Servicing - 09G: Removal & Installation Audi TT 8N facelift

REMOVAL & INSTALLATION

1. Remove sound insulation bolts (arrows). see scheme 9 Place drip tray under transmission.
2. Unscrew ATF drain plug (B) and drain ATF. see scheme 6
3. Unscrew ATF inspection plug (A). Unscrew overflow pipe (C) and allow remaining ATF to drain away. see scheme 10
4. Loosen oil pan bolts (arrows) in diagonal sequence. (Scheme 29) Remove oil pan and gasket.
5. To install, clan magnets in flanges of oil pan. Watch for full contact of magnets with oil pan. Magnets must always be installed at intended location in oil pan.
6. Clean seal and sealing surfaces and remove oil residue. Ensure oil pan gasket is correctly positioned. Install oil pan bolts (arrows) in a diagonal sequence and tighten in stages. (Scheme 29)
7. Replace ATF drain plug seal. Screw in ATF drain plug (B). see scheme 6 Install overflow pipe (C).
8. Fill with ATF. See «DRAINING & REFILLING»(ref-170597-S32383465402005011200000). Check ATF level, and top off as necessary. See «CHECKING FLUID LEVELS»(ref-170597-S16947090572005011200000). Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000).

Scheme 22

Scheme 23

Scheme 24

Scheme 25

1. Pull parking brake up as far as possible. Pry up lid (3) located under parking brake lever at front. (Scheme 30) Following direction of arrow, pull lid (3) located under parking brake lever pit of center console (1). Remove lid (2) vertically.
2. Remove rear lid (1) upward. (Scheme 31) Remove screws (5). Remove connector (6) from bracket (3). Remove screws (2). (Scheme 32)
3. Remove center console grab handles. (Scheme 33)
4. For easier removal, pry out screw caps (8). (Scheme 32) Remove screws (7). Pull apart footwell vent trim. Pull apart rear section of center console (1) at mounts (5). Pull rear section of center console (1) out from under footwell vent trim to rear.
5. Lift out rear section of center console (1) forward over parking brake lever. Turn rear section of center console (1) and unplug connectors (6, 9 and 10).
6. Installation is reverse of removal procedure. Slide rear section of center console (1) under footwell vent trim. (Scheme 32)

