel drive
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2006 Audi TT
Fig. 250: Exhaust System, Vehicles With Front Wheel Drive Remove/Install
Components
1 - Tunnel cross-piece
With drilling for aligning exhaust system. Refer to Exhaust system, aligning
stress-free
2 - Mounting
Position. See Fig. 2
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2006 Audi TT
3 - 25 Nm
With catalytic converter
With de-coupling element
Protect from damage by knocks and impact
De-coupling element may only be bent slightly (not more than 10°)
Removing and installing. Refer to Front exhaust pipe, removing and

installing
5 - 40 Nm
Always replace
6 - Spacer sleeve
For all four nuts
7 - Gasket
Always replace
8 - Turbocharger
Removing and installing. Refer to Turbocharger, removing and installing
9 - Heated Oxygen Sensor (HO2S), 55 Nm
Grease only threads with part no. G 052 112 A3 hot bolt paste (anti-seize
compound). Grease must not get into slots on sensor body
CAUTION: Part numbers are for reference only. Always check

with your Parts Dept. for the latest parts information.
Checking:
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2006 Audi TT
Refer to
Heated Oxygen Sensor (HO2S) connector is located under a protective cover.
Refer to Front exhaust pipe, removing and installing
10 - Heated Oxygen Sensor (HO2S) after catalytic converter, 55 Nm

Checking:
Refer to


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2006 Audi TT

11 - Clamp
Align exhaust system so it is free of stress before tightening clamp. Refer to
Exhaust system, aligning stress-free.
Installation position: horizontal in vehicle, bolted connection facing to left
Tighten bolted connections evenly.
12 - 40 Nm
13 - Mounting
14 - 25 Nm
15 - Front and rear mufflers
Can be replaced separately

Exhaust pipe with cutting point. See Fig. 1
Aligning exhaust system free of stress. Refer to Exhaust system, aligning
stress-free
16 - Mounting
17 - 25 Nm
18 - 25 Nm
Exhaust system, vehicles with all wheel drive
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2006 Audi TT
Fig. 251: Exploded View Of Exhaust System, Vehicles With All Wheel Drive
1 - Turbocharger
Removing and installing. Refer to Turbocharger, removing and installing
2 - Gasket
Always replace
With de-coupling element

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2006 Audi TT
Protect from damage by knocks and impact

De-coupling element may only be bent slightly (not more than 10°)
installing
4 - Heated Oxygen Sensor (HO2S) before catalytic converter, 55 Nm
Grease only threads with Part no. G 052 112 A3 hot bolt paste (anti-seize

Checking:
Refer to


5 - Heated Oxygen Sensor (HO2S) after catalytic converter, 55 Nm


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2006 Audi TT
Checking:
Refer to


6 - Catalytic converter
installing
7 - Mounting
Loosen mounting to center tailpipe in relation to bumper.
8 - 25 Nm
9 - Front and rear mufflers
Can be replaced separately

Exhaust pipe with cutting point. See Fig. 1
Aligning exhaust system free of stress. Refer to Exhaust system, aligning
stress-free
10 - 25 Nm
11 - Mounting
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2006 Audi TT
12 - Rubber hanger
13 - 25 Nm
14 - Retainer hose
15 - Clamp
Align exhaust system so it is free of stress before tightening clamp. Refer to

Exhaust system, aligning stress-free.
Installed position: horizontal in vehicle, bolted connection facing left
16 - Gaskets
Replace
Installed position: horizontal in vehicle, bolted connection facing left
17 - 25 Nm
18 - 40 Nm
19 - Spacer sleeve
For all four nuts

Marked position for cutting exhaust pipe
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2006 Audi TT
Fig. 252: Separating Point On Exhaust Pipe

For individual replacement of front or rear muffler.

Position is marked with three indentations on exhaust pipe.
Cut through exhaust pipe at right angles with body saw (e.g. V.A.G 1523) at
position marked (arrow -2-).
Position clamp -4- between side markings (arrow -1- and arrow -3-) when
installing.
Align exhaust system free of stress. Refer to Exhaust system, aligning stress-
free.
Align rear muffler so it is horizontal.
Tighten bolted connections on clamp evenly to 40 Nm.
Installed position of clamp: horizontal in vehicle, bolted connections facing front.

Vehicles with front wheel drive
Installed position of mounting
Fig. 253: Installed Position Of Mounting

Angled end of base of mounting (arrow) faces in direction of travel.

