1999-2006 Audi TT Factory Service Repair Manual

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- 4700 235 @1950- 4700 2006 Audi TT ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): ATC, AWP 2006 Audi TT ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): ATC, AWP

10 ENGINE - ASSEMBLY ENGINE, REMOVING AND INSTALLING Engine, removing and installing 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° 2006 Audi TT ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): ATC, AWP

Fig. 2: Identifying Special Tools - Engine, Removing And Installing (1 Of 3) Courtesy of VOLKSWAGEN UNITED STATES, INC. 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 2006 Audi TT ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): ATC, AWP

 2024 A Lifting tackle Fig. 3: Identifying Special Tools - Engine, Removing And Installing (2 Of 3) Courtesy of VOLKSWAGEN UNITED STATES, INC.  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 2006 Audi TT ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): ATC, AWP

Fig. 4: Identifying Special Tools - Engine, Removing And Installing (3 Of 3) Courtesy of VOLKSWAGEN UNITED STATES, INC.  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 2006 Audi TT ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): ATC, AWP

 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 Courtesy of VOLKSWAGEN UNITED STATES, INC.  Remove engine cover from cylinder head cover. 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. 2006 Audi TT ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): ATC, AWP

Fig. 6: Removing Cover In Front Of Intake Manifold Courtesy of VOLKSWAGEN UNITED STATES, INC.  Remove cover in front of intake manifold. Fig. 7: Disconnecting Air Duct At Bottom Of Right Side Longitudinal Member Courtesy of VOLKSWAGEN UNITED STATES, INC.  Disconnect air duct at bottom of right side longitudinal member (air duct leads to charge air cooler). 2006 Audi TT ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): ATC, AWP

Fig. 8: Removing Noise Insulation Panels (Center, Left And Right) Courtesy of VOLKSWAGEN UNITED STATES, INC.  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 Courtesy of VOLKSWAGEN UNITED STATES, INC.  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 2006 Audi TT ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): ATC, AWP

stabilizer bar.  Remove front exhaust pipe. Refer to Front exhaust pipe, removing and installing . Fig. 10: Securing Support Rails 457/1 To Subframe With Bolt M8 X 25 And Engine Support Device 3300A To Support Rails 457/1 Courtesy of VOLKSWAGEN UNITED STATES, INC.  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. Fig. 11: Loosening Right Side 12 - Point Nut For Drive Axle NOTE: Do not bend the flexible connection on the front exhaust pipe more than necessary (not more than 10°). NOTE: Make sure not to damage the power steering line. 2006 Audi TT ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): ATC, AWP

Courtesy of VOLKSWAGEN UNITED STATES, INC.  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 Courtesy of VOLKSWAGEN UNITED STATES, INC.  Press out drive axle using special tool 3283.  Remove drive axle.  Place drip tray V.A.G 1306 below engine.  Remove cap from coolant expansion tank. NOTE: Make sure there is enough clearance when pressing out the axle shaft. 2006 Audi TT ENGINE 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): ATC, AWP

1999-2006 Audi TT Factory Service Repair Manual

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