Gearbox removal & installation: Audi 1.8 (AEB, AJL, ANB, APU, …)

🧭 Before you start

Fits: Audi A4 B5 (8D)

• Timing position: the crankshaft or camshaft is set and locked during this job

Don't miss

• Detach cooling pipe for power steering hydraulic fluid (arrows) and move clear; do not open hydraulic fluid circuit.
• Observe rules for cleanliness when working on automatic gearbox 37.
• Risk of damage to condenser, refrigerant lines and refrigerant hoses.Do NOT stretch, kink or bend refrigerant lines and hoses. — Remove bolts (4) (left and right) for air cowls from radiator.
• Protect side panel (front) from damage.
• Unbolt and remove lock carrier. Place clear of vehicle and ensure that it cannot tip over.

🔧 Engine codes this applies to

📋 Procedure

1. Move selector lever to position "“N”" on vehicles with automatic gearbox.
2. ⚠ To prevent irreparable damage to the electronic components when disconnecting the battery:Observe notes on procedure for disconnecting the battery. — Disconnect earth wire (arrow) from battery terminal 27.
3. ⚠ Hot steam/hot coolant can escape - risk of scalding.The cooling system is under pressure when the engine is hot.To allow pressure to dissipate, cover filler cap on coolant expansion tank with cloth and open carefully. — Open filler cap on coolant expansion tank.
4. Release quick-release fasteners and remove engine cover panel (arrows).
5. Detach air cleaner cover (arrow).

6. Remove bolts (arrows).
7. Remove air duct (1) and (2).
8. Remove front bumper 63.
9. Release fasteners (arrows) and remove noise insulation.
10. Unbolt bracket for noise insulation (arrow).
11. Remove air duct in front of charge air cooler (arrows).
12. Detach cooling pipe for power steering hydraulic fluid (arrows) and move clear; do not open hydraulic fluid circuit.
13. Tighten bracket for outside temperature sensor back on finger-tight.
14. Place drip tray for workshop hoistVAS 6208 beneath engine.
15. Turn drain plug (arrow) on radiator anti-clockwise, if necessary fit drain hose to connection.
16. Lift retaining clip and disconnect coolant hose (bottom) from radiator (arrow).
17. Unplug electrical connector (1) at radiator fan thermal switch F18/F54 at radiator (bottom left) and move wiring clear.
18. Also open drain plug (arrow) on coolant pump bearing housing.
19. Remove coolant hose from hose connection at thermostat.
20. Detach air hose going to charge air cooler at lock carrier (bottom left) (arrow).
21. Detach air hose going to turbocharger from lock carrier (bottom right). [Note: Observe rules for cleanliness when working on automatic gearbox 37.]
22. Position used oil collection and extraction unitV.A.G 1782 below connection point.
23. Disconnect ATF lines (arrows).
24. Detach bracket for ATF lines (left-side) from engine.
25. Unclip and disconnect green electrical connector (arrow) for magnetic clutch of air conditioner compressor at lock carrier (bottom right) and move wiring clear.
26. Unplug connectors for headlights and headlight adjustment (arrows).
27. Turn bulb holders for turn signals anti-clockwise and remove from turn signal housing (left arrow) (both sides of vehicle).
28. Lift retaining clip (arrow) and disconnect coolant hose (top left) from radiator.
29. Detach cable for bonnet at lock carrier 55.
30. Remove cover (arrow) at power steering fluid reservoir.
31. Unplug electrical connectors (arrows).
32. Move electrical wiring clear.
33. Unplug connector for anti-theft alarm on lock carrier (top left) and move wiring clear.
34. Unplug electrical connectors on both horns (1) and (2), detach wiring at bracket (arrow) and move wiring clear.
35. ⚠ Risk of damage to condenser, refrigerant lines and refrigerant hoses.Do NOT stretch, kink or bend refrigerant lines and hoses. — Remove bolts (4) (left and right) for air cowls from radiator.
36. Remove bolts (1 and 2) for condenser.
37. Unplug electrical connector (3) at air conditioner pressure switch F129.
38. Pull condenser up out of its bracket, pivot to side and secure to right-side front wheel with wire. [Note: Protect side panel (front) from damage.]
39. Unbolt and remove lock carrier. Place clear of vehicle and ensure that it cannot tip over.
40. Unplug electrical connectors:
41. Move wiring harness clear and lay on top of engine.
42. Detach hose connections and remove air cleaner housing (arrows).
43. Disconnect vacuum line leading to fuel system diagnostic pump V144(arrow).
44. Detach coolant hoses (1) and (3).
45. Remove bolts (arrows).
46. Unplug electrical connector at coolant shortage indicator switch F66 and detach coolant expansion tank (2).
47. Detach coolant hose (left-side) going to heat exchanger from coolant pipe (bottom) on engine.
48. Disconnect coolant hose (right-side) going to heat exchanger at cylinder head connection.
49. Disengage operating rod at throttle valve module J338.
50. Detach vacuum hose at vacuum unit.
51. Detach throttle cable from throttle valve module J338 and from support bracket (arrows) (do not remove retainer). Move throttle cable clear to the side.
52. Remove air hose (1).
53. ⚠ The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection. — Disconnect fuel supply line (1) and fuel return line (2) and move clear.
54. Disconnect vacuum hoses: [Note: On vehicles with automatic gearbox, disconnect vacuum hose (3) behind suction-jet pump.]
55. Remove cover for electronics box in plenum chamber (arrows).
56. Carefully lever out retaining strap using a screwdriver (arrow).
57. Release retainer catches and unplug electrical connectors (3 and 4) from engine control unit.
58. Unplug electrical connectors at altitude sender F96(1) and at connector point (2).
59. Unhook wiring harness (arrow) and move it clear.
60. Unplug electrical connector at kickdown switch (arrow).

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