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

1. On vehicles equipped with coded radio, obtain anti-theft code. On all vehicles, shift selector lever into Tiptronic gate. With ignition off, disconnect battery ground cable. See «BATTERY DISCONNECT PRECAUTIONS»(ref-170597-S34422722222005011200000).
2. Loosen clamp (4) and disconnect intake hose and connector (1) from Mass Air Flow (MAF) sensor. see scheme 16 Disconnect hose (5) from air cleaner housing, if installed. Unscrew bolts (2 and 3). Remove entire air cleaner housing.
3. Using an open-end 10 mm wrench (2), or similar, pry off selector lever cable (1) from lever/selector shaft (3). see scheme 20 Press catches on support bracket of selector lever cable together (arrows) and pull selector lever cable out of support bracket/transmission.
4. Disengage selector lever cable (1) from clip (arrow) at transmission. (Scheme 36) Raise and support vehicle.
5. Detach cover for both heated oxygen sensor connectors and pull electric wire with retaining clips off heat shield (arrows). (Scheme 37) Pull connector out of cover and disconnect. Unbolt front exhaust pipe from turbocharger.
6. On vehicles equipped with front wheel drive, slacken bolted connections on clamp between catalytic converter and middle silencer. Move clamp toward rear. On vehicles equipped with all wheel drive, unbolt connecting flanges on catalytic converter.
7. On all vehicles, remove front exhaust pipe (A). (Scheme 38) Remove cross-piece (B) underneath exhaust system. Remove protective plates (C and D).
8. Unscrew nuts (arrows "A"). Unscrew bolts (arrows "B"). (Scheme 39) Carefully push cover with protective sleeve forward over selector lever cable, taking care not to damage protective sleeve.
9. Ensure selector lever is in Tiptronic gate (arrow "A"). see scheme 55 Using a screwdriver, pry off selector lever cable (2) from selector lever (3). Pull locking plate (1) for selector lever cable on mounting bracket out downward. Carefully pull selector lever cable out of mounting bracket.
10. Installation is reverse of removal. Ensure protective sleeve is not damaged. Protective sleeve can only be replaced together with selector lever cable. Ensure protective sleeve is seated correctly.
11. Insert selector lever (3) in Tiptronic gate (arrow "A"). see scheme 56 Insert selector lever cable (2) in mounting bracket and press on selector lever (3) with screwdriver (4). Mount NEW locking plate (1) for selector lever cable on mounting bracket.
12. Correct installation position of lock washer points toward end of selector lever cable. Move selector lever from "P" to "S" position. Move selector lever to "P" position. Screw cover with bonded gasket to mounting bracket hand tight. Note gasket installation.
13. Tighten nuts (arrows "A"). (Scheme 39) Tighten bolts (arrows "B"). Insert protective sleeve of selector lever cable in cover. Set lever/selector shaft (3) on transmission to "P" position. see scheme 21 Detent lever must engage in parking lock gear, and lock both front wheels.
14. Loosen bolt (2) at front ball socket of selector lever cable (1). see scheme 21 Insert selector lever cable in support bracket/transmission and carefully press onto lever/selector shaft. Tighten bolt (2).
15. Engage selector lever cable (1) in clip (arrow) at transmission. (Scheme 36) When routing selector lever cable to ATF cooler, maintain a minimum clearance of 5 mm.
16. Install exhaust system free of stress. Check DTC memory according to scan tool instructions. DTCs will be stored in memory due to connectors being unplugged. Check and erase DTC memory after installation.
17. Reconnect battery ground cable. See «BATTERY DISCONNECT PRECAUTIONS»(ref-170597-S34422722222005011200000). Check shift mechanism. See «SHIFT MECHANISM»(ref-170597-S41371128862005011200000). Enter radio code, if necessary.

Scheme 32

Scheme 33

Scheme 34

1. Shift selector lever into "N" position. Switch ignition off. Disconnect hose (5) from air cleaner housing. see scheme 16
2. Using a screwdriver, press selector lever cable (1) off lever/selector shaft (6). see scheme 17 Do not loosen bolt (2). Do not kink selector lever cable. Disconnect connector (5) at multi-function TR switch.
3. Remove lever/selector shaft (1). see scheme 18
4. Using a screwdriver, bend back hook of circlip (2). see scheme 57 If one or more circlip hooks break off while being bent, circlip must be replaced.
5. Remove nut (3) with washer (2 and 1). Remove both bolts (B) and disconnect multi-function TR switch (A) up over selector shaft. Using a screwdriver, remove seal without damaging selector shaft. see scheme 58
6. Installation is reverse of removal procedure. Lightly lubricate outer circumference and sealing lips of sealing ring with ATF. Correct installation position of sealing ring, is open side facing transmission. Drive NEW sealing ring in up to stop of thrust piece. see scheme 59 Ensure sealing ring goes on straight.
7. Attach multi-function TR switch to selector shaft. Screw in multi-function TR switch securing bolts (B) hand tight. see scheme 57 Install washers (1 and 2) and nut (3) on selector shaft. Tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000).
8. Bend up hooks on circlip (2) to secure nut. If one or more circlip hooks break off while being bent, circlip must be replaced. Adjust multi-function TR switch. See «MULTI FUNCTION TRANSMISSION RANGE SWITCH»(ref-170597-S33599513562005011400000) under ADJUSTMENTS.
9. Install lever/selector shaft (1). see scheme 18 Tighten lever/selector shaft nut (3) to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000). Transmission must remain in "N" position. Shift back to "N" position if necessary.
10. Connect harness connector (5) to multi-functional TR switch. see scheme 17
11. Press selector lever cable (1) onto lever/selector shaft (6). Connect hose (5) to air cleaner housing. see scheme 16 Check setting of selector lever cable, and adjust as necessary. See «SELECTOR LEVER CABLE»(ref-170597-S16863672122005011200000) under ADJUSTMENTS.