Gap between exhaust pipe and heat shield for steering box: at least 24 mm
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2006 Audi TT
Fig. 254: Identifying Gap Between Exhaust Pipe And Heat Shield For Steering
Box
To measure gap:
Install a 17 mm 1/2"-drive socket (outside diameter approx. 24 mm) to a long
extension and insert between front exhaust pipe and heat shield. Gap should be
large enough to allow socket to be inserted without difficulty.
Front exhaust pipe, removing and installing
Removing
NOTE: Avoid excessive bending of the de-coupling element

(no more than 10°).
When performing repairs, replace all seals and gaskets
as well as self-locking nuts and bolts that have a
specified tightening angle.
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2006 Audi TT
Fig. 255: Removing Cover For Both Heated Oxygen Sensor (Ho2S) Connectors
And Pull Electrical Wire With Retaining Clips From Heat Shield
Remove cover for both Heated Oxygen Sensor (HO2S) connectors and pull
electrical wire with retaining clips from heat shield (arrows).
Pull connector out of cover and disconnect.
Unbolt front exhaust pipe from turbocharger.
Loosen bolted connections on clamp between catalytic converter and middle

muffler, then move clamp toward rear.
Vehicles with all wheel drive
Unbolt connecting flanges on catalytic converter.

Remove front exhaust pipe.
Installing
Align exhaust system free of stress. Refer to Exhaust system, aligning stress-
free.
Check DTC memory:
Refer to
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2006 Audi TT

NOTE: DTCs will have been stored in the memory because

connectors have been disconnected. Therefore check and
erase the DTC memory after installing the engine.

Tightening torques
Components Nm
Heated Oxygen Sensor (HO2S) to 55
front exhaust pipe
Nuts on clamp 40
Tightening torques
Components Nm
Heated Oxygen Sensor (HO2S) to 55
front exhaust pipe
Nuts on connecting flange of catalytic 25
converter
Exhaust manifold, removing and installing
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2006 Audi TT
Removing

Remove section of engine cover from cylinder head cover.
Fig. 257: Removing Cover In Front Of Intake Manifold

Remove cover in front of intake manifold.
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2006 Audi TT

Unbolt heat shield for right drive axle.
Remove front exhaust pipe. Refer to Exhaust system, vehicles with front
wheel drive.
NOTE: The de-coupling element on the front exhaust pipe may

only be bent slightly (not more than 10°).

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2006 Audi TT
Remove air hose -1- between upper air line and lower air line.
Unbolt bracket -2- for upper air line.
NOTE: Do not disconnect oil return line -3- for turbocharger.
Fig. 260: Identifying Turbocharger Bracket Bolts

Loosen bolted connection -3- for turbocharger bracket by a few turns.

Remove turbocharger bracket from cylinder block (bolts -1- and -2-).
Unbolt bracket for coolant return line (bolt -4-).
Disconnect air intake hose from connection on turbocharger as follows:

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2006 Audi TT
Disconnect vacuum line -1- from air recirculation valve.

Disconnect hose from pressure control valve -2- for crankcase breather.
Disconnect connector -3- from Wastegate bypass regulator valve -N75-.
Remove hose -5- from bulkhead (hose runs between solenoid valve and
turbocharger).
Remove wastegate bypass regulator valve from intake air hose and place valve
to one side on engine.
Remove hose from bulkhead (hose runs between EVAP canister and
turbocharger).
Pull locking clip out of turbocharger connection and take off air intake hose.
Fig. 262: Identifying Air Pipe Clamps, Turbocharger Hose & Upper Air Line
Hose
Disconnect hose -2- (leading to turbocharger) and remove hose -1- from upper
air line.
Remove bolts on heat shield on back of cylinder head.
Release clamps -3- and -4- on air line.
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2006 Audi TT
Fig. 263: Unbolting Turbocharger From Exhaust Manifold

Unbolt turbocharger (arrows) from exhaust manifold.
Remove gasket.
Turbocharger will drop down slightly.
Fig. 264: Removing Exhaust Manifold Nuts

Remove all nuts (arrows) on exhaust manifold (nuts can be reached from
above).
Remove washers and exhaust manifold.
Installing
Installation is performed in the reverse order.
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2006 Audi TT
Tightening torques
Components Nm
Clamps for air lines 10
Heat shield to manifold 10
Turbocharger bracket to turbocharger 30
Turbocharger bracket to cylinder block 25
Turbocharger to exhaust manifold 30
Exhaust manifold to cylinder head 25
Drive axle heat shield to cylinder 35
block
Nuts for clamp 40
Nuts on connecting flange of catalytic 25
converter
Heated Oxygen Sensor (HO2S) in 55
front pipe
Exhaust system, aligning stress-free
The exhaust system must be aligned when cold.
Fig. 265: Identifying Manufactured Alignment Tool

