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

Pry Lever - Rmv Outside Mirror 80 - 200
Engine/Transmission Jack V.A.G 1383 A
Step Ladder VAS 5085
Drip Tray VAS 6208
Locking Pin T10060 A
Assembly Tool T10118
Hose Clamps Up to 25 mm Dia. 3094
Torque Wrench SAT 8010/3
Engine mount T40074
Qty. 1 M12 nut
Qty. 2 M10 bolts

Procedure

NOTE:

Assemble engine with transmission downward.

During installation, cable ties must be installed at the same location.

Collect escaping coolant in a clean container for disposal or reuse.

CAUTION:

Risk of destroying electrical components when battery is disconnected.

Observe measures when disconnecting battery.

-- Remove luggage compartment floor covering.

-- If the battery negative pole cover is under the rear cross panel trim, remove rear cross panel trim. Refer to Removal and Installation .

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

Fig 1: Battery Cover

Courtesy of AUDI OF AMERICA, LLC

-- Loosen nut a few turns and remove terminal clamp -arrow- on Ground (GND) cable from battery pole.

Fig 2: Identifying Ground Wire Terminal Clamp

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Risk of scalding due to hot steam and hot coolant.

When the engine is warm the cooling system is under pressure.
Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.

-- Open coolant reservoir cap.

-- Remove both front wheels.

-- Remove noise insulation in center by loosening mounting sections -1 through 4-.

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

Courtesy of AUDI OF AMERICA, LLC

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

Fig 4: Identifying Right Noise Insulation -Arrows-

Courtesy of AUDI OF AMERICA, LLC

-- Remove noise insulation frame -arrow-.

Fig 5: Identifying Noise Insulation Frame

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect electrical connector -1- on engine coolant temperature (ECT) sensor (on radiator) -G83-.

Fig 6: Identifying Coolant Hose

Courtesy of AUDI OF AMERICA, LLC

-- Place VAS 6208 under engine.

-- Remove coolant hose downward from radiator -arrow- and allow coolant to drain.

-- Remove lower coolant hose to after-run coolant pump -V51- -arrow- and allow coolant to drain.

Fig 7: After-Run Coolant Pump -V51

Courtesy of AUDI OF AMERICA, LLC

NOTE:

The illustration shows the coolant hose on a vehicle with direct shift automatic transmission (DSG).

-- Remove resonance tube -2- from air guide hose.

Fig 8: Identifying Air Guide Hose, Resonance Tube And Sensor -G70- Electrical Connector

Courtesy of AUDI OF AMERICA, LLC

-- Remove air guide hose -1- from throttle valve control module -J338-.

-- Disconnect the electrical connector -3- for the mass air flow sensor -G70-.

-- Detach upper section of air filter housing -arrow- and remove air filter insert.

-- Remove bolts -arrows- and remove air duct.

Fig 9: Identifying Bolts -Arrows- And Air Guide

Courtesy of AUDI OF AMERICA, LLC

-- Remove lower section of air filter housing -arrows-.

Fig 10: Identifying Screws For Lower Portion Of Air Cleaner Housing

Courtesy of AUDI OF AMERICA, LLC

-- Remove air filter housing bracket -arrows-.

Fig 11: Air Filter Housing Bracket

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect electrical connector -1- for heated oxygen sensor (HO2S) 2 -G108- and electrical connector -2- for heated oxygen sensor (HO2S) -G39-.

Fig 12: Disconnecting Heated Oxygen Sensor (HO2S) Electrical Harness Connector

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect electrical connector -3- for brake fluid level warning switch -F34-.

-- Free up electrical wires to oxygen sensors.

-- Pry cover caps off windshield wiper arms with screwdriver.

Fig 13: Wiper Arm Nuts

Courtesy of AUDI OF AMERICA, LLC

-- Loosen nuts -arrows- a few turns.

-- Loosen wiper arms in succession by tilting wiper axles slightly.