Scheme 35

Scheme 36

Scheme 37

Scheme 38

1. On vehicles equipped with coded radio, obtain anti-theft code. On all vehicles, shift selector lever into "D" position. Turn ignition off. Disconnect battery ground cable. See «BATTERY DISCONNECT PRECAUTIONS»(ref-170597-S34422722222005011200000).
2. Remove selector lever handle. (Scheme 34) Remove rear center console. See «REAR CENTER CONSOLE»(ref-170597-S22561534702005011200000).
3. Disconnect connector (1) of printed circuit board. see scheme 60
4. Remove connector from hole (arrow) in bracket (2). Disconnect connector (arrow) for shift lock solenoid. see scheme 61
5. Using a screwdriver at four hooks (arrows), carefully bend frame outward and remove together with retaining ring, printed board and cover (A). see scheme 62
6. Move selector lever to "P" position. Loosen bolt on support bracket (arrow "A") of locking cable. (Scheme 27) Carefully remove locking cable from shift mechanism (arrow "B"), and disengage from locking lever (arrow "C"). Unscrew shift mechanism front mounting nuts (arrows). see scheme 63
7. Loosen clamp (4) and disconnect intake hose and connector (1) from Mass Air Flow (MAF) sensor. see scheme 16 Disconnect hose (5) from air cleaner housing, if installed. Unscrew bolts (2 and 3). Remove entire air cleaner housing.
8. Using an open-end 10 mm wrench (2), or similar, pry off selector lever cable (1) from lever/selector shaft (3). see scheme 20 Press catches on support bracket of selector lever cable together (arrows) and pull selector lever cable out of support bracket/transmission.
9. Disengage selector lever cable (1) from clip (arrow) at transmission. (Scheme 36) Raise and support vehicle.
10. Detach cover for both heated oxygen sensor connectors and pull electric wire with retaining clips off heat shield (arrows). (Scheme 37) Pull connector out of cover and disconnect. Unbolt front exhaust pipe from turbocharger.
11. On vehicles equipped with front wheel drive, slacken bolted connections on clamp between catalytic converter and middle silencer. Move clamp toward rear. On vehicles equipped with all wheel drive, unbolt connecting flanges on catalytic converter.
12. On all vehicles, remove front exhaust pipe (A). (Scheme 38) Remove cross-piece (B) underneath exhaust system. Remove protective plates (C and D).
13. Unscrew shift mechanism from body (arrows "B"). (Scheme 39) Do not loosen nuts (arrows "A"). Remove shift mechanism with selector lever cable downward.
14. Installation is reverse of removal procedure. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000).
15. Insert selector lever cable in support bracket/transmission and carefully press onto lever/selector shaft. Engage selector leer cable (1) in clip (arrow) at transmission. (Scheme 36) When routing selector lever cable to ATF cooler, maintain a minimum clearance of 5 mm.
16. Install exhaust system free of stress. Check DTC memory according to scan tool instructions. DTCs will be stored in memory due to connectors being unplugged. Check and erase DTC memory after installation.
17. Adjust locking cable. See «LOCKING CABLE»(ref-170597-S15076695172005011200000) under ADJUSTMENTS. Check function of ignition key removal lock. see scheme 13and see scheme 14.
18. Install rear center console. See «REAR CENTER CONSOLE»(ref-170597-S22561534702005011200000). Install selector lever handle. (Scheme 35)
19. Reconnect battery ground cable. See «BATTERY DISCONNECT PRECAUTIONS»(ref-170597-S34422722222005011200000).
20. Adjust selector lever cable. See «SELECTOR LEVER CABLE»(ref-170597-S16863672122005011200000) under ADJUSTMENTS. Check shift mechanism. See «SHIFT MECHANISM»(ref-170597-S41371128862005011200000) under INSPECTION. Enter radio code, if necessary.