As a tool for aligning exhaust system, modify an M10 bolt according to the
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2006 Audi TT
dimensions given.
Dimension -x- = 4 mm
Dimension -y- = 25 mm
NOTE: Two technicians are required to align the exhaust system.
Loosen bolted connections on clamp. Refer to Exhaust system, vehicles with

front wheel drive, item - 11.
Fig. 266: Manufactured Tool Inserted Through Rearmost Hole In Tunnel

Bridge
Insert modified bolt (aligning tool) through rear drilling (arrow) in tunnel
cross-piece, with flat part of bolt facing toward mounting pin on exhaust
system.
NOTE: With bolt inserted, exhaust system is pre-tensioned in the

direction of travel.
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2006 Audi TT
Fig. 267: Aligning Catalytic Converter Horizontally And Making Sure Gaps
Between Catalytic Converter And Tunnel Are Equal
Align catalytic converter horizontally -C- and make sure that gaps -A- and -B-
between catalytic converter and tunnel are equal.
Fig. 268: Aligning Catalytic Converter Horizontally And With Equal Spacing
From Heat Shield In Center Tunnel
Align catalytic converter horizontally -4- and make sure that gaps -3- between
catalytic converter and heat shield in tunnel -2- are equal.
All vehicles
Align front and rear mufflers horizontally.
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2006 Audi TT
Fig. 269: Mounting Pin On Exhaust Pipe Must Be Parallel To Tunnel Cross-
Piece
Mounting pin on exhaust pipe must be parallel to tunnel cross-piece (dimension -x-
must be same on left and right).
Fig. 270: Aligning Tailpipe In Bumper Cut-Out

Aligning tailpipe in bumper cut-out
Align rear muffler so that gaps -a- and -b- between muffler and bumper cut-out
are equal. To do this, it may be necessary to loosen rear muffler mounting.
NOTE: On vehicles where the exhaust has been cut through

between the front and rear mufflers, it may be necessary to
loosen the clamp in order to achieve proper alignment.
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2006 Audi TT
Fig. 271: Installing sleeve clamps so screws are at right and screw ends do not
project out over lower edge
Install sleeve clamps so that screws are at right and screw ends do not project
out over lower edge.
Fig. 272: Positioning Clamp At Distance Of About 5 mm From Notched

Markings
Position each clamp at a distance of about 5 mm from notched markings.
Arrange horizontally, then tighten evenly to 40 Nm.
Bolted connections on clamp point to left.
Exhaust system, checking for leaks
Start engine and run at idling speed.

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2006 Audi TT
Plug tailpipe (e. g. with rags or stoppers) and leave plugged until check is
complete.
Listen for noise at connection points (cylinder head/exhaust manifold, exhaust
manifold/turbocharger, turbocharger/front exhaust pipe etc.) to determine
whether there are any leaks.
Repair any leaks that are found.
Secondary air system, components and function
The secondary air system results in quicker heating and therefore earlier operating
readiness of the catalytic converter following a cold start.
Principle
Due to over-enrichment of the mixture during the cold start phase, there is an
increased amount of uncombusted carbon monoxide in the exhaust. Secondary Air
Injection (AIR) improves secondary oxidation in the catalytic converter and
therefore reduces emissions. The heat produced by secondary oxidation greatly
reduces start-up time for the catalytic converter, therefore improving exhaust
quality during the cold start phase significantly.
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2006 Audi TT
Fig. 273: Secondary Air System, Components And Function

Function
After cold start, the ECM -2- starts the secondary air pump -12- via the relay
for Secondary Air Injection (AIR) -1-. Air is blown to the mechanical
secondary air valve -10-.
Parallel to this, the Secondary Air Injection (AIR) solenoid valve -3- is
activated, which permits negative pressure to reach the mechanical secondary
air valve -10- and the pressure unit for charge air pressure regulation -7-.
The mechanical secondary air valve thereby opens the path for secondary air to
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2006 Audi TT
the exhaust channels of the cylinder head.

To prevent unnecessary heating, secondary air is led around the turbocharger.
For this, the charge air pressure regulation pressure unit opens the charge air
pressure valve. The pressure unit, designed as a double reservoir, has a vacuum
connection for this on the intake side.
1 - Secondary Air Injection (AIR) pump relay -J299-
2 - Motronic Engine Control Module (ECM) -J220-

3 - Secondary Air Injection (AIR) solenoid valve -N112-
4 - Intake manifold
5 - Check valve
Installed position (light/dark side): Arrow points in direction of flow as shown
in diagram
6 - Vacuum reservoir
Mounted at cylinder head cover

