Scheme 440
- Bolt Transmission support to transmission Tightening specification, refer to item 1 in: «SUBFRAME MOUNT OVERVIEW»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-roadster)
- Bolts Pendulum supports to transmission Tightening specification, refer to item 2 in: «SUBFRAME MOUNT OVERVIEW»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-roadster)
- Engine Support With support arm
- Bolt 45 Nm Engine support to engine
- Engine Mount
- Bolt Replace 40 Nm plus an additional 90° ( 1 / 4 turn). Engine mount to body
- Bracket
- Bolt Replace 20 Nm plus an additional 90° ( 1 / 4 turn). Bracket to engine mount
- Bolt Replace 20 Nm plus an additional 90° ( 1 / 4 turn). Bracket to body
- Bolt Replace 40 Nm plus an additional 90° ( 1 / 4 turn). Engine mount to body
- Bolts Replace 60 Nm plus an additional 90° ( 1 / 4 turn). Engine mount to engine support
- Pendulum Support
- Bolt Replace 100 Nm plus an additional 90° ( 1 / 4 turn). Pendulum supports to subframe
- Bolt Transmission mount to transmission support Tightening specification, refer to item 14 in: «SUBFRAME MOUNT OVERVIEW»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-roadster)
- Bolt Transmission mount to body Tightening specification, refer to refer to item 15 in: «SUBFRAME MOUNT OVERVIEW»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-roadster)
- Transmission Mount With support arm
- Bolt Transmission support to transmission Tightening specification, refer to item 17 in: «SUBFRAME MOUNT OVERVIEW»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-roadster)
- Bolt Transmission support to transmission Tightening specification, refer to item 18 in: «SUBFRAME MOUNT OVERVIEW»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-roadster)
- Transmission Support
SUBFRAME MOUNT, ADJUSTING
Special tools and workshop equipment required
- Engine Support Bridge 10 - 222 A
- Spindle 10 - 222 A /11; quantity: 2
- Special Hook 10 - 222 A /20; quantity: 2
- Additional Hooks (2)10 - 222 A /2
- Engine Support Basic Set T40091
- Engine Support Supplement Set T40093 with Engine Supplement Left and Right T40093/3-2 and Engine Supplement Left and Right T40093/3-3
Adjusting
- For the correct tightening specifications, refer to «SUBFRAME OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-engine-assembly-engine-codes-bpy-roadster) .
Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.
Scheme 441
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 Evaporative Emission (EVAP) canister with connected lines upward out of bracket -arrow- and lay aside.
Scheme 442
Remove EVAP canister bracket.
Loosen coolant pipe -arrows-.
Scheme 443
Disengage shift cable -arrow-.
Scheme 444
Position the 10 - 222 A on fender bolting edge with the following tool parts
Scheme 445
- Bracket for engine 10 - 222 A /1, quantity: 2
- Engine support bridge 10 - 222 A
- Spindle 10 - 222 A /11 (spindle faces forward)
- Additional hooks 10 - 222 A /2
- Special hooks 10 - 222 A /20
- Connectors T40091/3 qty. 2
Engage the 10 - 222 A /11 with the 10 - 222 A /2 and the 10 - 222 A /20 on transmission lifting eye.
Tension engine/transmission subframe with spindle.
Install the T40092/3-2 (left) and T40093/3-3 (right) on supports T40093/3.
Scheme 446
Remove ground (GND) line from left longitudinal member.
Remove the left and right connecting bolt for front part of longmember.
Tighten the T40092/3-2 (left) and T40093/3-3 (right) on longmembers with bolts removed earlier -arrow-.
Note. The illustration shows the left side of the vehicle.
Place the square pipes T40091/1 with connector T40093/4 in the T40091/3 and T40093/3-3 as shown in the illustration.
Scheme 447
Slide the support T40091/2 into both connectors T40093/4 with slide T40093/5.
Scheme 448
| WARNING | Risk of accident due to loose engine support bridge spindles. Secure the T40091/2 with connector pins and splints T40093/4. Secure connector and supports with clamping bolts. |
Install 10 - 222 A /11 with 10 - 222 A /20 on slide and on engine lifting eye.
Tension engine/transmission subframe by evenly tightening the 2 spindles.
