Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Engine support bracket 10-222A with supports 10-222A/1 and adapters 10-222 A/3
• ◆ Lifting tackle 2024 A
• ◆ Gearbox support 3282
• ◆ Alignment plate 3282/3
• ◆ Engine/gearbox jack
  V.A.G 1383 A
• ◆ 15 mm A/F socket: Matra V/175
• ◆ Waste fluid container

Removing

• ‒ Obtain code on vehicles with coded radio/integrated radio and navigation system.
• ‒ Shift selector lever into "P" position.
• ‒ With ignition switched off disconnect battery earth strap.

Vehicles with 1.8 ltr. petrol engine:

• ‒ → Remove cover over injectors -arrows on right-.

Vehicles with TDI engine:

• ‒ → Remove engine cover -arrows-.
• ‒ Unbolt exhaust pipe from turbocharger.

=> Engine Mechanics; Repair group 26

• ‒ → Set up engine support bracket 10-222 A on bolted flanges of wing panels with spindle at front.

• ‒ → Remove lifting eye from lifting appliance 2024 A. Insert pin -1- in centre hole of lifting appliance again and secure with a split pin.
• ‒ Engage pin of lifting appliance 2024 A onto spindle of engine support bracket 10-222 A.
• ‒ Engage lifting tackle 2024 A in lifting eyes at front and rear of engine.

• ‒ Take up weight of engine on spindle of engine support bracket 10-222 A.

• ‒ Remove both front wheels.

Vehicles with petrol engine:

• ‒ → Remove noise insulation -arrow A and B-.

Vehicles with TDI engine:

• ‒ In addition, remove rear noise insulation -D- -arrows C-.

• ‒ → Slacken bolt -2- on noise insulation cover above left-hand and right-hand drive shaft.
• ‒ Disengage retainer -1- and remove noise insulation cover.

All models

• ‒ → Unbolt bracket for noise insulation -arrow-.

• ‒ → Disconnect speedometer sender connector -arrow A- at gearbox.

• ‒ → Mark connections -arrows C and D- to aid reinstallation.
• ‒ Remove electrical connections -arrows A to D- on gearbox.
• ‒ Unbolt cable clamp -arrow E-.
• ‒ Unbolt heat shield for selector lever cable.
• ‒ Remove front exhaust system with catalytic converter.

=> Engine Mechanics; Repair group 26

• ‒ → Remove heat shield for right drive shaft -arrows-.
• ‒ Unbolt left and right-hand drive shafts from gearbox flange.

=> Running gear, Front and four-wheel drive; Repair group 40; Removing and installing drive shaft

• ‒ Lift drive shafts up as high as possible and tie to body.
• ‒ Remove heat shield for bonded rubber bush at right-hand gearbox mounting.
• ‒ Place container under the gearbox.

Notes:

• ◆ When disconnecting ATF pipes, observe rules for cleanliness for automatic gearbox .
• ◆ Clean connections of ATF pipes before disconnecting.

Vehicles with petrol engine and without air conditioner

• ‒ Disconnect ATF pipes from engine/gearbox assembly and tie-up
  => Page 37-77.

Vehicles with petrol engine and air conditioner and vehicles with TDI engine:

• ‒ → Unscrew connections -arrows- and remove ATF pipes -1- completely.

All models

• ‒ → Detach wires -1- and -2- from starter; remove insulator from positive connection on starter.
• ‒ Unbolt cable clamp -4-.
• ‒ Unbolt bracket -3- from cylinder block.
• ‒ Unbolt starter from gearbox and remove.

• ‒ → After removal, unscrew 3 torque converter nuts through starter opening using socket attachment SW 15 Matra V/175 (turn crankshaft 1/3 turn each time).
• ‒ Unscrew engine/gearbox securing bolts accessible from below.

• ‒ Pull selector lever cable off selector shaft lever upwards.
• ‒ → Unscrew bolt on selector lever cable support bracket -arrow- and remove selector lever cable.

Vehicles with petrol engine and without air conditioner

• ‒ → Set up gearbox support 3282.

The gearbox mount 3282 is set up with the adjusting plate 3282/2 for removing the automatic gearbox 01N.

The symbols on the adjusting plate indicate the mounts required, the arrow points forward.

• ‒ → Move jack V.A.G 1383 A with gearbox support 3282 under the gearbox and support gearbox.
• ‒ Align adjustment plate parallel to gearbox and lock safety support -arrow- on gearbox.

Vehicles with petrol engine and air conditioner and vehicles with TDI engine

• ‒ → Set up gearbox support 3282.

