2000-2004 ENGINE PERFORMANCE Turbocharger, G-Changer, … · 2019. 12. 13. · Turbocharger, G-Changer, Generic Scan Tool: 1.8L Turbo, AMU, BEA, ATC & AWP - TT ... zAlways replace

2000-2004 ENGINE PERFORMANCE

Turbocharger, G-Changer, Generic Scan Tool: 1.8L Turbo, AMU, BEA, ATC & AWP - TT

TURBOCHARGER, G-CHARGER

CHARGE AIR SYSTEM WITH TURBOCHARGER

Turbocharger with attachments, removing and installing

Observe RULES OF CLEANLINESS .

Assembly overview

Part I

1. - Front exhaust pipe

WARNING: Observe the following for all installations, especially in engine compartment due to lack of room:

Route lines of all types (for example, for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed. Watch for sufficient clearance to all moving or hot components. Switch on passenger-side airbag again after completing work.

NOTE: Always replace self-locking nuts, bolts which have been tightened to tightening torque as well as gaskets and O-rings. Secure all hose connections using hose clamps appropriate for the model type:

See Parts Catalog.

Before performing a test or repair, check all hoses and wires for secure fitting and proper seal. Charge air system must be properly sealed. Charge pressure hoses and their connections must be free of grease before re-installation.

NOTE: Always replace seals.

NOTE: The following list refers to items in Fig. 1 .

2000 Audi TT

2000-2004 ENGINE PERFORMANCE Turbocharger, G-Changer, Generic Scan Tool: 1.8L Turbo, AMU, BEA, ATC & AWP - TT

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January-06-08 12:26:59 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.

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2. - 40 Nm replace

3. - Spacer sleeve 4. - Seal

replace 5. - 10 Nm

use fluid securing material D 000 600 A2 to insert. 6. - Vacuum diaphragm

For boost pressure regulator valve 7. - Fuse 8. - Turbocharger

Boost pressure regulation, checking, see BOOST PRESSURE SYSTEM, CHECKING 9. - O-ring

replace 10. - 10 Nm 11. - Connection 12. - Seal

replace Note installed position

13. - 20 Nm 14. - Heat shield 15. - 10 Nm 16. - Banjo fitting -30 Nm 17. - Oil supply line

From oil filter bracket 18. - 30 Nm

replace Coat threads and bolt head contact surface with G000500

19. - Exhaust manifold 20. - Seal

replace Note installed position

21. - 20 Nm 22. - Banjo fitting -30 Nm 23. - 25 Nm

replace 24. - Banjo fitting -35 Nm

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25. - Coolant return line 26. - 25 Nm 27. - Spacer sleeve 28. - Banjo fitting -35 Nm 29. - 10 Nm 30. - Coolant supply line 31. - Banjo fitting -35 Nm 32. - Bracket 33. - 30 Nm

only use original equipment bolts

See Parts Catalog.

34. - 25 Nm 35. - Seal

replace 36. - Seal

replace 37. - 10 Nm 38. - Oil return line

To oil pan 39. - 10 Nm 40. - 10 Nm

use fluid securing material D 000 600 A2 to insert.

Fig. 1: Exploded View Of Exhaust Manifold And Turbocharger With Attachments (Part I) Courtesy of AUDI OF AMERICA, INC.

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Part II

1. - To boost pressure regulator valve 2. - Retaining clip 3. - O-ring

replace 4. - Intake air hose

to connection on turbocharger 5. - Wastegate Bypass Regulator Valve -N75-

Check activation. See WASTEGATE BYPASS REGULATOR VALVE, CHECKING . 6. - Mechanical recirculation valve

Checking, see DECELERATION SHUT-OFF VALVE, CHECKING 7. - Hose

to Recirculating valve for turbocharger -N249- 8. - Pressure regulator valve

For crankcase ventilation 9. - Hose

from mechanical recirculation valve to upper air guide pipe 10. - to crankcase breather valve 11. - upper air guide pipe 12. - 25 Nm 13. - 25 Nm 14. - to throttle valve connections 15. - Check-valve

Installation position (light/dark side): As shown in illustration 16. - to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- 17. - Hose 18. - Check-valve

Installation position (light/dark side): As shown in illustration 19. - Coolant line 20. - to connection on turbocharger 21. - to vacuum diaphragm for boost pressure regulator valve


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Fig. 2: Exploded View Of Turbocharger With Attachments (Part II) Courtesy of AUDI OF AMERICA, INC.