Remove the bolts -arrows- from the engine assembly mounts one after the other, replace them (unless already done during engine installation) and screw them in loosely.
Scheme 449
Remove the bolts -arrows- from the transmission assembly mounts one after the other, replace them (unless already done during engine installation) and screw them in loosely.
Scheme 450
Loosen left and right support arm bolts approximately 2 turns.
Slide engine/transmission assembly with a pry bar between engine mount -1- and engine support -4- until the following dimensions are set
Scheme 451
- Both bolt heads -2- must be parallel to edge of support arm -3-.
- A distance of -x- = 16 mm must be present between engine mount -1- and engine support -4-.
Note. Distance -x- = 16 mm can also be checked with suitable round stock.
Tighten subframe mount to transmission bolts.
The edges on the support arm -1- and transmission mount -2- are parallel on the transmission side.
Scheme 452
- Dimension -x- same size on both sides of bracket.
Tighten subframe mount bolts.
The rest of the installation is performed in reverse order of removal, noting the following
Tighten bolts for front part of longitudinal member. Refer to Removal and Installation .
FASTENER TIGHTENING SPECIFICATIONS
| Component | Bolt Size | Nm |
|---|---|---|
| Bolts/Nuts | ||
| M6 | 10 | |
| M8 | 20 | |
| M10 | 45 | |
| M12 | 65 | |
| Bracket to Body (1) , (2) | 20 + 90° | |
| Bracket to Engine Mount (1) , (2) | 20 + 90° | |
| Engine Mount to Body (1) , (2) | 40 + 90° | |
| Engine Mount to Engine Support (1) , (2) | 60 + 90° | |
| Engine Support to Engine | 45 | |
| Exceptions | ||
| Pendulum Supports to Transmission (1) , (2) | 40 + 90° | |
| Pendulum Supports to Subframe (1) , (2) | 100 + 90° | |
| Clamp B+ to Starter | 16 | |
| Ground (GND) Cable to Transmission | 23 | |
| (1) Always replace (2) 90° corresponds to a quarter turn. | ||
| (1) | Always replace |
| (2) | 90° corresponds to a quarter turn. |
Engine/Transmission, Fastening
Scheme 453
| Item | Bolt | Nm |
|---|---|---|
| 1, 2 | M12 X 65 | 80 |
| 3 (1) , 4 (1) | M12 X 135 | 80 |
| 5 to 7 | M10 X 60 | 40 |
| 8 | M12 X 90 | 65 |
| (1) Bolt with threaded pin M8 | ||
| (1) | Bolt with threaded pin M8 |
SUBFRAME MOUNT, CHECKING ADJUSTMENT
Procedure
Pull the Evaporative Emission (EVAP) canister with connected lines upward in direction of -arrow- out of the retainer and lay it aside.
Check dimensions on right mount for engine and transmission
- Both bolt heads -2- must be parallel to edge of engine mount support arm -3-.
- A distance of -x- = 16 mm must be present between engine mount -1- and engine support -4-.
Note. Distance -x- = 16 mm can also be checked with corresponding round stock.
If distance is too small or too large, subframe mount must be adjusted. Refer to SUBFRAME MOUNT, ADJUSTING .
ENGINE, REMOVING
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.
Scheme 454
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-.
Scheme 455
| 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-.
Scheme 456
Remove noise insulation at left and right -arrows-.
Scheme 457
Remove noise insulation frame -arrow-.
Scheme 458
Disconnect the electrical connector on the Mass Airflow (MAF) Sensor -G70- -3-.
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.
Scheme 459
Remove electrical connector -arrow- for oxygen sensor before catalytic converter from the bracket, disconnect it and lay it aside.
Scheme 460
Remove the heated oxygen sensor (HO2S) -G39- -arrow- using a tool from the 3337.
Scheme 461
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.
Scheme 462
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.
Scheme 463
Release pass-through for engine wiring harness -arrow- and pull off upward.
Scheme 464
Open bracket of wiring -arrows-.
Scheme 465
Free up and disconnect the electrical connector -1-.
Scheme 466
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.
Disconnect the connector -1- from the back-up lamp switch.
Scheme 467
Remove ground (GND) cable -2-.
Separate electrical connector -3-.
Push cover -4- toward rear.
Remove wiring -arrow- on starter and free it up.