-- Remove nuts completely and remove wiper arms.

NOTE:

If wiper arms cannot be removed in this way, use a standard puller.

-- Remove rubber seal -1-.

Fig 14: Rubber Seal & Plenum Chamber Cover

Courtesy of AUDI OF AMERICA, LLC

-- Remove plenum chamber cover -2- by carefully pulling cover out of retainer on windshield.

-- Free up rear engine wiring harness on plenum chamber partition.

-- Remove bolt -arrow- and remove engine control module from bracket.

Fig 15: Identifying Bolt, Engine Control Module, And Bracket

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect electrical connector -arrow- for body wiring harness -1-.

Fig 16: Disconnect Electrical Connector

Courtesy of AUDI OF AMERICA, LLC

-- Release engine wiring harness feed through -1- and remove upward -arrow-.

Fig 17: Release Engine Wiring Harness

Courtesy of AUDI OF AMERICA, LLC

-- Remove E-box cover by sliding both latches in direction of -arrow-.

Fig 18: Identifying E-Box Cover And Latches

Courtesy of AUDI OF AMERICA, LLC

-- Open wiring router bracket -arrows-.

Fig 19: Open Wiring Router Bracket And Locating Cable Ties

Courtesy of AUDI OF AMERICA, LLC

-- Cut off cable ties -1-.

-- Unclip electrical connector -1- from bracket and disconnect.

Fig 20: Unclip Electrical Connector

Courtesy of AUDI OF AMERICA, LLC

-- Open wiring router bracket below.

-- Unclip engine wiring harness to engine control module from wiring router.

-- Place engine wiring harness with engine control module on engine.

-- Secure engine control module against falling down.

-- Unclip electrical connector -2- from bracket and disconnect.

-- Remove terminal 30 wiring -arrow- from engine compartment E-box and free up.

Fig 21: Locating Engine Compartment E-Box Nut

Courtesy of AUDI OF AMERICA, LLC

NOTE:

To unclip spiral clip, use 80 - 200.

Fig 22: Free Electrical Wiring Up To Generator Using Pry Lever - Rmv Outside Mirror 80-200

Courtesy of AUDI OF AMERICA, LLC

Manual Transmission

-- Cut off cable ties -arrow- for protective boot -3-.

Fig 23: Ground (GND) Cable, Electrical Connector, Cable Tie & Protective Boot

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect electrical connector -2-.

-- Fold back protective boot and remove B+ wire from starter solenoid.

-- Remove Ground (GND) cable -1-.

-- Remove upper starter bolt.

-- Remove cable bracket from transmission -arrows-.

Fig 24: Cable Bracket From Transmission

Courtesy of AUDI OF AMERICA, LLC

-- Unclip lock washer -1- from shift cable and lock washer -2- from selector cable.

Fig 25: Locking Washer At Shift Lever Cable And Locking Washer At Selector Lever Cable

Courtesy of AUDI OF AMERICA, LLC

-- Remove cable retainers with cables from selector shaft lever or relay lever.

-- Tie cables with cable bracket off to side.

-- Clamp off pressure line to clutch slave cylinder with 3094.

Fig 26: Pulling Retainer Upward And Pulling Pressure Line Out Of Hose Coupling

Courtesy of AUDI OF AMERICA, LLC

-- Pull fastener upward -arrow- and remove hose/line assembly -1- from clutch slave cylinder bleeder.

CAUTION:

Risk of contamination from escaping brake fluid.

If the hose/line assembly is disconnected from the clutch slave cylinder breather, do not press clutch pedal.

Vehicles with DSG transmission:

-- Cut off cable ties -arrow- for protective boot -1-.

Fig 27: Disconnecting Ground (Gnd) Wire -3-

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect electrical connector -2-.

-- Fold back protective boot and remove B+ wire from starter solenoid.

-- Remove Ground (GND) wire -3-.

