Tài liệu hướng dẫn sửa chữa đại tu động cơ xăng trên xe 4cylinder direct petrol injection engine 1.8L 2.0L_Audi TT_Type_8J_MK2_Dong co xang. Cung cấp các thông tin cần thiết cho Kỹ thuật viên thực hiện sửa chữa nhanh chóng, hiệu quả, chính xác
Service Workshop Manual Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics Engine ID CCT CCZ CDA CES A A A A CET A Edition 11.2010 Service Department Technical Information Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups Repair Group 00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling 21 - Turbocharging/supercharging 26 - Exhaust system Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed All rights reserved No reproduction without prior agreement from publisher Copyright © 2010 Audi AG, Ingolstadt A005TT02420 Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 Contents 00 - Technical data 3.1 3.2 3.3 3.4 3.5 3.6 4.1 Engine number Engine data Safety precautions Working on the fuel system Procedure before opening high-pressure section of injection system Working on the cooling system Working on vehicles with start/stop system Using testers and measuring instruments during a road test Working on the exhaust system General repair instructions Rules for cleanliness when working on fuel supply system, injection system and turbocharger Checking fuel system for leaks Foreign particles in engine Contact corrosion! Routing and attachment of pipes, hoses and wiring Checking vacuum system Installing radiators, condensers and charge air coolers 3 4 5 10 - Removing and installing engine 4.2 4.3 4.4 4.5 4.6 4.7 6.1 6.2 6.3 Removing engine Separating 6-speed manual gearbox 02S from engine Separating dual-clutch gearbox 02E from engine Securing engine to engine and gearbox support Installing engine Assembly mountings Assembly mountings - exploded view Checking adjustment of assembly mountings (engine/gearbox mountings) Adjusting assembly mountings 6 7 31 33 36 38 42 42 43 44 13 - Crankshaft group 49 1.1 1.2 1.3 1.4 1.5 2.1 2.2 2.3 3.1 3.2 3.3 3.4 3.5 3.6 4.1 Cylinder block (pulley end) Poly V-belt drive - exploded view Removing and installing poly V-belt Removing and installing tensioner for poly V-belt Removing and installing bracket for ancillaries Removing and installing vibration damper Cylinder block (gearbox end) Sealing flange (gearbox end) and dual-mass flywheel - exploded view Removing and installing dual-mass flywheel Removing and installing sealing flange (gearbox end) Crankshaft Crankshaft - exploded view Removing and installing sender wheel Allocation of crankshaft bearing shells (classification) Crankshaft dimensions Measuring axial clearance of crankshaft Measuring radial clearance of crankshaft Pistons and conrods Pistons and conrods - exploded view Contents 49 49 51 52 55 56 59 59 60 61 64 64 65 66 67 67 68 70 70 i Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 4.2 4.3 Separating parts of new conrod Piston and cylinder dimensions 73 73 15 - Cylinder head, valve gear 74 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 2.1 2.2 2.3 2.4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 Chain drive Timing chain cover - exploded view Removing and installing camshaft control valve N205 Removing and installing timing chain cover (top) Removing and installing timing chain cover (bottom) Renewing oil seal for vibration damper Camshaft timing chain - exploded view Removing and installing camshaft timing chain Balance shaft timing chain - exploded view Removing and installing balance shaft timing chain Renewing balance shaft for inlet camshaft Renewing balance shaft for exhaust camshaft Checking valve timing Cylinder head Cylinder head without AVS - exploded view Removing and installing cylinder head without AVS Cylinder head with AVS - exploded view Removing and installing cylinder head with AVS Checking compression Valve gear Valve gear without AVS - exploded view Removing and installing camshafts without AVS Valve gear with AVS - exploded view Removing and installing camshafts with AVS Renewing valve stem oil seals with cylinder head installed Renewing valve stem oil seals with cylinder head removed Checking valve guides 74 75 76 76 78 84 88 89 94 96 98 101 103 105 105 108 123 126 135 137 138 140 149 151 163 167 170 17 - Lubrication 171 1.1 1.2 1.3 1.4 1.5 1.6 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 Sump and oil pump Sump, oil pump - exploded view Removing and installing coarse oil separator Removing and installing sump (bottom section) Removing and installing oil pump Removing and installing sump (top section) Removing and installing valve for oil pressure control N428 Oil filter and engine oil cooler Oil filter, engine oil cooler - exploded view Removing and