Parts of charge air cooler, removing and installing

1. - Air duct 2. - Charge air cooler 3. - Charge Air Pressure Sensor -G31-

Checking, see CHARGE AIR PRESSURE SENSOR, CHECKING 4. - 10 Nm 5. - Rubber grommet

With sleeve 6. - 10 Nm 7. - Hose

between intake manifold and charge air cooler 8. - Rubber grommet

With sleeve 9. - Hose

between upper and lower air guide pipe 10. - 10 Nm 11. - lower air guide pipe

NOTE: All hose connections are secured with clamps. Charge air system must be properly sealed. Note assembly markings at hoses and components during installation.


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12. - 10 Nm 13. - Bracket 14. - Rubber grommet

With sleeve 15. - Hose 16. - 10 Nm

Fig. 3: Exploded View Of Charge Air Cooler Courtesy of AUDI OF AMERICA, INC.

Overview of turbocharging system

1. - From fuel tank 2. - EVAP canister

with Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- 3. - Check-valve for EVAP canister

between EVAP canister and intake manifold before turbocharger Installation position (light/dark side): Arrow points in direction of aperture, as shown in figure.

4. - Turbocharger Boost pressure regulation, checking, see BOOST PRESSURE SYSTEM, CHECKING

5. - Vacuum diaphragm for boost pressure regulation 6. - Mechanical recirculation valve

Checking, see DECELERATION SHUT-OFF VALVE, CHECKING 7. - Brake booster


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8. - Check-valve Between brake booster and intake manifold Installation position (light/dark side): Arrow points in direction of aperture, as shown in figure.

9. - Wastegate Bypass Regulator Valve -N75- Check activation. See WASTEGATE BYPASS REGULATOR VALVE, CHECKING .

10. - Mass Air Flow (MAF) Sensor -G70- 11. - Air filter housing 12. - Pressure regulator valve for crankshaft housing ventilation 13. - Vacuum reservoir

Bolted on at cylinder head 14. - Fuel pressure regulator 15. - Intake manifold

with Intake Air Temperature (IAT) Sensor -G42- 16. - Check-valve

Installation position (light/dark side): Arrow points in direction of aperture, as shown in figure. 17. - Recirculating valve for turbocharger -N249-

Checking, see RECIRCULATING VALVE FOR TURBOCHARGER, CHECKING 18. - Secondary Air Injection (AIR) Solenoid Valve -N112- 19. - Crankcase ventilation 20. - Secondary Air Injection (AIR) Pump Motor -V101- 21. - Throttle Valve Control Module -J338- 22. - Charge air cooler

with Charge Air Pressure Sensor -G31- 23. - Check-valve

between EVAP canister and intake manifold Installation position (light/dark side): Arrow points in direction of aperture, as shown in figure.

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Fig. 4: Overview Of Turbocharging System Components With Vacuum Diagram Courtesy of AUDI OF AMERICA, INC.

Rules of cleanliness

When working on turbocharger, carefully observe the following "5 Rules of Cleanliness":

Thoroughly clean all connections and the surrounding area before disconnecting. Place parts that have been removed on a clean surface and cover. Use lint-free cloths only! Carefully cover over opened components or seal, if repairs are not performed immediately. Only install clean components:Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (in tool boxes etc.) When the system is open: Do not work with compressed air if it can be avoided. Do not move vehicle unless absolutely necessary.

Safety precautions

If special testing equipment is required during road test, note the following:

Audi TT Coupe:

Test equipment must always be secured to the rear seat and operated from there by a second person.

If test and measuring equipment is operated from the passenger seat, the person seated there could be injured in the event of an accident involving deployment of the passenger -side airbag.

Audi TT Roadster:

Deactivate the passenger-side airbag using the key switch in the glove compartment or via On Board Diagnostic (OBD). Switch on passenger-side airbag again after completing work.

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BOOST PRESSURE SYSTEM, CHECKING

Boost pressure regulation, checking

Recommended special tools and equipment

V.A.G 1397 A Turbocharger Tester

Fig. 5: Identifying V.A.G 1397 Turbocharger Tester Courtesy of AUDI OF AMERICA, INC.