CAUTION:

Risk of destroying control module (Mechatronic) with static discharge.

Do not touch contacts in transmission connector with hands.

-- To discharge static electricity, touch vehicle ground with hand (without gloves).

-- Disconnect electrical connector -4- by turning twist lock counterclockwise.

All Vehicles

-- Remove coolant hoses to heater core from bulkhead -arrows-.

Fig 28: Identifying Coolant Hoses To Heater Core From Bulkhead

Courtesy of AUDI OF AMERICA, LLC

-- Remove upper left coolant hose from radiator -arrow-.

Fig 29: Identifying Upper Coolant Hose

Courtesy of AUDI OF AMERICA, LLC

WARNING:

There is a risk of injury because the fuel is under high pressure.

Before opening the fuel system, lay a clean cloth around the connection point and carefully loosen it, which lowers the pressure.

-- Disconnect fuel supply hose -4- by pressing release ring.

-- Free up fuel supply hose.

-- Remove the coolant hoses -2- and -3-.

-- Remove vacuum hose to brake booster -arrow-.

Fig 30: Identifying Vacuum Hose To Brake Booster

Courtesy of AUDI OF AMERICA, LLC

Vehicles with engine code CBRA:

-- Disconnect the vacuum hoses from the intake manifold and free them up:

Fig 31: Identifying Rear Vacuum Hoses -1, 2 And 4-

Courtesy of AUDI OF AMERICA, LLC

2 - To Leak detection pump (LDP) -V144-

4 - To Evaporative emission (EVAP) canister purge regulator valve -N80-

-- Remove the evaporative emission (EVAP) canister purge regulator valve -N80- from the bracket and lay it to the side.

NOTE:

Ignore -1 and 3- and -arrows-.

All Vehicles

-- Remove nuts -1- and -2- (accessible from top) from front exhaust pipe to exhaust manifold connection.

Fig 32: Identifying Exhaust Manifold Nuts

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Nuts -3 through 6- are removed at a later time.

-- Remove upper fan shroud bolts -top arrows-.

Fig 33: Coolant Fan Control (FC) Control Module J293

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Risk of destroying due to reversed running direction on a used ribbed belt.

Before removing ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.

-- To release ribbed belt tension, rotate tensioner in direction of -arrow-.

Fig 34: Relieving Tension On Ribbed Belt

Courtesy of AUDI OF AMERICA, LLC

-- Secure tensioner with T10060 A.

-- Remove ribbed belt.

-- Loosen subframe mounts bolts on engine -arrows- approximately 2 turns.

Fig 35: Identifying Engine Mount To Engine Mount Bracket Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Loosen subframe mounts bolts on transmission -arrows- approximately 2 turns.

Fig 36: Identifying Engine Mount To Engine Mount Bracket Bolts

Courtesy of AUDI OF AMERICA, LLC

Manual Transmission

-- Disconnect electrical connector -2- on back-up light switch -F4-.

Fig 37: Back-Up Light Switch F4 Electrical Connector & Nut

Courtesy of AUDI OF AMERICA, LLC

-- Remove nut -1- and bracket with electrical wires from lower starter bolt.

All Vehicles

-- Disconnect electrical connector -1- at secondary air injection (AIR) pump motor -V101- and free up electrical wiring.

Fig 38: Disconnect Electrical Connector

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore -2, 3 and arrows-.

-- Free up coolant hose on bottom of fan shroud.

-- Disconnect electrical connectors -1- for coolant fan on bottom of fan shroud.

Fig 39: Coolant Fan Control (FC) Control Module J293

Courtesy of AUDI OF AMERICA, LLC

-- Remove fan shroud lower bolts -bottom arrows-.

-- Remove fan shroud downward with both coolant fans.

-- Disconnect solenoid clutch electrical connector -1- on A/C compressor.

Fig 40: Electrical Harness Connector For A/C Clutch On A/C Compressor

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Risk of injury from refrigerant.