installing engine oil cooler Removing and installing oil pressure switch F22 Removing and installing oil pressure switch for reduced oil pressure F378 Checking oil pressure switch Checking oil pressure Engine oil Checking oil level 171 172 174 174 177 178 181 183 183 184 185 186 186 186 187 187 19 - Cooling 188 1.1 1.2 1.3 ii Contents Parts of cooling system (on engine) Diagram of coolant hose connections Draining and filling cooling system Checking cooling system for leaks 188 189 191 196 Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 2.1 2.2 2.3 2.4 Continued coolant circulation pump V51 - exploded view Removing and installing continued coolant circulation pump V51 Coolant pipes - exploded view Removing and installing coolant pipes (front) Removing and installing small coolant pipe Coolant pump and thermostat - exploded view Removing and installing coolant temperature sender G62 Removing and installing toothed belt for coolant pump Renewing oil seal for coolant pump drive Removing and installing coolant pump Removing and installing thermostat Parts of cooling system (on body) Radiator and radiator fans - exploded view Removing and installing radiator Removing and installing radiator cowl Removing and installing radiator fan V7 and radiator fan V177 198 198 200 200 203 206 207 208 210 211 213 216 217 217 219 221 21 - Turbocharging/supercharging 222 1.1 1.2 1.3 1.4 1.5 1.6 2.1 2.2 2.3 2.4 2.5 Turbocharger Turbocharger - exploded view Removing and installing air pipes and hoses with plug-in connectors Removing and installing turbocharger Checking vacuum unit for turbocharger Removing and installing vacuum unit for turbocharger Adjusting vacuum unit for turbocharger Charge air system Turbocharging diagram Charge air cooler - exploded view Removing and installing charge pressure sender G31 Checking charge air system for leaks Removing and installing charge air cooler 222 223 227 227 232 234 234 240 240 241 242 242 244 26 - Exhaust system 247 1.1 1.2 1.3 1.4 Components of exhaust system Silencers - exploded view Removing and installing front exhaust pipe with catalytic converter and front silencer Aligning exhaust system Checking exhaust system for leaks Exhaust manifold Contents 247 248 249 253 254 255 iii Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 iv Contents Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 00 – Technical data Engine number The engine number („Engine code“ and „Serial number“) can be found at the front of the joint between engine and gearbox Additionally there is a sticker on the toothed belt cover showing the „engine code“ and „serial number“ The engine code is also indicated on the vehicle data stickers Engine number Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 Engine data Code letters CDAA CCTA CCZA CESA Capaci‐ ltr 1.789 1.984 1.984 1.984 ty Power kW at 118/4200 147/5100 147/5100 155/4300 output rpm Torque Nm at 250/1500 280/1700 280/1700 350/1600 rpm Bore ∅ in 82.5 82.5 82.5 82.5 mm Stroke mm 84.2 92.8 92.8 92.8 Compression ra‐ 9.6 9.6 9.6 9.6 tio RON 95 2) 98 1) 98 1) 95 2) Injection/ignition FSI FSI FSI FSI system Firing 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 order Knock control yes yes yes yes Turbocharging/ yes yes yes yes supercharging Exhaust gas re‐ no no no no circulation Intake manifold no no no no change-over Variable valve yes yes yes yes timing Secondary air no no no no system • 1) Unleaded petrol RON 95 can also be used, but results in reduced power • 2) Unleaded petrol RON 91 can also be used, but results in reduced power Rep gr.00 - Technical data Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 Safety precautions ♦ ⇒ „3.1 Working on the fuel system“, page ♦ ⇒ „3.2 Procedure before opening high-pressure section of in‐ jection system“, page ♦ ⇒ „3.3 Working on the cooling system“, page ♦ ⇒ „3.4 Working on vehicles with start/stop system“, page ♦ ⇒ „3.5 Using testers and measuring instruments during a road test“, page ♦ ⇒ „3.6 Working on the exhaust system“, page 3.1 Working on the fuel system When working on the fuel system note the following warnings: WARNING The fuel system operates at extremely high pressure This can cause injury ♦ The fuel pressure in the high-pressure section of the in‐ jection system must be reduced to a residual pressure prior to opening the system ♦ Wrap a clean cloth around the connection and carefully loosen the connection to allow the residual pressure to dissipate – Procedure before opening high-pressure section of injection system ⇒ Rep gr 24 Observe the following to prevent injuries to persons and damage to the injection and ignition system: ♦ Always switch off the ignition before connecting or discon‐ necting electrical wiring for