Test requirements

No leaks on intake or exhaust side. Engine oil temperature at least 80 °C.

Test sequence

Charge pressure is measured under Wide Open Throttle (WOT) while driving or on the roller type test stand.

Using VAG1397A Turbocharger Tester test hose, connect T-piece to front of intake manifold.

WARNING: To reduce the risk of accident during road tests, always observe safety precautions. See SAFETY PRECAUTIONS .

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Fig. 6: Connecting VAG1397/A Turbocharger Tester To Front Of Intake Manifold Courtesy of AUDI OF AMERICA, INC.

Guide test hose over rear corner of hood and through right window into vehicle interior. Turn turbocharger tester on and select measuring range (absolute pressure).

Fig. 7: Identifying VAG1397/A Turbocharger Tester Courtesy of AUDI OF AMERICA, INC.

Connect test hose to connection flange.

NOTE: Using turbocharger tester, see operating instructions. Hoses must be connected so there is no possibility of leaks, otherwise incorrect readings may result. Ensure test hose is not pinched at hood and side window. By pressing memory button "M" on turbocharger tester, the last test value

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Accelerate vehicle in 3rd gear at full throttle from 2000 RPM and watch tachometer. At 3000 RPM press memory button "M" on VAG1397A.

Fig. 8: Identifying VAG1397/A Turbocharger Tester Courtesy of AUDI OF AMERICA, INC.

Specification on VAG1397A: 1.700 ... 1.900 bar positive pressure

If boost pressure is exceeded:

Check Wastegate Bypass Regulator Valve -N75-. (Throughput in hose from turbocharger via valve to vacuum diaphragm with connector disconnected) Check for proper seating of vacuum diaphragm for wastegate bypass regulator valve at turbocharger. Check vacuum diaphragm. See VACUUM DIAPHRAGM FOR WASTEGATE BYPASS REGULATOR VALVE, CHECKING . Check bearing for shaft of wastegate bypass regulator valve in turbocharger for ease of movement. If rusted solid, replace turbocharger.

is saved until either memory button "M" is pressed again or the turbocharger tester is shut - off. A blinking comma in display field indicates a value has been saved. An arrow appears in the top left corner of display field if turbocharger tester battery voltage drops below the permissible specification. Before testing drive vehicle rapidly at least 3 km (without frequent stops and similar). A second technician is required because the indicated values must be read out during vehicle operation.

NOTE: Repeat measurement if full charge pressure has not yet built up.

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If boost pressure is not reached:

Check Wastegate Bypass Regulator Valve -N75-. Check bearing for shaft of wastegate bypass regulator valve in turbocharger for ease of movement. If rusted solid, replace turbocharger. Turbocharger faulty, replace.

Wastegate bypass regulator valve, checking


VAG1526 multimeter or VAG1715 multimeter VAG1594 connector test kit

Test sequence

Switch ignition off. Disconnect connector at solenoid valve for boost pressure regulation.

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Fig. 9: Measuring Solenoid Valve For Boost Pressure Regulation Resistance Courtesy of AUDI OF AMERICA, INC.

Measure resistance between terminals of valve.

Specified value: 25...35

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If specified value is not obtained:

Replace Wastegate Bypass Regulator Valve -N75-.

Vacuum diaphragm for wastegate bypass regulator valve, checking


VAG1526 multimeter or VAG1715 multimeter VAG1594 connector test kit

Test requirement

Engine oil temperature at least 80 °C.

Test sequence

Disconnect connector at Wastegate Bypass Regulator Valve -N75-(-1-). See Fig. 10 .

Fig. 10: Identifying Operating Rod Courtesy of AUDI OF AMERICA, INC.

Start engine and increase speed to maximum RPM by depressing accelerator pedal suddenly. Operating rod - 2- for wastegate bypass regulator valve must move.

If operating rod does not move:

Check lever for wastegate bypass regulator valve -1- for ease of movement. If rusted solid, replace turbocharger.

If operating rod does not move despite freely moving lever:

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Check Wastegate Bypass Regulator Valve - N75-. (Throughput in hose from turbocharger via valve to vacuum diaphragm with connector disconnected)

If solenoid valve is OK:

Replace turbocharger, item no. 8 .

Deceleration shut-off valve, checking


VAG1390 hand vacuum pump

Fig. 11: Identifying VAG1390 Hand Vacuum Pump Courtesy of AUDI OF AMERICA, INC.

