Engine and Transmission, Separating Audi TT 8N

Special tools and equipment required

Scheme 56

1. Workshop crane VAS 6100

Scheme 57

1. Bracket T10013
2. Bolt M8 x 40 with nut and 30 mm diameter washer

Work sequence

1. Engine/transmission assembly removed and attached to engine bracket T10102

Scheme 58

1. Remove bolts -1- and -2- at bracket for bevel box and remove bracket.

Scheme 59

1. Disconnect coolant hose at ATF cooler (arrow).

Scheme 60

1. Remove circlip and remove pin from bracket T10013.
2. Secure bracket T10013 with bolt M8 x 40 and 30 mm diameter washer to transmission lifting eye.
3. Attach workshop crane VAS 6100 to bracket T10013.

Scheme 61

1. Remove bolts -1...10- on engine/transmission flange.
2. Separate transmission from engine.

Scheme 62

Special tools and equipment

1. Engine and transmission support VW 540
2. Engine and transmission support supplement VW540/1B
3. Lifting tackle 3033
4. Engine stand VAS 6095

1. Workshop crane VAS 6100

Not illustrated

1. Bolt M12 x 160

Work sequence

Scheme 63

1. Attach lifting tackle 3033 to engine and workshop crane VAS 6100 as shown in illustration.
2. Lift engine off engine bracket T10102 using workshop crane VAS 6100.

Scheme 64

1. Secure engine and transmission support VW 540 with parts from engine and transmission support supplement VW 540/1B to cylinder block.

Note. Use the M12 x 160 bolt to secure the lower right arm (arrow).

1. Fasten engine to engine and transmission support VW 540 for assembly work.

Installing

Installation is performed in reverse order of removal. Note the following

Note. On assembly, replace the self-locking nuts and bolts that are tightened by turning through to a specified angle, as well as oil seals and gaskets. Secure all hose connections with the correct type of hose clamps (same as original equipment).

1. Check whether dowel sleeves for centering engine/transmission assembly are installed in cylinder block; install dowel sleeves if necessary.
2. Bolt transmission to engine using new bolts.

Note. Tightening torques only apply to lightly greased, oiled, phosphated or blackened nuts and bolts. Additional lubricant such as engine oil or transmission oil may be used, but do not use lubricant containing graphite. Do not use degreased parts. Tolerance for tightening torques: ± 15 %.

Securing engine to transmission

A - dowel sleeves for centering

1) Bolt with M8 stud

2) Bolt is only used to secure starter to transmission

1. Install bracket -A- for bevel box; note following procedure
2. Initially tighten bolts -1- to 3 Nm.
3. Tighten bolts -2- to 35 Nm.
4. Tighten bolts -1- to 45 Nm.

1. Guide engine/transmission assembly into body.

1. Tighten bolts (use new bolts) for engine support to engine console (arrows)...

1. ..and transmission support to transmission mount (arrows) initially finger tight.

Note. The bolts are tightened to final torque only after adjusting the engine mountings. Refer to Engine mountings, checking and adjusting .

1. Remove engine bracket T10102 from engine.
2. Install axle shafts and tighten bolts hand tight.

Refer to 40 FRONT SUSPENSION

Note. Axle shafts must be installed prior to further assembly.

Scheme 65

1. Secure pendulum support at transmission (arrows -B-). Use new bolts.

1. Push engine/transmission assembly toward bulkhead. Journal of bevel box must be simultaneously inserted horizontally and carefully into flange of driveshaft.

Scheme 66

1. Secure pendulum support at subframe (arrows -A-). Use new bolts.

1. Secure driveshaft with flexible coupling to flange of bevel box (arrows).
2. Tighten axle shaft bolts.

Refer to 40 FRONT SUSPENSION

Perform further installation in reverse order. Pay attention to the following

1. Install exhaust system and align it free of stress. Refer to «Exhaust system, aligning free of stress»(ref-276269-S03604659422008010300000) .
2. Install selector lever cable.

Refer to 34 MANUAL TRANSMISSION - CONTROLS, HOUSING

1. Install bracket for ancillary units. Refer to «Bracket for ancillary units, removing and installing»(ref-276269-S32732737022008010300000) .
2. Drive back respective bushings for securing bolts slightly to facilitate installation of Generator, power steering pump and A/C compressor.
3. Install Generator.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

1. Install air conditioning compressor.

Refer to 87 AIR CONDITIONING

1. Install radiator cowl. Refer to «Radiator, removing and installing»(ref-276269-S03116130422008010300000) .
2. Install power steering pump.

Refer to 48 STEERING

1. Install body brace and cross piece.

Refer to 40 FRONT SUSPENSION

1. Install poly V-belt.
2. Adjust engine mountings. Refer to «Engine mountings, checking and adjusting»(ref-276269-S22031994392008010300000) .
3. Connect electrical connections and check routing.

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

1. Connect Ground strap to battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

1. Check oil level. Refer to «Oil pump, component overview»(ref-276269-S42746714842008010300000) .

1. Fill cooling system. Refer to «Cooling system, draining and filling»(ref-276269-S04050758062008010300000) .

Note. Drained coolant may only be used again if the original cylinder head or cylinder block are reinstalled. Contaminated or dirty coolant must not be used again.

Tightening torques

1) Replace nuts and bolts

2) 90° equals one quarter turn

1) Replace nuts and bolts

2) 90° equals one quarter turn