Scheme 468
Press both latches in direction of -arrow- and remove engine compartment E-box cover.
Scheme 469
Remove the electrical harness -1- and free up the wiring to the engine.
Scheme 470
Disconnect the electrical connector -2-.
Remove the bolts -1- from above.
Scheme 471
Place the VAS 6208 under engine.
Drain the coolant, by pulling off the lower coolant hose -arrows-.
Scheme 472
Remove the air duct -1 and 2- for charge air cooler.
Scheme 473
Disconnect the connector -2-.
Remove bolts -3- and remove the fan shroud downward and off.
Disconnect upper coolant hose from radiator -arrow-.
Scheme 474
Disconnect coolant hoses to heat exchanger -arrows-.
Scheme 475
Remove the accessible nuts -arrows- for the front exhaust pipe/turbocharger from above.
Scheme 476
Note. The illustration depicts the engine removed from behind.
Disconnect vacuum hose -arrow- from brake booster.
Scheme 477
Unclip the lock washers -1- and -2- at both cables.
Scheme 478
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-.
Scheme 479
| 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-.
Scheme 480
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-.
Scheme 481
Discharge the air conditioning system. Refer to DESCRIPTION AND OPERATION .
Remove refrigerant lines -arrow- at the compressor.
Scheme 482
Seal off openings with sealing plugs from VAS 6122.
Unscrew the bolts -arrows- of the engine mountings approximately 2 turns.
Unscrew the bolts -arrows- of the transmission mountings approximately 2 turns.
Disconnect electrical connector -arrow-.
Scheme 483
Remove air duct -arrows-.
Scheme 484
Disconnect electrical connector -1- from high pressure sensor -G65-.
Scheme 485
Disconnect refrigerant line from condenser -2-.
Disconnect the electrical connector on the oil level sensor -1-.
Scheme 486
Unclip the retainer -2-.
Remove the right drive axle heat shield -arrows-.
Scheme 487
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.
Scheme 488
Remove bolt -3- and free up electrical wiring to oxygen sensor.
Remove connector coupling from bracket -arrow-.
Scheme 489
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.
Remove exhaust system bracket and tunnel brace -arrows-.
Scheme 490
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-.
Scheme 491
Remove front exhaust pipe with catalytic converter and front muffler.
Remove bolts -1 - 3- and remove pendulum support.
Scheme 492
Remove auxiliary coolant pump bolts -arrows-.
Scheme 493
Attach the T10012 to the cylinder block using the bolt -1- and nut -2- and tighten to approximately 20 Nm.
Scheme 494
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.
Remove bolts -arrows- at transmission assembly mounting.
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.
ENGINE AND TRANSMISSION, SEPARATING
- Engine/transmission assembly removed and mounted on engine/transmission supportT10012.
Remove the bolt -1- from mounted transmission.
Scheme 495
Remove the shield -2- upward and out.
Note. Shown in the illustration with transmission removed.
Remove bolts -1 through 8- at engine/transmission flange.
Remove the starter.
Pull transmission off from engine.
ENGINE, SECURING TO ASSEMBLY STAND
Special tools and workshop equipment required
- Lifting Sling 2024 A
- Shop Crane VAS 6100
- Engine and Transmission Holder VAS 6095
- Transmission separated from engine.
Hook the 2024 A to engine and to the VAS 6100.
Scheme 496
Note. To be aligned to the center of gravity of the engine assembly, the hole rails of the lifting hook must be inserted as shown in the illustration.
| WARNING | Lifting hooks and alignment pins on the engine sling must be secured with securing pins -arrows-. |
Lift the engine off from the T10012 using the VAS 6100.
Secure engine on the VAS 6095 when working on engine.
ENGINE, INSTALLING
- Engine mounted on engine/trans. support T10012.
Installation is performed in the reverse of removal, noting the following
Note. During installation, all cable ties must be re-installed at the same location. Secure all hose connections using hose clamps appropriate for the model type. During assembly, replace self-locking nuts and bolts. Always replace bolts that are tightened to torque as well as O-rings and gaskets. Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of lubricant on splines. Then move the clutch plate back and forth on the input shaft, until the hub can be easily moved on the shaft. Remove all excess grease.
Make sure alignment sleeves for engine to transmission are installed in cylinder block. Install if necessary.
