Exhaust Manifold, Removing and Installing Audi TT 8N

Special tools and equipment

Scheme 238

1. Puller T10095 A

1. Installation tool T10118

Note. All cable ties which are released or cut open when removing must be reinstalled in the same position.

1. With ignition switched off, disconnect Ground cable (arrow) at battery (in luggage compartment, under floor cover).

1. Remove fasteners -1- at lock carrier by pressing pin -2- approx. 4 mm (do not push in completely). Then pull fastener out upward.

1. Remove covers (left side) -1- and -2- at lock carrier and above main fuse box (arrows).

1. Remove covers (right side) -1- and -2- at lock carrier and above coolant expansion tank (arrows).
2. Pull out oil dipstick.

Note. Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is reinstalled, breakage can result.

1. Release tension of poly V-belt by screwing an M8 x 40 bolt (arrow) into bore on tensioning element.
2. Remove poly V-belt from Generator pulley.

1. Remove upper securing bolt -2- for Generator.

1. Remove upper securing bolts (upper arrows) for radiator cowl.

1. Disconnect secondary air hose at position marked with an arrow.
2. Move air hose at bracket clear.

1. Open filler cap on coolant expansion tank.

1. Remove fasteners -1...3- and remove center sound insulation.

1. Remove left sound insulation (arrows).

1. Remove right sound insulation (arrows).

1. Remove cross piece (arrows).

1. Place drip tray V.A.G 1306 under engine.
2. Turn drain plug (arrow) on radiator counter-clockwise. If necessary, install a drain hose to connection.

1. Additionally, remove lower coolant hose at After-run coolant pump -V51- (arrow) and drain remaining coolant.

1. Remove pulley for power steering pump (counterhold with mandrel).
2. Remove bolts (arrows) and remove power steering pump from bracket.
3. Hang power steering pump on lock carrier with hydraulic hoses -1- and -2- attached.

1. Disconnect electrical connector -1- at Secondary Air Injection (AIR) pump motor -V101-.
2. Move wiring clear.
3. Remove bolt -2- for coolant hose bracket.
4. Remove bolt -3- for secondary air pump filter bracket.

1. Remove bolts -1- and -2- and remove secondary air pump with bracket -A-.

1. Disconnect electrical connectors -1- for coolant fans at bottom of radiator cowl.
2. Unscrew lower securing bolts (lower arrows) for radiator cowl.
3. Remove radiator cowl with both fans from below.

1. Disconnect electrical connector -1- for magnetic clutch of air conditioning compressor.

Note. The air conditioning compressor can only be removed from the bracket with the upper securing bolt still inserted. To do so, press the engine simultaneously to the left side with an assembly lever (second technician required). If required, loosen all bolts of the assembly mounting 1 turn.

1. Remove bolts (arrow) for air conditioning compressor.
2. Tie up air conditioning compressor together with refrigerant hoses at front of longitudinal member (refrigerant hoses remain connected).
3. Remove lower securing bolt -1- for Generator.
4. Remove Generator from bracket for ancillary units (electrical wires remain connected).

1. Unscrew clamp -3-.
2. Remove nut and disconnect wire -1- at Generator.
3. Disconnect electrical connector -2-.
4. Remove Generator.

1. Remove bolt -3- and pull out guide tube for oil dipstick -2-.
2. Remove bolt -4- and remove vacuum reservoir -1- from manifold.
3. Move vacuum reservoir to side (hoses remain attached).

1. Remove bolt (arrow) at bracket for After-run coolant pump -V51-.
2. Remove bolts -1...5- and remove bracket for ancillary units.

Note. To avoid damage, the flexible joints in the front exhaust pipe must not be bent more than 10°.

1. Unbolt front exhaust pipe from exhaust manifolds (arrows).

1. Remove bolts (arrows) at front of intake manifold.

1. Disconnect electrical connectors at ignition coils by releasing tab (arrow) with assembly tool T10118 and carefully pulling connector.

1. Attach puller T10095 A to ignition coils as shown in illustration (arrow) and remove ignition coils one at a time.

1. Remove body brace -1- (arrows).

1. Move electrical wire (arrow) clear.
2. Loosen hose clips -1- and -2- and remove air hose between air cleaner housing and Throttle valve control module -J338-.

1. Disconnect electrical connectors -2- and -3-.
2. Disconnect crankcase breather hose -1-.

1. Remove bolts (arrows) and remove Throttle valve control module -J338- from intake manifold.

1. Disconnect vacuum hoses -1...4- at rear of intake manifold.

Note. The other hoses remain connected in the hose bracket.

1. Unbolt hose bracket (arrows) and remove.
2. Unscrew securing bolts at right and at rear (arrows) for intake manifold.

Note. Illustration shows view from the rear with engine removed.

1. Protect intake manifold from damage with a clean cloth -1-.
2. Swing intake manifold forward (arrow).

Note. Cover or plug the intake ports in the cylinder head with a clean cloth or foam plastic to prevent small items from falling in.

1. Remove both bolts from heat shield and remove shield.

Scheme 239

1. Unscrew 7 nuts (arrows) on both exhaust manifolds and remove together with washers.
2. Pull exhaust manifolds to rear and remove.

Installing

Installation is performed in the reverse order. Note the following

Note. Replace gaskets and self-locking nuts.

1. Install intake manifold. Refer to «Intake manifold, removing and installing»(ref-276269-S38653353982008010300000) .

Tightening torques

1) Replace nuts