Engine, Removing

WARNING: This page is about a different car, the 2009 Audi TT and 2008 Audi TT. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Drip tray VAS 6208
Engine/Transmission Jack V.A.G 1383 A
Hose Clip Pliers V.A.G 1921
Step Ladder VAS 5085
Engine/Trans. Support T10012
Pry Lever - Rmv Outside Mirror 80 - 200
Ring Spanner 7-Piece Set 3337
Engine Bung Set VAS 6122

NOTE:

The engine is removed downward together with the transmission.

All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.

Heat insulation sleeves removed during engine removal should be reinstalled in the same location when installing engine.

Drained coolant must be stored in a clean container for disposal or reuse.

WARNING:

Observe procedures for disconnecting battery. Refer to [For transmission(s) 02E] Removal and Installation .

-- Remove luggage compartment floor covering.

-- Release retaining clips -arrows- and remove negative post cover.

Fig 1: Battery Cover

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NOTE:

If the battery negative terminal cover is under the rear cross panel trim, trim must be removed. Refer to Removal and Installation .

-- With ignition switched off, disconnect battery ground (GND) cable -arrow-.

Fig 2: Identifying Ground Wire Terminal Clamp, Removal

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WARNING:

Cover cap of expansion tank with rag and open carefully, as hot steam or hot coolant may escape when opening.

-- Open cap of coolant expansion tank.

-- Remove both front wheels.

-- Remove center noise insulation fasteners -1 to 4-.

Fig 3: Center Noise Insulation Fasteners And Center Noise Insulation Panel

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-- Remove noise insulation at left and right -arrows-.

Fig 4: Identifying Right Noise Insulation -Arrows-, Removal

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-- Remove noise insulation frame -arrow-.

Fig 5: Identifying Noise Insulation Frame, Removal

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-- Disconnect the electrical connector on the Mass Airflow (MAF) Sensor -G70- -3-.

Fig 6: Identifying Mass Air Flow (MAF) Sensor G70 Electrical Harness Connector, Clips & Front Air Intake Connector On Lock Carrier

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-- Open clips -1 and 2- and remove air guide hose from MAF sensor.

-- Remove front air intake connector on lock carrier -4-.

-- Remove engine cover.

-- Remove air guide hose -arrow- with the V.A.G 1921.

Fig 7: Identifying Air Guide Hose, Removal

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-- Remove electrical connector -arrow- for oxygen sensor before catalytic converter from the bracket, disconnect it and lay it aside.

Fig 8: Disconnecting Heated Oxygen Sensor (HO2S) G39 Harness Connector

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-- Remove the heated oxygen sensor (HO2S) -G39- -arrow- using a tool from the 3337.

Fig 9: Oxygen Sensor

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-- Pry off the caps on the wiper arms with a screwdriver and remove the nuts.

-- Pull off and remove wiper arms from wiper axles.

-- Remove rubber seal -1- for plenum chamber cover.

Fig 10: Plenum Chamber Cover And Rubber Seal

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-- Remove the plenum chamber cover -2-.

-- Free up engine wiring harness in plenum chamber.

-- Remove the engine control module. Refer to Removal and Installation .

-- Separate the electrical connector -1- for engine wiring harness.

Fig 11: Engine Wiring Harness Connector

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-- Release pass-through for engine wiring harness -arrow- and pull off upward.

Fig 12: Engine Wiring Harness

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-- Open bracket of wiring -arrows-.

Fig 13: Engine Wiring Harness Bracket

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-- Free up and disconnect the electrical connector -1-.

Fig 14: Engine Wiring Harness Connector And Guide Brackets

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-- Open the underlying wiring guide bracket -2-.

-- Open the wiring guide bracket -3-.

-- Remove engine wiring harness to control module from wiring.

NOTE:

To unclip spiral clip, use the 80 - 200.

Fig 15: Freeing Electrical Wiring Up To Generator Using Pry Lever 80-200

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-- Disconnect the connector -1- from the back-up lamp switch.

Fig 16: Identifying Starter Connections

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-- Remove ground (GND) cable -2-.

-- Separate electrical connector -3-.

-- Push cover -4- toward rear.

-- Remove wiring -arrow- on starter and free it up.

Fig 17: Identifying Starter Wire

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-- Press both latches in direction of -arrow- and remove engine compartment E-box cover.

Fig 18: Identifying E-Box Cover And Latches

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-- Remove the electrical harness -1- and free up the wiring to the engine.

Fig 19: Identifying Electrical Harness, Removal

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-- Disconnect the electrical connector -2-.

-- Remove the bolts -1- from above.

Fig 20: Fan Shroud Bolts And Electrical Connector

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-- Place the VAS 6208 under engine.

-- Drain the coolant, by pulling off the lower coolant hose -arrows-.

Fig 21: Identifying Coolant Hose Quick Acting Coupling

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-- Remove the air duct -1 and 2- for charge air cooler.

Fig 22: Air Cooler Air Duct

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-- Disconnect the connector -2-.

Fig 23: Fan Shroud Bolts And Electrical Connector

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-- Remove bolts -3- and remove the fan shroud downward and off.

-- Disconnect upper coolant hose from radiator -arrow-.

