Gearbox removal & installation: Audi 3.0 TDI (CJGA, CJGC, CJMA, CLZB, …)

🧭 Before you start

Fit engine supports, check the dowel sleeves and torque converter depth, and bolt the gearbox to the engine while watching the converter. Refit ancillaries, ATF lines, front propshaft and exhaust components, then raise the assembly into the body on the platform. Align subframe and carriers to the marks, tighten provisionally and reconnect steering, propshafts, suspension, brakes, refrigerant and electrics. Fill oil, power steering fluid, refrigerant, coolant and ATF, bleed the fuel system, check alignment and finally tighten the subframe bolts.

Fits: Audi Q7 (4L, 2005–2015)

Don't miss

• Check the torque converter installation depth before joining engine and gearbox.
• Do not drive the car until subframe bolts are finally tightened after the alignment check.
• Align subframe and carriers to the marks made on the longitudinal members during removal.
• Never use battery charging equipment for boost starting.
• Do not run the power steering pump dry; top up before starting.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📋 Procedure

1. Install engine supports and engine mountings .
2. Check whether dowel sleeves (A) for centring engine and gearbox are fitted in cylinder block; install missing dowel sleeves. [Note: If the torque converter has not been fully inserted, this distance will be approx. 11 mm.]
3. ⚠ Risk of damage to drive lug of ATF pump if torque converter is installed incorrectly.Check installation depth of torque converter. — Before bringing engine and gearbox together, turn torque converter and drive plate on engine so that holes for bolts (1) are in line with aperture for starter motor.
4. Secure gearbox to engine.
5. ⚠ Risk of damage to automatic gearbox.Before and during tightening of bolts securing engine to gearbox, continually check that the torque converter behind the drive plate can be turned. If the torque converter cannot be turned, it must be assumed that it has not been installed correctly.Use only new bolts of the correct type (same as original equipment) to secure torque converter on drive plate. — Secure torque converter 37.

6. Install hydraulic line for power steering 48.
7. Install starter and alternator Electrical system27.
8. Install poly V-belt .
9. Install ATF lines 37.
10. Secure front propshaft to transfer box Transfer box 0BU, front final drive 0BM, 0C1 and rear final drive 0BN, 0BP39.
11. Install coolant pipe on left side of gearbox .
12. Install starter catalytic converter and particulate filter .
13. Guide engine/gearbox assembly together with subframe into body from below using scissor-type assembly platformVAS 6131 A (take care not to damage drive shaft boots).
14. Adjust the subframe, engine cross member and gearbox carrier according to the markings made on the longitudinal members during removal.
15. Tighten bolts for subframe, engine cross member and gearbox carrier only to specified torque and 40 (do not turn further); the bolts are only fully tightened after performing the wheel alignment check.
16. ⚠ Risk of accident because of loose bolted connections.The vehicle must not be driven at this stage. — Fit universal joint to steering rack 48.
17. Install selector lever cable 37.
18. Secure rear propshaft to transfer box Transfer box 0BU, front final drive 0BM, 0C1 and rear final drive 0BN, 0BP39.
19. Install anti-roll bar 40.
20. Install brake calipers 46.
21. Install suspension struts and suspension links 40.
22. Install exhaust gas temperature sender 3G495.
23. Install refrigerant lines 87.
24. Install engine control unit J623, air filter element and throttle valve module J33823.
25. Install air hoses with screw-type clips .
26. Install stud of jump start socket U6Electrical system27.
27. Electrical connections and routing .
28. Install cover for electronics box in plenum chamber Electrical system97.
29. Observe notes on procedure for connecting the battery Electrical system27.
30. ⚠ Risk of irreparable damage to control units because of excessive voltage.Never use battery charging equipment for boost starting. — Install and adjust wiper arms Electrical system92.
31. Fill with engine oil and check oil level 406.
32. Before starting engine, top up hydraulic fluid in power steering reservoir 48. [Note: The power steering pump must not be run when dry.]
33. Charge refrigerant system Air conditioner with refrigerant R134a.
34. Bleed fuel system 23.
35. Connect coolant hose with plug-in connector .
36. Fill up with coolant . [Note: Drained-off coolant may only be used again if the original cylinder head and cylinder block are re-installed.Contaminated or dirty coolant must not be used again.]
37. Install wheel housing liners 66.
38. Align subframe 40.
39. For information on whether wheel alignment is required, refer to table 44.
40. ⚠ Risk of accident because of loose bolted connections.Tighten bolts for subframe to final setting after performing wheel alignment check. — Fill up with ATF 37.
41. Install underbody covers and noise insulation panels 66.

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