The air conditioning refrigerant circuit must not be opened.

-- Remove A/C compressor bolts -arrows-.

-- Secure A/C compressor with connected refrigerant hoses on front of longitudinal member.

-- Disconnect electrical connector -1- on oil level thermal sensor -G266-.

Fig 41: Identifying Oil Level Thermal Sensor G266 Wire On Subframe

Courtesy of AUDI OF AMERICA, LLC

-- Unclip bracket -2- for electrical wiring to oil level thermal sensor -G266- from subframe.

-- Remove right drive axle heat shield from bevel box -arrows-.

Fig 42: Identifying Right Driveshaft Heat Shield And Bevel Box

Courtesy of AUDI OF AMERICA, LLC

-- Remove right drive axle. Refer to Removal and Installation .

-- Remove left drive axle from transmission flange shaft.

-- Remove front exhaust pipe to exhaust manifold connecting nuts -3 through 6-.

Fig 43: Identifying Exhaust Manifold Nuts

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Nuts -1 and 2- were already removed.

-- Remove nuts -1- and -2- under vehicle floor.

Fig 44: Identifying Retaining Screws And Cover

Courtesy of AUDI OF AMERICA, LLC

-- Remove cover from oxygen sensor electrical connector bracket.

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

-- Remove electrical connectors from bracket and disconnect:

Fig 45: Disconnecting Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) Electrical Harness Connector

Courtesy of AUDI OF AMERICA, LLC

For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWO) -G130-
For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWO) -G131-

-- Remove exhaust system bracket -arrows-.

Fig 46: Identifying Exhaust System Bracket Bolts

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Risk of damaging decoupling elements.

Do not bend decoupling element in front exhaust pipe more than 10°.

-- Disconnect exhaust system at clamping sleeve -1-.

Fig 47: Identifying Exhaust System Clamping Sleeve

Courtesy of AUDI OF AMERICA, LLC

-- Remove front exhaust pipes with catalytic converters and front muffler.

-- Mark position of flexible disc to bevel box flange for reinstallation.

Fig 48: Driveshaft Flexible Disc

Courtesy of AUDI OF AMERICA, LLC

-- Remove driveshaft flexible disc from bevel box -arrows- while counterholding on triangle flange with lever.

CAUTION:

Risk of damaging sealing ring -arrow- in driveshaft flange.

Press driveshaft horizontally as far back and to right side of vehicle as possible.

Fig 49: Identifying Driveshaft Flange Shaft Seal

Courtesy of AUDI OF AMERICA, LLC

Vehicles with DSG transmission:

-- Remove bracket bolts -1-.

Fig 50: Elector Lever Cable Bracket Bolts And Locking Washer

Courtesy of AUDI OF AMERICA, LLC

-- Remove locking washer -3- -arrow- and remove selector lever cable from transmission.

NOTE:

Ignore -2-.

All Vehicles

CAUTION:

Risk of damaging sealing ring in driveshaft flange.

Engine/transmission swings forward slightly when pendulum support/subframe bolts are loosened.

-- Remove bolts -1, 2, 3- and remove pendulum support.

Fig 51: Identifying Pendulum Support & Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Secure the T40074 to the cylinder block using one M12 nut and two M10 bolts -arrows- tightened to approximately 20 Nm.

Fig 52: Engine Mount T40074 To Cylinder Block Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Place V.A.G 1383 A on T40074 and raise engine/transmission assembly slightly.

NOTE:

To remove subframe mounting bolts, use VAS 5085.

-- Remove subframe mount bolts on engine -arrows-.

Fig 53: Identifying Engine Mount To Engine Mount Bracket Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Remove subframe mount bolts on transmission -arrows-.

Fig 54: Identifying Engine Mount To Engine Mount Bracket Bolts

Courtesy of AUDI OF AMERICA, LLC

NOTE:

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

To prevent damage, carefully guide engine/transmission assembly when lowering.

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