Audi TT (2007 year). Instruction - page 2
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
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.
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