Audi TT (2007 year). Manual - part 55

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.

– Remove bolts -arrows- and pull charge pressure sender -

G31- / intake air temperature sender -G42- out of air pipe.

Installing
• Tightening torque 

⇒ page 208

 .

Installation is carried out in the reverse order; note the following:

Note

Fit new O-ring.

– Install air pipe (front) 

⇒ page 208

 .

2.3

Removing and installing charge air cool‐

er

Removing
– Remove radiator 

⇒ page 191

 .

– Remove charge air hose (left-side) -1- from charge air cooler.
– Release air ducts (left and right) and push to one side in order

to remove bolts -arrows-.

– Push top edge of charge air cooler slightly towards rear.
– Lift charge air cooler out of bottom mounting points.
– Push charge air cooler towards engine.
– Support charge air cooler from below to prevent charge air

cooler from dropping.

2. Charge air cooling    

211

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.

WARNING

Risk of injury caused by refrigerant.

♦ The air conditioner refrigerant circuit must not be opened.

Caution

Make sure that condenser and refrigerant pipes and hoses are

not damaged.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.

– Remove bolts -arrows- and -1-.
– Detach condenser from charge air cooler and take charge air

cooler out from below.

Installing
• Tightening torques 

⇒ page 208

Installation is carried out in the reverse order; note the following:

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 air hoses can be properly secured at their

connections, spray rust remover onto the worm thread of used

hose clips before installing.

⇒ page 209

 .

– Install radiator 

⇒ page 191

 .

2.4

Checking charge air system for leaks

Special tools and workshop equipment required
♦ Charge air system tester -V.A.G 1687- with adapter -V.A.G

1687/12-

212

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.

Procedure
– Release fasteners -1 ... 4- and remove centre noise insulation.

– Release hose clip -2-, lift retaining clip -1- and remove air hose.

– Insert adapter -1687/12- into air hose -1- and secure with hose

clip.

Prepare charge air system tester -V.A.G 1687- as follows:
– Unscrew pressure control valve -2- completely and close

valves -3- and -4-.

• Make sure knob is pulled out before turning pressure control

valve -2-.

2. Charge air cooling    

213

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.

– Connect charge air system tester -V.A.G 1687- as shown on

illustration.

214