Audi Workshop Service and Repair Manuals

Removing gearbox on vehicles with 1.6 ltr. engine   Note! All cable ties which are released or cut open when removing the gearbox must be refitted in the same position when installing the gearbox. –  Shift selector lever to position “P”.

–  Unclip air intake hose from air duct -arrows-.

–  Unplug electrical connector at intake air temperature sender -2- -G299-. –  Detach vacuum hose -1- from actuator for intake air preheater.

–  Pull dipstick -1- out of guide tube. –  Remove engine cover panel with air cleaner housing -arrows-. –  Re-insert dipstick in guide tube.

–  Press release tab -arrow- and remove cover -1- over battery.   Caution Follow steps required when disconnecting battery → Electrical system; Rep. Gr.27.

–  With ignition switched off, disconnect earth wire -arrow- at battery.

–  Remove battery → Electrical system; Rep. Gr.27. –  Remove battery tray -arrows-.

–  Use an open-end spanner (10 mm) -item 1- or similar to lever selector lever cable -3- off selector shaft lever. –  Press together the retainers on the support bracket of the selector lever cable -arrows- and pull the selector lever cable out of the support bracket on the gearbox. –  Unplug electrical connector -4- and move electrical wiring clear at bracket -2-. –  Unscrew support bracket for gearshift cable from gearbox.

–  Unscrew earth wire -3-. –  Detach electrical wires -1- and -2- at starter and move them clear.

–  Mark hoses leading to ATF cooler to avoid confusion when re-installing.   Note! Depending on the version, the vehicle may be fitted with a small plastic tube in the supply line to the ATF cooler. This tube has to be re-fitted as part of installation. –  Clamp-off ATF cooler hoses using hose clamps -3094- and detach at ATF cooler. –  Seal off ATF cooler with clean plugs.

–  Detach rubber bellows from air duct -2-. –  Release both retainer tabs -arrows- and remove air duct.

–  Unscrew warm air collector plate -arrows-.

–  Unbolt front exhaust pipe from exhaust manifold -arrows-.

–  Remove all engine/gearbox securing bolts which are accessible from above.

–  Set up support bracket -10-222 A- on wing mounting flange. –  Hook spindle of support bracket into engine lifting eye (left-side). –  Take up weight of engine with spindle; do not lift.

–  Remove gearbox console -A-, to do so unscrew bolts -1- and -2-.

–  Remove front wheels. –  Remove centre noise insulation -fasteners 1 ... 3-.

–  Remove noise insulation (left and right) -fasteners 1 ... 3-.

–  Unplug electrical connector -1- at oil level/oil temperature sender -G266-. –  Unclip bracket -2- for electrical wiring to oil level/oil temperature sender -G266- at subframe.

–  Remove bolts -1 ... 3- and detach pendulum support.

–  Unplug electrical connector -2- for Lambda probe -G39- and electrical connector -1- for exhaust gas temperature sender -1- -G235-.

–  Detach electrical connector -1-. –  Pull off vacuum hose -2-. –  Unscrew bolts -arrows- and remove vacuum pump for brake servo.

–  Unplug electrical connectors -1- and -3- at automatic gearbox. –  Unscrew bracket for electrical wiring from bottom bolt securing starter. –  Tie bracket and electrical wiring to the front.   Note! -Item 2- can be disregarded.

–  Remove nuts -2- and -3- from exhaust system flange. –  Detach exhaust system at flange. –  Remove bolts -1- and -5-. –  Pull bracket -4- for exhaust system off pins on front exhaust pipe.   Note! To prevent damage, the flexible couplings in the front exhaust pipe must not be bent further than 30°.

–  Remove bolts -arrows-, swivel front exhaust pipe forwards and detach. –  Unscrew nuts -1- and detach support for exhaust manifold.

–  Unscrew nuts -arrow- on both sides of vehicle and detach coupling rods from anti-roll bar.

–  Remove nuts -arrows- on swivel joint (left-side). –  If fitted, remove nut on bracket for front left vehicle level sender -G78-. –  Unhook wishbone from swivel joint.

–  Swivel suspension strut outwards, at the same time pressing drive shaft out of wheel bearing unit with special tool -T10161-, tapping it lightly if necessary.

–  Swivel drive shaft forwards, pulling engine/gearbox assembly forwards with force. –  Tie drive shaft to longitudinal member -arrow-. –  Repeat procedure on other side of vehicle.

–  Remove cover cap from opening for torque converter nuts. –  Remove the 6 nuts -arrow- from torque converter. To do so, turn crankshaft 60° further in each case.   Note! t  Ensure that hose/pipe -1- does not get damaged when removing nuts. t  If the 6 nuts have not all been removed from torque converter, the torque converter will be pulled out when you remove the gearbox from the engine.

–  Lower the engine/gearbox assembly by approx. 50 mm using the spindles.

–  Drill two 7 mm diameter holes in support -T10036-, as illustrated. l  Distance -a- = 70 mm l  Distance -b- = 98 mm l  Distance -c- = 11 mm

–  Bolt support -T10036- onto subframe -arrows- using two M6×20 bolts.

–  Bolt engine support -3300 A- onto support -T10036-. –  Press engine approx. 50 mm towards front of vehicle using spindle of engine support.

–  Set up gearbox support -3282- on engine/gearbox jack -V.A.G 1383 A-. –  Place adjustment plate -3282/36- on gearbox support -3282- (adjustment plate only fits in one position). –  Align arms of gearbox support to coincide with holes in adjustment plate. –  Attach support elements as illustrated on adjustment plate. –  Place engine/gearbox jack -V.A.G 1383 A- under vehicle; arrow symbol faces in direction of travel. –  Position adjustment plate so it is parallel with gearbox. –  Secure gearbox to gearbox support -3282- with bolt -1-. –  Support the gearbox by lifting the gearbox jack from below.

–  Remove remaining securing bolts between engine and gearbox.

–  Push gearbox off engine and at the same time press torque converter out of drive plate. –  Press torque converter against ATF pump -arrow-. –  Carefully pivot gearbox towards subframe. –  Then carefully lower gearbox and guide it downwards past the subframe. –  When lowering the gearbox, change position of gearbox using the spindles on gearbox support -3282-. –  Secure the torque converter to prevent it from falling out.