the injection or ignition system or tester cables ♦ Always switch off ignition before washing engine ♦ Faults are stored in engine control units if electrical connectors were unplugged and engine was started: „Generate readiness code“ in „Guided Functions“ ⇒ Vehicle diagnostic tester Caution To prevent irreparable damage to the electronic components when disconnecting the battery: ♦ Observe notes on procedure for disconnecting the battery ♦ Always switch off the ignition before disconnecting the battery – Disconnect battery ⇒ Rep gr 27 Safety precautions Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 3.2 Procedure before opening high-pres‐ sure section of injection system WARNING ♦ The injection system consists of a high-pressure section (maximum approx 120 bar) and a low-pressure section (approx bar) ♦ The fuel pressure in the high-pressure section must be reduced to a residual pressure of approx bar prior to opening the system Procedure ⇒ Rep gr 24 3.3 Working on the cooling system When working on the cooling system note the following warnings: WARNING Hot steam/hot coolant can escape - risk of scalding ♦ The cooling system is under pressure when the engine is hot ♦ To allow pressure to dissipate, cover filler cap on coolant expansion tank with cloth and open carefully Caution Overheating can occur if the filler cap is not fitted properly ♦ The filler cap must engage positively and audibly when it is closed 3.4 Working on vehicles with start/stop sys‐ tem When performing repairs on vehicles with start/stop system, note the following: WARNING Risk of injury due to automatic engine start on vehicles with start/stop system ♦ On vehicles with activated start/stop system (this is indi‐ cated by a message in the instrument cluster display), the engine may start automatically on demand ♦ Therefore it is important to ensure that the start/stop sys‐ tem is deactivated when performing repairs (switch off ignition, if required switch on ignition again) Rep gr.00 - Technical data Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 2.2 Charge air cooler - exploded view Note ♦ Hose connections and air pipes and hoses must be free of oil and grease before assembly ♦ Secure all hose connections with the correct type of hose clips (same as original equipment) ⇒ Electronic parts catalogue ♦ To ensure that the charge air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing ♦ If there are slight impressions on the fins, refer to ⇒ page - Bolt ❑ Nm - Mounting ❑ For charge air cooler - Charge air cooler - Charge air pipe ❑ Fitting hose connec‐ tions with plug-in con‐ nectors ⇒ page 227 - Bolt ❑ 10 Nm - Charge air hose ❑ Fitting hose connec‐ tions with plug-in con‐ nectors ⇒ page 227 - Hose clip - Charge air hose ❑ To throttle valve module -J3389 - Hose clip 10 - Bolt ❑ 10 Nm 11 - Charge air pipe 12 - Hose clip 13 - Charge air hose ❑ Fitting hose connec‐ tions with plug-in con‐ nectors ⇒ page 227 14 - Seal ❑ Renew 15 - Charge pressure sender -G31❑ Removing and installing ⇒ page 242 16 - Bolt ❑ Nm 17 - Bolts ❑ 10 Nm Charge air system 241 Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 2.3 Removing and installing charge pres‐ sure sender -G31- Removing – Unplug electrical connector -2- – Unscrew bolts -1- and remove charge pressure sender -G31- Installing • Tightening torque ⇒ „2.2 Charge air cooler - exploded view“, page 241 Install in reverse order 2.4 Checking charge air system for leaks Special tools and workshop equipment required ♦ Charge air system tester -V.A.G 1687- ♦ Adapter -V.A.G 1687/5– Remove noise insulation ⇒ Rep gr 66 – Remove noise insulation frame ⇒ Rep gr 50 – Release retaining clip -A- and disconnect hose -B- from charge air pipe 242 Rep gr.21 - Turbocharging/supercharging Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 – Fit adapter -V.A.G 1687/5- onto charge air hose -A- and turn by approx 90° -B- Prepare charge air system tester -V.A.G 1687- as follows: – Unscrew pressure control valve -2- completely and close valves -3- and -4- Note Make sure knob is pulled out before turning pressure control valve -2- – Connect charge air system tester -V.A.G 1687- as shown in illustration Charge air system 243 Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 – Connect pressure hose -1- (compressed air supply line) to charge air system tester -V.A.G 1687- Note If sight glass contains water, loosen drain plug and drain water -6- – Open valve -3- – Adjust pressure to 0.5 bar via pressure control valve -2- Caution The pressure must not exceed 0.5 bar If the pressure is set too high this can damage the engine – Open valve -4- and wait until test system is pressurised If necessary, adjust pressure to 0.5 bar again – Check charge air system