Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 6-cyl. 2.4 ltr. or 3.0 ltr. petrol engine (also for Audi Cabriolet)

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Removal lever -80-200-

t	Gearbox support -3282-

t	Adjustment plate -3282/30-

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

t  Wing compensation plate -T40045- Procedure   Note All cable ties which are released or cut open during removal must be fitted in the same position when installing. –  Shift selector lever to position “P”.   Caution Follow steps required when disconnecting battery → Electrical system; Rep. Gr.27.

–  Slide battery cover towards right side of vehicle -arrow 1- and lift off -arrow 2-.

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

–  Pull off rear engine cover -arrows-.

–  Pull off front engine cover -arrows-.

–  Remove cover -1- on left side of engine compartment.

–  Unbolt coolant expansion tank -arrow-. –  Disconnect electrical wire for coolant shortage indicator switch -F66- at bottom of coolant expansion tank. –  Tie up coolant expansion tank to one side, leaving coolant hoses -1 ... 3- connected. –  If fitted, remove heat shield for connectors from left side of plenum chamber partition panel.

–  Detach electrical connectors -1 ... 4- from retainer at left of plenum chamber partition panel. –  Unplug electrical connectors -1- and -4-. –  Guide wiring to Lambda probes downwards.

–  Unscrew nut -2- (access from above), connecting left front exhaust pipe with exhaust manifold.   Note For illustration purposes here shown with engine removed.

–  Remove cover -1- on right side of engine compartment.

–  Remove bolts -arrows-. –  Disengage activated charcoal filter solenoid valve -N80--1- at air duct. –  Remove air duct -2-.

–  Remove air cleaner housing -arrows-.

–  Remove bolts -arrows- from solenoid valve mounting plate -3-. –  Detach electrical connector at air mass meter -G70-. –  Pull hose -4- for crankcase breather system off air duct -2-.

–  Unscrew bolt -arrow- and disconnect air duct -2- from throttle valve module. –  Pull hose -1- off air duct.   Note For illustration purposes, the air duct is shown from rear, with engine removed.

–  Detach electrical connectors -1 ... 4- from retainer at right of plenum chamber partition panel. –  Unplug electrical connectors -1- and -4-. –  Guide wiring to Lambda probes downwards.

–  Unscrew nut -2- (access from above), connecting right front exhaust pipe with exhaust manifold.   Note For illustration purposes here shown with engine removed.

–  Detach rubber seal from edges of 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.

–  Set up support bracket -10-222 A- on wing mounting flanges (spindle faces to front). –  Take up some of the engine weight by tightening spindle of support bracket, but do not lift.

–  Remove both front wheels. –  On vehicles fitted with auxiliary heater, remove bolts -arrows- securing exhaust pipe of auxiliary heater to noise insulation.

–  Loosen bolts/quick-release fasteners -1 ... 3- and detach front and rear noise insulation.

–  Unbolt bracket for noise insulation -arrows-.

–  Unscrew bolted connections -1 … 4- and remove front cross member on vehicle underside.   Note

The flexible pipe connection (de-coupling element) on the front exhaust pipe must not be bent more than 10° – otherwise it can be damaged. –  Loosen clamps -arrows- on both exhaust pipes to disconnect exhaust system.

–  Apply lifting column of engine and gearbox jack -V.A.G 1383 A- to gearbox from below (place a block of wood -1- between lifting column and gearbox). –  Support the tunnel cross member with engine and gearbox jack -V.A.G 1383 A-.   WARNING Injury risk - the lock carrier must be installed on the vehicle.

–  First unscrew bolts -1- and -2-, then bolts -3- and -4-. –  Slowly lower tunnel cross member with engine and gearbox jack -V.A.G 1383 A-.

–  Unscrew nuts -arrows- and detach tunnel cross member.

–  Unscrew noise insulation bolt -1- above drive shaft (left and right). –  Disengage retainer -2- and remove noise insulation cover.

–  Remove heat shields -1- for drive shafts (left and right). –  Unbolt drive shafts (left and right) from gearbox flanges → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40.

–  Unbolt front exhaust pipe bracket on left side -arrow-.

–  Move Lambda probe wiring clear. –  Unscrew nuts -1- and -3- (accessible from below) connecting front exhaust pipe to exhaust manifold on left side.   Note For illustration purposes here shown with engine removed. –  Remove front exhaust pipe with starter catalytic converter and main catalytic converter.

–  Unbolt front exhaust pipe bracket on right side -arrows-.

–  Move Lambda probe wiring clear. –  Unscrew nuts -1- and -3- (accessible from below) connecting front exhaust pipe to exhaust manifold on right side. –  Remove front exhaust pipe with starter catalytic converter and main catalytic converter.   Note For illustration purposes here shown with engine removed.

–  Remove engine speed sender -G28- on left of gearbox -arrow- and move clear.

–  Unbolt bracket for ATF pipes -arrow-.   Note

Observe rules for cleanliness when working on automatic gearbox → Chapter. –  Remove bolt -arrow- and detach ATF pipes from gearbox. –  Tie ATF pipes to one side.

Vehicles with wiring harness with oval connector: –  Release connector -A- in direction of -arrow- and unplug from gearbox. –  Move wiring harness clear.

Vehicles with wiring harness with round connector: –  Release electrical connector -1- and detach from gearbox. –  Move wiring harness clear -arrows-.

All models: –  Unscrew bolts -2- and remove bracket -3- for selector lever cable.

–  Use removal lever -80-200- to prise selector lever cable -A- off gearbox selector lever -arrow-.

–  Unscrew bolts -2- and detach gearbox support -1- from gearbox.

–  Remove bolts -2 ... 7- from engine/gearbox flange. –  Only slacken bolt -Item 8- and leave it in position (finger-tight).   Note The starter does not have to be removed.

–  Set up gearbox support -3282- on engine and gearbox jack -V.A.G 1383 A-. –  Place adjustment plate -3282/30- 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 M10 x 20 -arrow-. Audi Cabriolet:   Note On Audi Cabriolet vehicles the following additional steps are required in order to remove the four bottom engine/gearbox bolts: –  Use engine and gearbox jack -V.A.G 1383 A- to lift gearbox up slightly.

–  Unbolt torque reaction support -arrows-.

–  Unscrew nuts -1- on left and right sides, and swivel anti-roll bar -2- downwards. –  Unscrew nuts -3- on left and right engine mountings until bottom of nut is flush with end of stud -arrow-. –  Using support bracket -10-222 A-, lift engine until the two nuts -3- (on left and right sides) come into contact with bottom of console.

All models: –  Remove bolts -1- and -9 ... 11- from engine/gearbox flange. Audi Cabriolet: –  Lower engine back down. –  Lower gearbox again slowly. All models: –  Move drive shafts to rear. –  Remove the last engine/gearbox securing bolt. –  Press gearbox off dowel sleeves and lower it carefully.