Gearbox removal & installation: Audi 2.0 TDI (CAGB, CAHA, CAHB, CBAA, …)

🧭 Before you start

Fits: Audi A3 (8P, 2003–2012)

• Opens: brake fluid
• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: 3094, locking pin

Don't miss

• The bolts (bottom arrows) are removed at a later stage.Disregard (item 1).
• Collect drained coolant in a clean container for re-use or disposal.
• The bolts (top arrows) are removed at a later stage.
• Disregard (item 1).
• Place a cloth underneath heat exchanger for heater to catch escaping coolant.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. ⚠ 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.
2. Remove engine cover panel (arrows).
3. Pull cover off air duct (release clips on sides) (arrows).
4. Release clips on left and right (arrow A) and unclip air duct at bottom (2).
5. Swivel air duct (bottom) slightly to the rear and detach air duct (bottom) from retainers (3).

6. Detach air pipe (1) from air duct (bottom) (arrow B).
7. Unplug electrical connector (2) from air mass meter G70.
8. Detach hose (1).
9. Release hose clip (3) and detach air hose.
10. Unscrew bolt (4) and remove air cleaner housing.
11. Remove bolts (arrows) and detach air duct from lock carrier.
12. ⚠ Risk of injury as the radiator fans may start up automatically. Even when the ignition is switched off, the radiator fans can start up without warning due to accumulated heat in the engine compartment, etc. — Remove bolts (top arrows) for radiator cowl. [Note: The bolts (bottom arrows) are removed at a later stage. Disregard (item 1).]
13. Remove both front wheels.
14. Remove noise insulation (1)50.
15. A3 Cabriolet: Remove noise insulation frame (arrow)50.
16. Remove front left and front right wheel housing liners (front section) (repair group 66).
17. Release hose clip (2), lift retaining clip (1) and remove air hose.
18. Release hose clip (2), lift retaining clip (1) and remove air hose.
19. Seal off open pipes/lines and connections with clean plugs from engine bung set VAS 6122.
20. Unplug electrical connector (1).
21. Remove bolts (bottom arrows) and take out air cowl downwards. [Note: Collect drained coolant in a clean container for re-use or disposal.]
22. Place drip tray for workshop hoist VAS 6208 beneath engine.
23. Lift retaining clip (arrow), disconnect coolant hose (bottom right) from radiator and drain off coolant.
24. Open hose clip (arrow), disconnect coolant hose (bottom) leading to pump for exhaust gas recirculation cooler V400 and drain off coolant.
25. Remove bolts (bottom arrows) on rear side of radiator. [Note: The bolts (top arrows) are removed at a later stage.]
26. As an additional step, open hose clip (arrow), disconnect coolant hose at top of engine oil cooler and drain off remaining coolant.
27. Remove battery Electrical system27.
28. Remove bolts (arrows) and take out battery tray (1).
29. Press release tabs and disconnect crankcase breather hose (1) from cylinder head cover.
30. Move clear vacuum hoses (arrows) at air pipe.
31. Loosen hose clip (2) and detach air pipe.
32. Detach vacuum hose (2) from vacuum unit of turbocharger.
33. Disconnect vacuum hose (3). [Note: Disregard (item 1).]
34. Detach vacuum hose from brake servo (arrow). [Note: Place a cloth underneath heat exchanger for heater to catch escaping coolant.]
35. Lift retaining clips (arrows) and disconnect coolant hoses from heat exchanger for heater.
36. Detach electrical connectors (3) from bracket and unplug.
37. Move clear electrical wiring (2-3-4-5). [Note: Disregard (item 1).]
38. Detach clamp (2) [Note: Disregard (items 1, 3).]
39. Unplug electrical connector (2) on exhaust gas pressure sensor 1G450.
40. Remove bolt (3) and detach exhaust gas pressure sensor 1G450 from bracket (arrow).
41. Remove top bolt (1) at bracket for particulate filter. [Note: The installation position can vary depending on version.]
42. On vehicles with engine code CBEA, detach pressure differential sender (3) from cylinder head cover.
43. Unplug electrical connector (4) on fuel temperature sender G81.
44. ⚠ The fuel can become extremely hot. This can cause injuries. In extreme cases the temperature of the fuel lines and the fuel can be up to 100 °C after the engine is switched off. Allow the fuel to cool down before disconnecting the lines - danger of scalding. Wear protective gloves. Wear safety goggles. — Release hose clips (2) and (3) and disconnect fuel supply hose and fuel return hose.
45. Seal off open pipes/lines and connections with clean plugs from engine bung set VAS 6122. [Note: Disregard (item 1) and (arrow).]
46. Release hose clip (1) and detach coolant hose. [Note: Ignore items marked (2) and (arrows).]
47. Remove bolt (1).
48. Push filler pipe with filler neck (2) for washer fluid reservoir to side. [Note: Disregard (item 3).For illustration purposes, the installation position is shown with the fuel filter removed.]
49. Disengage fuel hose (2) at bracket.
50. Pull off bracket for fuel lines upwards (arrow) and move clear to one side.
51. Unplug electrical connector (1) at supplementary fuel pump V393.
52. Remove bolts (3), detach bracket with supplementary fuel pump V393 and move clear to one side.
53. Release hose clip (1), detach coolant hose from coolant expansion tank and move coolant hose clear. [Note: Disregard (items 2, 3).]
54. Lift retaining clip (arrow) and disconnect coolant hose (top left) from radiator.
55. Unplug electrical connector (A) at high-pressure sender G65(item B). [Note: Disregard (item C).]
56. Remove bolts (top arrows) at rear and lift out radiator.
57. Remove wiper arms Electrical system92.
58. Unclip washer jets (arrow).
59. Push washer jets through assembly opening back into plenum chamber, leaving hoses connected.
60. Remove seal (1).

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