Make sure that the intermediate plate is hooked in at the sealing flange and is pushed onto the alignment sleeves -arrows-.
Scheme 497
Check clutch release bearing for wear and replace if necessary.
Bolt transmission to engine.
Note. Tightening specifications only apply to lightly greased, oiled, phosphate or blackened nuts and bolts. Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not. Do not use any degreased parts. Tolerance for tightening specifications 15%.
Engine/Transmission, Fastening
| Item | Bolt | Nm |
|---|---|---|
| 1, 2 | M12 X 65 | 80 |
| 3 (1) , 4 (1) | M12 X 135 | 80 |
| 5 to 7 | M10 X 60 | 40 |
| 8 | M12 X 90 | 65 |
| (1) Bolt with threaded pin M8 | ||
| (1) | Bolt with threaded pin M8 |
A: Alignment bushings for centering
Push the cover plate -2- in so that the lower tab hooks in at the cylinder block, and fasten it at the top with the bolt -1-.
Note. Shown in the illustration with transmission removed.
Guide the engine/transmission assembly into the body.
Hand-tighten the bolts -arrows- at engine assembly mounting.
Hand-tighten the bolts -arrows- at transmission assembly mounting.
Note. Secure with new bolts. The bolts are first tightened to final torque after the engine mounts have been adjusted. Refer to SUBFRAME OVERVIEW .
Remove T10012 from engine.
Fasten the pendulum supports to the transmission and subframe -1 to 3-.
Install the drive axles. Refer to Removal and Installation .
Install exhaust system and align it free of tension. Refer to EXHAUST SYSTEM, ALIGNING .
Install heated oxygen sensor (HO2S) -G39-. Refer to Removal and Installation .
Fill the refrigerant circuit. Refer to CHARGING REFRIGERANT .
Install the shift mechanism on the transmission and adjust. Refer to REMOVAL AND INSTALLATION .
Adjust the engine mounts. Refer to SUBFRAME MOUNT, ADJUSTING .
Electrical connections and routing.
Install fuel system. Refer to Removal and Installation .
Check oil level.
Connect the battery. Refer to [For transmission(s) 02E] Removal and Installation .
Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .
Air duct pipes with connector, installing. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS, ASSEMBLING .
Note. Only reuse drained coolant if cylinder head or engine block was not replaced. Dirty coolant may not be used again.
| WARNING | Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged. |
Tightening Specification
| Component | Nm | |
|---|---|---|
| Bolts/nuts | M6 | 10 |
| M8 | 20 | |
| M10 | 45 | |
| M12 | 65 | |
| Exceptions | ||
| Pendulum supports to transmission | 40 + 90° 1)2) | |
| Pendulum supports to subframe | 100 + 90°1)2) | |
| Clamp B+ to starter | 16 | |
| Ground (GND) cable to transmission | 23 | |
| Replace bolt.1)2) 90° corresponds to a quarter turn.1)2) | ||
Scheme 498
Special tools and workshop equipment required
- Lifting Sling 2024 A
- Shop Crane VAS 6100
- Engine and Transmission Holder VAS 6095
Scheme 499
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
Scheme 500
Special tools and workshop equipment required
- Engine Support Bridge 10 - 222 A
- Spindle 10 - 222 A /11; quantity: 2
- Special Hook 10 - 222 A /20; quantity: 2
- Additional Hooks (2) 10 - 222 A /2
- Engine Support Basic Set T40091
- Engine Support Supplement Set T40093 with Engine Supplement Left and Right T40093/3-2 and Engine Supplement Left and Right T40093/3-3
Special tools and workshop equipment required
Scheme 501
Scheme 502
- Ring Spanner 7-Piece Set 3337
- Engine Bung Set VAS 6122
See also:
• SUBFRAME MOUNT OVERVIEW
• Removal and Installation
• [For transmission(s) 02E] Removal and Installation
• Removal and Installation
• Removal and Installation
• DESCRIPTION AND OPERATION
• Removal and Installation
• EXHAUST SYSTEM, ALIGNING
• CHARGING REFRIGERANT
• COOLING SYSTEM, DRAINING AND FILLING
• HOSE CONNECTIONS WITH CONNECTOR COUPLINGS, ASSEMBLING
• SUBFRAME OVERVIEW
• SUBFRAME MOUNT, ADJUSTING