Scheme 39

1. Disconnect battery. See «BATTERY DISCONNECT PRECAUTIONS»(ref-170597-S34422722222005011200000).
2. Remove oil pan. See «OIL PAN»(ref-170597-S21594399982005012000000).
3. Remove ATF screen. See «ATF SCREEN»(ref-170597-S25984169962005012000000).
4. Make a hand drawn diagram similar to illustration. see scheme 64 Include solenoid valves and harness connectors. Mark all harness connectors in appropriate color. Mark corresponding wiring in appropriate color.
5. Use a small screwdriver to carefully pry out retaining tabs on harness connectors at solenoid valves (1-8) and disconnect harness connectors.
6. Remove bolts (D and E). see scheme 65 Carefully disconnect connector at sender 1 for hydraulic pressure, connector to sensor for transmission input RPM, connector at sender 2 for hydraulic pressure and connector to sender for transmission output RPM.
7. Carefully remove transmission fluid temperature sensor (8) together with bracket (7) from valve body. see scheme 65 Disengage wiring harness at bracket (C).
8. Carefully hold gear lever (A) secure with universal pliers (B), so that torque is not transferred to multi-function transmission range switch. see scheme 66 Remove gear lever at selector shaft.
9. Unscrew securing bolts (arrows) on valve body in a diagonal sequence and carefully take out valve body. see scheme 67 Remove bracket (1 and 2). Secure shock absorber piston (E) against falling out or remove it together with two springs. Remove valve body.
10. To install, route wiring harness (C) as illustrated in specified indentation in valve body. see scheme 68
11. Route wiring harnesses (A, B and D) over edge of transmission. If shock absorber was removed, fit two springs into each other and coat outer wall of shock absorber piston and aperture in transmission with ATF. Place all components in transmission. Press shock absorber piston into transmission and secure against falling out until valve body is installed.
12. Install valve body without exerting force. Screw down bracket for wiring harness (1 and 2) hand tight with corresponding bolt. see scheme 67 Tighten remaining valve body bolts (arrows) hand tight.
13. Ensure no wires are actually being pinched. Tighten valve body bolts (arrows). starting from outside and working in. see scheme 67 Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000).
14. Engage wiring harness in bracket (arrow "B"). see scheme 69 Install gear lever (2) on selector shaft (5). Install washer (4) and nuts (3) on selector shaft. Centering collar of nut must face toward washer and run into washer when screwed on. Ensure wiring harness is routed under gear lever.
15. Carefully hold gear lever (A) secure with universal pliers (B), so that torque is not transferred to multi-function transmission range switch. see scheme 66 Tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000).
16. Connect harness connectors (1-8) on solenoid valves as indicated in hand drawn diagram. see scheme 64 Note colors of wires and connectors. Route wiring harness (B) as illustrated.
17. Connect harness connector (2). see scheme 65 Connect harness connector (8). Install bracket (7) on transmission fluid temperature sensor (8). Install sensor together with bracket in valve body, and tighten bolt (E) to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000).
18. Connect connectors (1 and 5) directly onto pressure senders. see scheme 65 Connect connectors (2 and 6) and secure bolts (D) on valve body.
19. Tighten harness connector bolts to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000). Engage wiring harness (B) in bracket (C) and route as illustrated.
20. Install ATF screen. See «ATF SCREEN»(ref-170597-S25984169962005012000000).
21. Install oil pan. See «OIL PAN»(ref-170597-S21594399982005012000000).
22. Connect battery. See «BATTERY DISCONNECT PRECAUTIONS»(ref-170597-S34422722222005011200000).
23. Fill with ATF. See «DRAINING & REFILLING»(ref-170597-S32383465402005011200000). Check ATF level and top off as necessary. See «CHECKING FLUID LEVELS»(ref-170597-S16947090572005011200000).