Test requirement

Performance deficiency or tip-in shocks

Test sequence

Attach VAG1390 vacuum pump to recirculation valve.

NOTE: The deceleration shut-off valve is located in front of the turbocharger. It is opened by vacuum during deceleration and at idle.

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Fig. 12: Attaching VAG1390 Vacuum Pump To Recirculation Valve Courtesy of AUDI OF AMERICA, INC.

Operate vacuum pump. Recirculation valve must open (arrow)

After approx. 30 seconds, operate vent valve on vacuum pump. Recirculation valve must close (arrow)

If recirculation valve does not open or close or valve plate does not seal correctly when valve is closed:

Replace recirculation valve. Secure connections of recirculation valve using screw clamps.

Charge air pressure sensor, checking


VAG1526 multimeter or VAG1715 multimeter VAG1594 connector test kit Wiring diagram

Checking voltage supply and wiring to control module

Switch ignition off. Disconnect connector at charge air pressure sensor. Use adapter cables from VAG1594 to connect multimeter to terminals 1 + 3 of connector for voltage measurement.

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Fig. 13: Identifying Charge Air Pressure Sensor Harness Connector Terminals Courtesy of AUDI OF AMERICA, INC.

Switch ignition on.

Specified value: at least 4.5 V

Switch ignition off.


Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected.

Fig. 14: Connecting VAG1598/31 Test Box To Control Module Wiring Harness Courtesy of AUDI OF AMERICA, INC.

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Check for open circuits in wires between test box and connector according to wiring diagram.

Terminal 1+socket 108

Terminal 3 + socket 98

Terminal 4 + socket 101

Wire resistance: max: 1.5

Fig. 15: Identifying Charge Air Pressure Sensor Harness Connector Terminals Courtesy of AUDI OF AMERICA, INC.

Check wires for short circuit to each other.

If no malfunctions are found in the wires and there was voltage between terminals 1 + 3:

See CHECKING FUNCTION .

If no malfunctions are found in wires and there was no voltage between terminals 1 + 3:

Replace Motronic Engine Control Module (ECM) -J220-. See REPLACING ENGINE CONTROL MODULE (ECM) .

Checking function

Connect test box to control module wiring harness. See CONNECT TEST BOX FOR WIRING TEST . Re-connect connector at Charge Air Pressure Sensor -G31-. Connect multimeter to socket 101 and socket 108 for voltage measurement. Start engine and measure voltage.

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Specified value: 1.80 to 2.00 volts

Bring engine to RPM by depressing accelerator pedal suddenly.

Specified value: 2.00 to 3.00 volts

If specified values are not obtained:

Replace the Charge Air Pressure Sensor - G31-.

Recirculating valve for turbocharger, checking

Test sequence

Switch ignition off. Disconnect connector from Recirculating valve for turbocharger -N249-.

NOTE: Valve opens between connection to intake manifold and connection to deceleration shut -off valve with no voltage. Connection to vacuum reservoir is closed.

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Fig. 16: Measuring Recirculating Valve For Turbocharger Resistance Courtesy of AUDI OF AMERICA, INC.

Measure resistance between terminals of valve.

Specified value: 27...30 ohm


Replace Recirculating valve for turbocharger -N249-.

If specified values are obtained:

Connect test box to control module wiring harness. See CONNECT TEST BOX FOR WIRING

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TEST . Check wire between test box socket 105 + 2-pin connector terminal 2 for open circuit according to wiring diagram.

Wire resistance: max: 1.5 ohm

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Fig. 17: Identifying Recirculating Valve For Turbocharger Harness Connector Terminals Courtesy of AUDI OF AMERICA, INC.

Also check the wire for short circuit to B+ and Ground (GND).

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If no malfunctions are found in wire:

Check wire between 2-pin connector terminal 1 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram.

Wire resistance: max: 1.5 ohm

If no malfunctions are found in wires:

Replace Engine Control Module (ECM). See REPLACING ENGINE CONTROL MODULE (ECM) .

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Documents

2000-2004 ENGINE PERFORMANCE Turbocharger, G-Changer, … · 2019. 12. 13. · Turbocharger, G-Changer, Generic Scan Tool: 1.8L Turbo, AMU, BEA, ATC & AWP - TT ... zAlways replace