7 - Pressure can for charge air pressure regulation
8 - Turbocharger
Checking. Refer to Turbocharger and charge air pressure regulating valve,

checking
9 - Cylinder head
10 - Combination valve
For Secondary Air Injection (AIR)
11 - Air filter
12 - Secondary Air Injection (AIR) pump motor -V101-
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2006 Audi TT
Secondary air injection system components, removing and installing
Checking secondary air injection system:
Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS

A- Secondary Air Injection (AIR) pump motor
Fig. 274: Loosening Bolt Approx. Two Rotations From Engine Compartment
Top
Loosen bolt -1- approx. two rotations from engine compartment top (visible
through opening of dip stick at bracket of intake manifold).
NOTE: Diagram illustrates the bracket and Secondary Air Injection

(AIR) pump on an uninstalled engine for photo/technical
reasons.
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2006 Audi TT

Remove center sound insulation.
Fig. 276: Disconnecting Hoses And Connectors On Secondary Air Pump

Disconnect connector and hoses at Secondary Air Injection (AIR) pump.
Fig. 277: Removing Bolts And Of Bracket For Secondary Air Injection (AIR)
Pump
Remove bolts -2- and -3- of bracket for Secondary Air Injection (AIR) pump.
Swing bracket to side and remove Secondary Air Injection (AIR) pump
downward.
B- Combination valve
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2006 Audi TT
Fig. 278: Removing Engine Cover Panel

Fig. 279: Removing Vacuum Hose And Connecting Line At Combination

Valve
Remove vacuum hose -1- and connecting line -2- at combination valve.
Remove combination valve from bracket (arrows).
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2006 Audi TT

00 GENERAL, TECHNICAL DATA

Fig. 1: Locating Engine Number

The engine code is also included on the vehicle data plate.

Engine code ATC AWP

Engine code ATC AWP

Engine, removing and installing

Fig. 2: Identifying Special Tools - Engine, Removing And Installing (1 Of 3)

Special tools, testers and repair equipment required

2024 A Lifting tackle

Fig. 3: Identifying Special Tools - Engine, Removing And Installing (2 Of 3)

V.A.G 1331 Torque wrench (5-50 Nm)

VW 457 Support rails

Fig. 4: Identifying Special Tools - Engine, Removing And Installing (3 Of 3)

3283 Pressing-out appliance

Bolt M10 X 25/8.8

NOTE: The engine is removed from underneath together with

Obtain radio anti-theft code on vehicles with coded radio.

Fig. 5: Removing Engine Cover Panel Above Cylinder Head

Fig. 6: Removing Cover In Front Of Intake Manifold

Fig. 7: Disconnecting Air Duct At Bottom Of Right Side Longitudinal Member

Fig. 8: Removing Noise Insulation Panels (Center, Left And Right)

Unbolt pendulum support.

NOTE: Do not bend the flexible connection on the front exhaust

NOTE: Make sure not to damage the power steering line.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press out drive axle using special tool 3283.

Remove drive axle.

Fig. 13: Turning Drain Screw On Radiator

Turn drain screw (arrow) on radiator counter-clockwise. If necessary, fit drain

Disconnect air hose -4- from mass air flow sensor.

The air intake hose connection on the turbocharger is removed as follows:

Fig. 16: Identifying Vacuum Hose, Crankcase Breather, Wastegate Bypass

Disconnect vacuum hose -1- from air recirculation valve.

Disconnect hose -5- at bulkhead (hose leads from solenoid valve to

Fig. 17: Removing Battery Platform

Fig. 18: Identifying Battery Ground Cable, Connector & Electrical

Unbolt Ground wire -1- on engine/transmission flange.

Fig. 19: Identifying Electrical Change-Over Valve Connector, Intake Manifold

Disconnect connector -1- for electrical change-over valve on underside of

Fig. 20: Locating Generator Connections

Disconnect wire -1- from terminal 30/B+ on generator.

Disconnect connector from a/c compressor.

Remove coolant hose -1- (complete).

2 - Knock Sensor (KS) I -G61-

4 - Knock Sensor (KS) II -G66-

6 - Oil pressure switch -F1-

Take Generator wire out of retainer.

Fig. 23: Locating Connector At Camshaft Position Sensor G40

Disconnect connector from Camshaft Position (CMP) sensor -G40- (arrow).

Fig. 24: Identifying Vacuum Pipe, Vacuum Reservoir, Connectors, Support

Disconnect vacuum pipe -1- from vacuum reservoir.

Disconnect connectors -7- from ignition coils.

Disconnect the following coolant hoses:

On expansion tank (top and bottom)

On oil cooler (rear hose)

Disengage wiring harness from retainers and place to one side.

Bracket, Removing Bolts & Selector Cable Support Bracket From

Fig. 27: Identifying Slave Cylinder