Audi TT (2007 year). Instruction - page 2

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3.2

Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 176

3.3

Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 178

3.4

Removing and installing pump for exhaust gas recirculation cooler V400 . . . . . . . . . . . . 178

3.5

Removing and installing coolant pipe (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

3.6

Removing and installing coolant pipe (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

3.7

Removing and installing coolant pipe (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

4

Radiator and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

4.1

Radiator and radiator fans - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

4.2

Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

4.3

Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

4.4

Removing and installing radiator fans V7 / V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

4.5

Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

1

Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

1.1

Diagram of vacuum connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

1.2

Turbocharger - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

1.3

Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

1.4

Renewing vacuum unit with position sender for charge pressure positioner G581 . . . . . . 202

2

Charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

2.1

Charge air cooler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

2.2

Removing and installing charge pressure sender G31 / intake air temperature sender G42

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

2.3

Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

2.4

Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

1

Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

1.1

Silencers - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

1.2

Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

1.3

Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

1.4

Aligning tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

1.5

Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

2

Exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

2.1

Exhaust gas temperature control - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

2.2

Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 223

2.3

Removing and installing exhaust gas temperature sender 3 G495 . . . . . . . . . . . . . . . . . . 224

2.4

Removing and installing exhaust gas temperature sender 4 G648 . . . . . . . . . . . . . . . . . . 225

3

Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

3.1

Diagram of vacuum connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

3.2

Exhaust gas recirculation with exhaust gas recirculation cooler - exploded view . . . . . . . . 227

3.3

Removing and installing exhaust gas recirculation valve N18 with exhaust gas recirculation

potentiometer G212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

3.4

Checking exhaust gas recirculation cooler change-over . . . . . . . . . . . . . . . . . . . . . . . . . . 230

3.5

Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Contents

iii

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

iv

Contents

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

00 – Technical data

1

Engine number

♦ The engine number (“Engine code” and “Serial number”)

-arrow- can be found at the front of the joint between engine

and gearbox.

♦ There is also a sticker on the toothed belt cover showing the

“Engine code” and “Serial number”.

♦ Starting with the letter “C”, the engine codes consist of 4 let‐

ters.

♦ The first 3 characters of the engine code stand for the engine

capacity and the mechanical construction and design. They

are stamped on the cylinder block, together with the serial

number.

♦ The 4th character indicates the power output and torque of the

engine, and is determined by the engine control unit.

Note

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

(in versions for some countries only) and on the vehicle data

sticker and the engine control unit.

Fitting locations of the type plate (certain countries only) and

the vehicle data sticker ⇒ Maintenance ; Booklet 810 .

1. Engine number

1

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2

Engine data

Code letters

CBBB

Capacity

ltr.

1.968

Power output

kW at rpm

125/4200

Torque

Nm at rpm

350/1750 … 2500

Bore

∅ in mm

81.0

Stroke

mm

95.5

Compression ra‐

tio

16.5

CN

not less than

51

Firing order

1-3-4-2

Emission standards

EU4 plus

Exhaust gas recirculation

yes

Exhaust gas temperature control

yes

Turbocharging/supercharging

Turbocharger

Glow plugs

Steel glow plugs

Charge air cooling

yes

Lambda control

1 Lambda probe

Particulate filter

yes

Valves per cylinder

4

Note

Audi TT models with a TDI engine (2.0 ltr. 4-valve common rail)

are always equipped with steel glow plugs.

2

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