for audible leaks or leaks that can be felt with the hand; apply commercially available leak detecting spray or use ultrasonic tester -V.A.G 1842- Note ♦ Fitting hose connections with plug-in connectors ⇒ page 227 ♦ A small amount of air escapes through the valves and enters the engine Therefore it is not possible to perform a pressure retention test ♦ Operation of ultrasonic tester -V.A.G 1842- ⇒ Operating in‐ structions ♦ Release pressure by detaching coupling from adapter -V.A.G 1687/5- before removing adapter ♦ Hose connections and hoses for charge air system must be free of oil and grease before assembly 2.5 Removing and installing charge air cool‐ er Special tools and workshop equipment required ♦ Engine bung set -VAS 6122- 244 Rep gr.21 - Turbocharging/supercharging Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 Removing – Remove radiator ⇒ page 217 – Remove bumper cover (front) ⇒ Rep gr 63 WARNING Risk of injury caused by refrigerant ♦ The air conditioner refrigerant circuit must not be opened Caution Danger of damage to refrigerant lines and hoses ♦ Do NOT stretch, kink or bend refrigerant lines and hoses – Release hose clip -arrow- and detach air hose from charge air cooler – Release hose clips -1- and -2- and remove air hose – Unscrew bolts -arrows-; to so, release air ducts (left and right) and swivel towards headlights – Swivel top edge of charge air cooler slightly towards rear – Lift charge air cooler out of bottom mounting points – Push charge air cooler towards engine and support from below to prevent it from dropping Charge air system 245 Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 – Remove bolts -arrows- – Take out charge air cooler from underneath Installing Installation is carried out in the reverse order; note the following: Note If there are slight impressions on the fins, refer to ⇒ page • Tightening torques ⇒ „2.2 Charge air cooler - exploded view“, page 241 Note ♦ Hose connections and hoses for charge air system must be free of oil and grease before assembly ♦ Secure all hose connections with the correct type of hose clips (same as original equipment) ⇒ Electronic parts catalogue ♦ To ensure that the charge air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing – Install radiator ⇒ page 217 – Install bumper cover (front) ⇒ Rep gr 63 – Install air pipes/hoses with plug-in connectors ⇒ page 227 – Check coolant level ⇒ page 196 246 Rep gr.21 - Turbocharging/supercharging Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 26 – Exhaust system Components of exhaust system ⇒ „1.1 Silencers - exploded view“, page 248 ⇒ „1.2 Removing and installing front exhaust pipe with catalytic converter and front silencer“, page 249 ⇒ „1.3 Aligning exhaust system“, page 253 ⇒ „1.4 Checking exhaust system for leaks“, page 254 Note ♦ The flexible joint (de-coupling element) in the front exhaust pipe must not be bent more than 10° – otherwise it can be damaged ♦ Renew gaskets and self-locking nuts ♦ After working on the exhaust system, ensure that the system is not under stress and that it has sufficient clearance from the body If necessary, loosen clamp and align silencers and ex‐ haust pipe so that sufficient clearance is maintained to the body at all points and the mountings are evenly loaded ♦ The exhaust manifold and the turbocharger are one compo‐ nent; removing and installing ⇒ page 222 Components of exhaust system 247 Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 1.1 Silencers - exploded view - Bolt ❑ 23 Nm - Bracket for exhaust system - Clamp ❑ Align exhaust system so it is free of stress before tightening clamp ⇒ page 253 ❑ Installation position ⇒ page 249 ❑ Tighten bolt connec‐ tions evenly - Nut ❑ 23 Nm - Bracket for exhaust system - Rubber mounting ❑ Renew if damaged - Bolt ❑ 23 Nm - Mounting ❑ Renew if damaged - Bolt ❑ 23 Nm 10 - Cross piece 11 - Gasket ❑ Renew 12 - Nut ❑ 40 Nm ❑ Renew ❑ Coat studs of turbocharger with high-temperature paste ❑ High-temperature paste ⇒ Parts catalogue 13 - Lambda probe -G39- and Lambda probe heater -Z19❑ 55 Nm ❑ Grease only the threads with high-temperature paste The paste must not penetrate into the slots on the Lambda probe body ❑ High-temperature paste ⇒ Parts catalogue ❑ Removing and installing ⇒ Rep gr 24 14 - Front exhaust pipe with catalytic converter and front silencer ❑ Do not bend flexible joint more than 10° - otherwise it can be damaged ❑ Install flexible joint so that it is not under tension ❑ Take care not to damage wire mesh on flexible joint ❑ Protect catalytic converter from damage by knocks and impact ❑ Removing and installing ⇒ page 249 ❑ Do not remove protective packaging from replacement part until you are ready to fit the flexible joint ❑ Align exhaust system so it is free of stress ⇒ page 253 248 Rep gr.26 - Exhaust system Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 15 - Lambda probe after catalytic converter -G130- and Lambda probe heater after catalytic converter -Z29❑ 55 Nm ❑ Grease only the threads with high-temperature paste The paste must not penetrate into the slots on the Lambda probe body ❑ High-temperature paste ⇒ Parts catalogue ❑ Removing and installing ⇒ Rep gr 24 16 - Rear silencer ❑ Align exhaust system so it is free of stress ⇒ page 253 17 - Rubber mounting ❑ Renew if damaged 18 - Nut ❑ 23 Nm Installation position of clamp – Position clamp at angle shown when installing • Bolt connections face to right • Nuts face upwards • α = approx 20° 1.2 Removing and installing front exhaust pipe with catalytic converter and front si‐ lencer Removing – Remove engine cover panel -arrows- Components of exhaust system 249 Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 – Unscrew bolts -arrows- and remove air duct – Detach air duct at bottom together with air hose – Unplug electrical connector -1- from air mass meter -G70- – Detach air intake hose -2- – Unscrew bolt -4- and remove air cleaner housing Note Disregard item -3- – Remove bolt -arrow- for air pipe – Loosen hose clip -1- and remove air pipe – Press release tabs and disconnect air hose -2- – Unplug electrical connector -arrow- for Lambda probe -G39and Lambda probe heater -Z19- and move wiring clear 250 Rep gr.26 - Exhaust system Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 – Unscrew accessible securing nuts -arrows- of front exhaust pipe/turbocharger from above Four-wheel drive: – Mark position of flexible coupling and flange for bevel box in relation to each other for re-installation – Remove bolts -arrows- for flexible coupling for propshaft at bevel box (counterhold using a suitable lever at the triangular flange) Caution Make sure not to damage the oil seal -arrow- in the propshaft flange ♦ Push the propshaft horizontally to the rear and towards the right side of vehicle as far as possible All vehicles (continued): – Unscrew nuts -1- and -2- at bracket for electrical connector for Lambda probe (on underbody) and remove cover – Remove bolt -3- and move electrical wiring to Lambda probe clear Components of exhaust system 251 Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 – Take plug-in connector out of bracket -arrow- – Unplug electrical connector for Lambda probe after catalytic converter -G130- – Unscrew remaining securing nuts -arrows- of front exhaust pipe/turbocharger from underneath – Unbolt bracket for exhaust system and cross piece -arrows- 252 Rep gr.26 - Exhaust system Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 Caution Avoid damage to flexible joints ♦ Do not bend flexible joints in front exhaust pipe more than 10° – Disconnect exhaust system at clamp -arrows- – Detach front exhaust pipe with catalytic converter and front silencer Installing Installation is carried out in the reverse order; note the following: • Tightening torques ⇒ „1.1 Silencers - exploded view“, page 248 Note Renew gaskets and self-locking nuts – Install propshaft ⇒ Rep gr 39 – Align the exhaust system so it is free of stress ⇒ page 253 1.3 Aligning exhaust system • The exhaust system must be aligned when it is cool • Tightening torques ⇒ page 248 – Loosen bolt connections of front clamp ⇒ Item (page 248) – Push rear silencer towards front of vehicle -arrow-, so that rubber mounting (left-side) is preloaded by dimension -a- = 11 13 mm – Position clamp at angle shown when installing • Bolt connections face to right • Nuts face upwards • α = approx 20° – Tighten bolt connections on clamp evenly Components of exhaust system 253 Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 Aligning tailpipe: – Align tailpipes so that distance -a- (left-side) is the same as distance -a- (right-side) – At the same time, distance -b- must be obtained between bumper cut-out and top of tailpipes ♦ Dimension b = at least 21 mm – If necessary, unfasten rear silencer mounting to align tailpipes 1.4 Checking exhaust system for leaks – Start the engine and run at idling speed – Plug the tailpipe (e g with rags or stopper) and leave plugged until the check is complete – Listen for noise at connection points (cylinder head/exhaust manifold, exhaust manifold/front exhaust pipe, etc.) to locate any leaks – Rectify any leaks that are found 254 Rep gr.26 - Exhaust system Audi TT 2007 ➤ 4-cylinder direct petrol injection engine (1.8 ltr., 2.0 ltr 4-valve turbo), mechanics - Edition 11.2010 Exhaust manifold The exhaust manifold and the turbocharger are combined as one unit; removing and installing ⇒ page 222 Exhaust manifold 255