Audi Workshop Service and Repair Manuals

Removing

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Rack -10 - 222 A/ 1-

t	Adapter -10 - 222 A /3-

t	Shackle -10 - 222 A /12-

t	Removal lever -80 - 200-

t	Gearbox support -3282-

t	Adjustment plate -3282/19-

t	Locating pins -3393-

t	Engine and gearbox jack -V.A.G 1383 A-

t	Wing compensation plate -T40045-

t  Support bridge -30 - 211 A-

t  Lifting tackle -2024 A- for 1.8 ltr. turbocharged petrol engine

t  Used oil collection and extraction unit -V.A.G 1782-

t  Stepladder -VAS 5085-

t  Engine bung set -VAS 6122- Procedure   Note All cable ties which are released or cut open when removing the gearbox must be fitted in the same position when installing.

Caution Follow steps required when disconnecting battery. –  With the ignition switched off, disconnect battery earth strap → Rep. Gr.27.

–  Detach air hose -arrow- from intake manifold.

–  Pull off bonnet seal at both wing mounting flanges. –  To avoid damaging edges of wing panels with support bracket -10 - 222 A-, insert wing compensation plates -T40045- on both sides between the wing mounting flange and the body panel underneath.

Vehicles with 1.8 ltr. turbocharged petrol engine: –  Release quick-release fasteners -arrows- and detach engine cover panel.

–  Set up support bracket -10 - 222 A- on wing mounting flanges.

–  Remove eye of lifting tackle -2024 A-. –  Re-insert pin -1- in centre hole of lifting tackle and secure with split pin. –  Hook pin on lifting tackle onto spindle of support bracket -10 - 222 A-. –  Hook lifting tackle into lifting eyes at front and rear of engine.   Caution The hook attachments and locating pins on the lifting tackle must be secured with locking pins -arrows-. –  Take up weight of engine on spindle of support bracket, but do not lift.

Vehicles with 3.0 ltr. petrol engine: –  Remove engine cover panel -arrows-.

–  Set up support bracket -10 - 222 A- with -10 - 222 A /1- and -10 - 222 A /3- on wing mounting flanges as shown in illustration. –  Hook spindles into lifting eyes at front and rear of engine. –  For this purpose, also use shackle -10 - 222 A /12- at front of engine to avoid damage. –  Partly take up weight of engine on spindles of support bracket, but do not lift.

Vehicles with 2.5 ltr. TDI engine: –  Remove engine cover panel -arrows-.

–  Set up support bracket -10 - 222 A- with -10 - 222 A /1- and -10 - 222 A /3- on wing mounting flanges as shown in illustration. –  Hook spindles into lifting eyes at front and rear of engine. –  Partly take up weight of engine on spindles of support bracket, but do not lift. Continued for all vehicles: –  Remove front wheels.

–  Vehicles with 2.5 ltr. TDI engine: detach drive shaft noise insulation (left-side) from wheel housing -arrows-.

–  Detach noise insulation -arrows-.

–  Remove heat shield -arrows- for drive shaft (left and right).   Note The third bolt is not shown in the illustration. –  Unbolt drive shaft -1- (left and right) from flange shaft on gearbox → Rep. Gr.40.

–  If fitted, remove heat shield -arrows-. –  Remove front exhaust pipe(s) with catalytic converter → Rep. Gr.26.

–  Remove bracket for noise insulation -1-. –  Detach electrical connector -2- at multifunction switch -F125-. –  Turn locking lever -3- and unplug multi-pin connector for gearbox wiring harness. –  Cut through cable tie -4-.   Note Take care not to damage wiring for multifunction switch.

–  Unbolt bracket -arrow- for ATF pipes from engine oil sump.

–  If fitted, unplug electrical connector (-arrow A-) from speedometer sender -G22- on gearbox. –  Remove engine speed sender -G28--arrow B- from gearbox.

–  Place used oil collection and extraction unit -V.A.G 1782- below connection. –  Mark ATF pipes if no existing paint markings are visible. –  Disconnect ATF pipes -1- leading to ATF cooler. –  Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-. –  Remove bolt -2- for starter on gearbox side.   Note -Item 3- can be disregarded. –  Unbolt starter and tie up to one side with wire.   Note The starter does not have to be removed completely for access to the torque converter bolts.

–  Unscrew 3 bolts from torque converter through opening for starter (turn crankshaft 1/3 of a turn to access one bolt after another). –  Remove all engine/gearbox securing bolts which are accessible from below.

–  Unbolt heat shield for propshaft -arrows-.

–  Unbolt propshaft -1- from gearbox → Rear final drive 01R; Rep. Gr.39 or → Rear final drive 08V; Rep. Gr.39 and rest propshaft on heat shield -2-.

–  Mark position of support bracket securing selector lever cable to gearbox housing (position must be the same when installing). Unbolt support bracket -arrow-.

–  Prise selector lever cable off selector shaft lever -arrow- using removal lever -80 - 200-.

–  Unscrew multifunction switch -F125- to protect it from damage -arrows- and move wiring harness clear.

–  Unbolt engine mountings -A- on left and right sides.

–  Set up gearbox support -3282- on engine and gearbox jack -V.A.G 1383 A-. –  Place adjustment plate -3282/19- on gearbox support -3282- (adjustment plate only fits in one position). –  Align arms of gearbox support according to holes in adjustment plate. –  Attach support elements as illustrated on adjustment plate.

–  Place engine and gearbox jack -V.A.G 1383 A- with gearbox support -3282- underneath gearbox and support gearbox.   Note The arrow symbol on the adjustment plate points in the direction of travel. –  Align adjustment plate parallel to gearbox and secure support to gearbox with bolt -A-. –  Fill up space between gearbox support and oil pan with washers. –  Remove gearbox supports (left and right) with gearbox mountings → Chapter.

–  Audi A4 Cabriolet: Remove rear diagonal struts -5- and -6- → Rep. Gr.42.

–  Before loosening the subframe, use locating pin -3393- to check that at least holes -1- and -2- are aligned on both sides of vehicle.   Note If the holes do not align, perform wheel alignment after installing the subframe.

–  Remove bolts -1- and -2- at rear of subframe on both sides. –  Remove bolts -3- at front of subframe on both sides. –  Remove two bolts -4- on both sides.

–  Turn spindles approx. 8 turns to lower engine/gearbox assembly. –  When lowering engine/gearbox assembly, turn spindles alternately approx. 2 turns at a time. –  At the same time lower engine/gearbox assembly using engine and gearbox jack -V.A.G 1383 A- (2nd mechanic required).   Note Take care not to damage any components when lowering the gearbox.

–  Remove remaining engine/gearbox securing bolts -arrows-.

–  Vehicles with 2.5 ltr. TDI engine: Slacken bolt -A- (at rear of turbocharger) a few turns and pivot brace -B- to one side in direction of -arrow-. –  Hand-tighten bolt -A-.   Note The illustration shows the engine from the rear with the gearbox removed. –  Push gearbox off engine and at the same time press torque converter out of drive plate.

–  Press torque converter against ATF pump -arrow-. –  Lower gearbox.

–  Secure torque converter in gearbox with support bridge -30 - 211 A- to prevent it dropping out.