Fig 24: Identifying The Upper Coolant Hose, Removal

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-- Disconnect coolant hoses to heat exchanger -arrows-.

Fig 25: Disconnecting Coolant Hoses To Heater Core At Bulkhead

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-- Remove the accessible nuts -arrows- for the front exhaust pipe/turbocharger from above.

Fig 26: Front Exhaust Pipe/Turbocharger Nuts

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NOTE:

The illustration depicts the engine removed from behind.

-- Disconnect vacuum hose -arrow- from brake booster.

Fig 27: Brake Booster Vacuum Hose

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-- Unclip the lock washers -1- and -2- at both cables.

Fig 28: Transmission Cable Mounting And Lock Washers

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-- Pull off the cable retainers from transmission selector lever and relay lever.

-- Remove cable mounting bracket from transmission and lay aside -arrows-.

WARNING:

Do not operate the clutch pedal anymore after hose for slave cylinder has been disconnected.

-- Pull out clip -2- to the stop in direction of -arrow- and pull off hose line -1-.

Fig 29: Pulling Out Clip And Pulling Off Hose Line

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WARNING:

The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Then release pressure by carefully pulling hose off connection.

-- Mark the fuel line -2- and the EVAP line -1-.

Fig 30: EVAP Line, Fuel Line And Vacuum Line

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-- Disconnect the fuel line -2- and lay it free.

-- Disconnect the EVAP line -1- and lay it free.

-- Disconnect the vacuum line -3- to EVAP canister (press release buttons).

-- Remove EVAP canister upward.

-- Disconnect coolant hoses -1 and 2-.

Fig 31: Coolant Hoses

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-- Discharge the air conditioning system. Refer to DESCRIPTION AND OPERATION .

-- Remove refrigerant lines -arrow- at the compressor.

Fig 32: Identifying Refrigerant Lines, Removal

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-- Seal off openings with sealing plugs from VAS 6122.

-- Unscrew the bolts -arrows- of the engine mountings approximately 2 turns.

Fig 33: Identifying Engine Mountings Bolts

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-- Unscrew the bolts -arrows- of the transmission mountings approximately 2 turns.

Fig 34: Identifying Bolts To Assembly Mounting On Transmission

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-- Disconnect electrical connector -arrow-.

Fig 35: Disconnecting Electrical Connectors

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-- Remove air duct -arrows-.

Fig 36: Air Guide Hose

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-- Disconnect electrical connector -1- from high pressure sensor -G65-.

Fig 37: Disconnecting Electrical Connectors

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-- Disconnect refrigerant line from condenser -2-.

-- Disconnect the electrical connector on the oil level sensor -1-.

Fig 38: Disconnecting Electrical Connectors On Oil Level Sensor

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-- Unclip the retainer -2-.

-- Remove the right drive axle heat shield -arrows-.

Fig 39: Identifying Protective Cap For Drive Axle On Engine

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-- Remove the left and right drive axles. Refer to Removal and Installation .

-- Remove nuts -1- and -2- on oxygen sensor electrical connector bracket under vehicle floor and remove cover.

Fig 40: Identifying Nuts -1- And -2- To Oxygen Sensor Electrical Connector Bracket And Bolt -3- To Electrical Wiring To Oxygen Sensor

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-- Remove bolt -3- and free up electrical wiring to oxygen sensor.

-- Remove connector coupling from bracket -arrow-.

Fig 41: Electrical Connector -Arrow-

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-- Disconnect electrical connector to oxygen sensor (O2S) after three way catalytic converter (TWC) -G130-.

-- Remove the remaining nuts -arrows- for the front exhaust pipe/turbocharger from below.

Fig 42: Front Exhaust Pipe/Turbocharger Nuts

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-- Remove exhaust system bracket and tunnel brace -arrows-.

Fig 43: Identifying Crossbrace Bolts -Arrows-

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NOTE:

Do not bend the flex joint in the front exhaust pipe more than 10° or it could be damaged.

-- Disconnect the exhaust system at the clamping sleeve -arrows-.

Fig 44: Clamping Sleeve -Arrows-

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-- Remove front exhaust pipe with catalytic converter and front muffler.

-- Remove bolts -1 - 3- and remove pendulum support.

Fig 45: Identifying Pendulum Support & Bolts

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-- Remove auxiliary coolant pump bolts -arrows-.

Fig 46: After-Run Coolant Pump -V51-

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-- Attach the T10012 to the cylinder block using the bolt -1- and nut -2- and tighten to approximately 20 Nm.

Fig 47: Attaching Engine Support T10012 On Engine

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-- Insert the V.A.G 1383 A into the T10012 and lift slightly.

NOTE:

Use the VAS 5085 to remove bolts for assembly mounting.

-- Remove bolts -arrows- at engine assembly mounting.

Fig 48: Identifying Engine Mountings Bolts

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-- Remove bolts -arrows- at transmission assembly mounting.

Fig 49: Identifying Bolts To Assembly Mounting On Transmission

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NOTE:

Verify that all hose and line connections between engine, transmission and body have been disconnected.

While lowering, carefully guide engine/transmission assembly in order to prevent damages.

-- Pull engine/transmission assembly as far forward as possible and slowly lower it.