2000 AUDI TT air intake

15-3


Part I

1 -
Cylinder head gasket Replacing page 15
-20
cylinder head,
removing
Installed position: part number faces
cylinder head After replacing, replace coolant
2 -
Cylinder head Removing Page 15
-20
Check for distortion Page 15
-8 , Fig.
1
Refacing measurement Page 15
-8 , Fig.
2

Installing Page 15
-25
After replacing, replace coolant
3 -
Oil deflector Verify correct installation position above
intake camshaft between cylinders 1 and 2
4 -
Cylinder head bolt Always replaceFollow sequence of removal Page 15
-20
Follow torque sequence Page 15
-25
Pa
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ylinder head, removin
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11/18/2002 htt
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e=re
pair&id=AUDI.B5.GE02.15.2

15-7


9 -
O-Ring
For upper coolant lineAlways replace
10 -
Socket-head bolt 10 Nm (7 ft lb)
11 -
Intake plenum Removing and installing Page 15
-10
12 -
Socket-head bolt
20 Nm (15 ft lb)
13 -
Brace For intake manifold
Pa
ge 6 of 35 C
ylinder head, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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pair&id=AUDI.B5.GE02.15.2

15-10

Intake manifold, removing and installing


Removing

Note:
All tie wraps opened or cut during removal must
be reinstalled at the same locations.

CAUTION!

BEFORE disconnecting the battery:

Stop the engine.
Be sure the ignition is switched OFF (also
applies when connecting the battery). Failure
to do so may damage the Engine Control
Module (ECM).
Determine the correct coding for the anti-
theft radio.

- Disconnect battery Ground (GND) strap.
- Remove engine covers.
- Drain coolant Page 19
-4 .
Pa
ge 9 of 35 C
ylinder head, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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e=re
pair&id=AUDI.B5.GE02.15.2

15-12


Note:
For vehicles with automatic transmission, remove vacuum hose -2- from
behind vacuum booster. - Disconnect Accelerator Pedal (AP) cable from throttle valve control
module -J338- and mounting flange (arrows) without removing
positioning clip.
- Remove air guide hose -6- at throttle valve control module.
- Remove vacuum hose -1-.
- Disconnect vacuum line -3- to Evaporative Emissions (EVAP) canister.
- Disconnect vacuum hose -2- at brake servo.
- Disconnect the following harness connectors:
4 - For Intake Air Temperature (IAT) sensor -G42-
5 - For throttle valve control module -J338-

- Disconnect harness connector from Camshaft Position (CMP) sensor -
G40- (arrow).
Pa
ge 11 of 35 C
ylinder head, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.15.2

15-13


- Unbolt fuel supply rail retaining bolts and disconnect vacuum line at
fuel pressure regulator (arrows).
- Disconnect fuel supply rail with injectors from intake manifold and lay
aside in rear of engine compartment on clean cloth.
- Disconnect coolant hoses at upper coolant line.

- Disconnect upper coolant line at intake line and rear coolant flange at
rear of cylinder head (arrows).
Pa
ge 12 of 35 C
ylinder head, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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e=re
pair&id=AUDI.B5.GE02.15.2

15-14


Note:
Stuff clean cloths into cylinder head intake ports. - Disconnect crankcase ventilation hose -1- at intake manifold.
- Remove intake manifold brace (arrows).
- Remove dipstick.
- Unbolt intake manifold at flange and remove.
Pa
ge 13 of 35 C
ylinder head, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.15.2

15-16

- Perform throttle valve control module adaptation
to Engine Control Module (ECM).

Repair Manual, 1.8 Liter 5V Turbo Fuel
Injection & Ignition, Repair Group 24
Tightening torques

Component

Tightening
torques
Intake manifold to cylinder
head 10 Nm (7 ft lb)
Intake manifold brace to intake
manifold 20 Nm (15 ft lb)
Intake manifold to bracket 20 Nm (15 ft lb)
Fuel supply rail to intake
manifold 10 Nm (7 ft lb)
Coolant line to coolant flange 10 Nm (7 ft lb)
Coolant line to intake manifold 10 Nm (7 ft lb)
Pa
ge 16 of 35 C
ylinder head, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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e=re
pair&id=AUDI.B5.GE02.15.2

15-21


- Remove Ground (GND) connection.
- Drain coolant Page 19
-4 .
- Remove intake manifold Page 15
-10
.
- Remove ribbed belt and ribbed belt tensioner Page 13
-15
.

- Remove the following lines/harness connectors:
1 - At Wastegate Bypass Regulator Valve -N75-
2 - At Evaporative Emission (EVAP) Canister Purge Regulator Valve -
N80-
3 - At Power outage stage -N122-
4 - At Mass Air Flow (MAF) sensor -G70-
- Pull off hose connections and remove air cleaner element housing
(arrows).
Pa
ge 21 of 35 C
ylinder head, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.15.2