Attach a retainer plate -arrow- in place of the retainer pin (the set-up is not as indicated by the symbols on the adjustment plate).

• ‒ → Move jack V.A.G 1383 A with gearbox support 3282 under the gearbox and support gearbox.
• ‒ Insert retainer plate -arrow B- between the oil pipes.
• ‒ Align adjustment plate parallel to gearbox and lock safety support -arrow A- on gearbox.

All models

• ‒ → Remove right gearbox support -arrow- with bonded rubber mounting.
• ‒ Remove left gearbox support together with bonded rubber mounting.
• ‒ Lower rear of engine/gearbox assembly slightly with jack V.A.G 1383 A.

• ‒ → Unscrew engine/gearbox securing bolts accessible from above.
• ‒ Press gearbox off engine; when doing this, press torque converter out of drive plate.
• ‒ Press torque converter against ATF pump.
• ‒ Lower gearbox.
• ‒ Secure the torque converter to prevent it from dropping out.

Installing

Install in reverse sequence; note the following points:

Notes:

• ◆ Before fitting a replacement gearbox, always blow through the ATF pipes and ATF cooler.
• ◆ When performing repairs, renew self-locking nuts, bolts which have a specified tightening angle, seals and gaskets..
• ◆ If a new torque converter with integrated needle bearing is fitted in a gearbox with sleeve bearing in the turbine shaft, the sleeve bearing must be removed =>Page32-5.

• ‒ Before installing the gearbox, ensure that the torque converter has been fitted correctly in the gearbox => Page 32-10.
• ‒ Before installing gearbox, make sure that dowel sleeves are correctly seated on cylinder block.
• ‒ Fit intermediate plate onto dowel sleeves.
• ‒ Align gearbox to engine.
• ‒ Make sure that no wiring or pipes are trapped when bringing engine and gearbox together.

• ‒ Install upper engine/gearbox securing bolts.
• ‒ Raise rear engine/gearbox assembly slightly using jack V.A.G 1383 A.

• ‒ → Install right gearbox support -arrow- with bonded rubber mounting.
• ‒ Install left gearbox support with bonded rubber mounting.
• ‒ Install lower engine/gearbox connecting bolts.
• ‒ Secure gearbox to engine.

Notes:

• ◆ The tightening torques listed in this manual apply only to lightly greased, oiled, phosphated, or black-finished nuts and bolts.
• ◆ Additional lubricant such as engine or gearbox oil may be used, but do not use graphite lubricant.
• ◆ Do not use degreased parts.
• ◆ Tolerance for tightening torques is ±15%.

1.6 ltr. engine:

→ Engine/gearbox mountings

A: centering sleeves

1.8 ltr. petrol engine, 1.9 ltr. TDI engine:

→ Engine/gearbox mountings

A: centering sleeves

All models

• ‒ To secure the torque converter on the drive plate only use the correct nuts as specified in the parts catalogue.

=> Parts catalogue

• ‒ → Tighten torque converter nuts with socket attachment SW 15 Matra V/175.
• ‒ Install front exhaust system with catalytic converter.

=> Engine Mechanics; Repair group 26

• ‒ Plug in electrical connectors.
• ‒ → Do not interchange electrical connections -arrows C and D- . Connection -arrow C- to road speed sender -G 68 (on right of gearbox). Connection -arrow D- to gearbox speed sender -G38 (on left of gearbox).
• ‒ Bolt on cable clamp -arrow E-.
• ‒ Install starter.

=> Electrical system; Repair group 27; Removing and installing starter

• ‒ Fit drive shafts to gearbox.

=> Running gear, Front and four-wheel drive; Repair group 40; Removing and installing drive shaft

• ‒ Install ATF pipes with new seals => Page 37-76.

Notes:

• ◆ When the battery is reconnected, re-activate electrical equipment (radio, clock, electric windows) as described in the Owner's Manual.
• ◆ Further procedures after reconnecting the voltage supply:

=> Injection and ignition system; Repair group 24

• ‒ Move selector lever to position "P" and fit selector lever cable=>Page37-18.
• ‒ Check selector lever cable adjustment, adjust if necessary => Page 37-21.
• ‒ Initiate basic setting:

=> Automatic gearbox 01N, Self-diagnosis; Repair group 01; Performing self-diagnosis; Initiating basic setting

• ‒ Check oil level in final drive of automatic gearbox => Page 39-1.
• ‒ Check ATF level => Page 37-59.

Tightening torques

→ Rear right (illustration) and left assembly mountings tightened to same torque.

A = 23 Nm
B = 40 Nm
C = 40 Nm