Gearbox removal & installation: Audi 3.0 TDI (CATA, CCMA)

🧭 Before you start

Fits: Audi Q7 (4L, 2005–2015)

• Opens: refrigerant (A/C), power steering fluid
• Special tools named: 3094, VAS 6131/11, VAS 6131/13, VAS 6131/10

Don't miss

• Move selector lever to position "“N”" to allow the propshaft to rotate freely.
• Disregard (item 2).
• The fuel filter bracket remains installed.
• Lay a cloth under the separating point to catch escaping hydraulic fluid.
• Danger of damage to refrigerant lines and hoses.Do NOT stretch, kink or bend refrigerant lines and hoses. — Remove bolts (1) and (5) for retaining clips.

🔧 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.

📐 18 workshop diagrams for CATA

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Activate jacking mode on vehicles with air suspension (repair group 43). [Note: Move selector lever to position "“N”" to allow the propshaft to rotate freely.]
2. ⚠ To prevent irreparable damage to the electronic components when disconnecting the battery:Observe notes on procedure for disconnecting the battery. Observe necessary waiting time for vehicles with urea injection. — Disconnect earth wire (4) from earth point Electrical system27.
3. Discharge refrigerant system Air conditioner with refrigerant R134a.
4. Extract hydraulic fluid for power steering from reservoir using used oil collection and extraction unit V.A.G 1782.
5. ⚠ 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.

6. Remove both front wheels.
7. Remove noise insulation panels (1) and (2)66.
8. Remove front left and front right wheel housing liners (repair group 66).
9. Place drip tray for workshop hoist VAS 6208 beneath engine.
10. Release hose clip (arrow), disconnect coolant hose from coolant pipe (left-side) and drain off coolant.
11. Unplug electrical connector (2) at radiator outlet coolant temperature sender G83.
12. Lift retaining clip (1), disconnect coolant hose (bottom right) from radiator and drain off coolant.
13. Release hose clips (arrows), disconnect coolant hoses from coolant pipes for heat exchanger for heater and drain off coolant.
14. Release hose clip (arrow), disconnect coolant hose from coolant pipe (right-side) and drain off remaining coolant.
15. Carefully pull engine cover panel off four retaining pins one after the other (arrows).
16. Disengage coolant hose (bottom) and detach cover above radiator (arrows).
17. Release hose clip (1) and detach coolant hose. [Note: Disregard (item 2).]
18. ⚠ The fuel can become extremely hot. This can cause injuries. In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with common rail engine, even 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. — Remove bolts (1) and (2) and nut (4).
19. Place fuel filter aside (fuel hoses (3, 5, 6) remain connected).
20. Unscrew bolts (1 ... 4) and move cooler for fuel cooling system clear to one side. [Note: The fuel filter bracket remains installed.]
21. Open cover over terminal 30 wiring junction 2TV22(arrow).
22. Remove stud (1) on jump start socket U6 and move wiring clear.
23. Release hose clips (arrows) and remove air hose.
24. Unplug electrical connector (3).
25. Remove bolts (1) and (2) and detach throttle valve module J338 from intake connecting pipe. [Note: Lay a cloth under the separating point to catch escaping hydraulic fluid.]
26. Clamp off hydraulic hose for power steering pump using a hose clamp 3094.
27. Release hose clip (1) and detach hydraulic hose from power steering pump.
28. Seal off open pipes/lines and connections with clean plugs from engine bung set VAS 6122. [Note: Disregard (item 2).]
29. ⚠ Danger of damage to refrigerant lines and hoses. Do NOT stretch, kink or bend refrigerant lines and hoses. — Remove bolts (1) and (5) for retaining clips.
30. Remove bolts (3) and (4) and disconnect refrigerant lines from air conditioner compressor.
31. Seal off open pipes/lines and connections with clean plugs from engine bung set VAS 6122. [Note: Disregard (item 2).]
32. Unclip coolant hose at air cleaner (top section).
33. Unclip breather hose (1) for front differential from air cleaner housing.
34. Unplug electrical connector (3) from air mass meter G70.
35. Release hose clip (4) and detach air hose from turbocharger.
36. Release retaining clips (2).
37. On vehicles with air suspension, push retaining ring (1) forwards off hose connector, press down release ring (2)(arrows) and detach breather hose (3) from air cleaner (top section).
38. Remove air cleaner (top section) and air filter element.
39. Working from wheel housing, press air duct (2) off air cleaner (bottom section) (1) using removal lever80 - 200.
40. Remove bolts (1) and (2).
41. Press filler neck for washer fluid reservoir slightly to one side and remove air cleaner (bottom section).
42. Release hose clips (1, 2, 3) and detach air hoses.
43. Unplug electrical connector (arrow).
44. Disconnect vacuum hose (arrow) going to brake servo.
45. ⚠ The fuel can become extremely hot. This can cause injuries. In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with common rail engine, even 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. Risk of injury - fuel system operates under high pressure. To reduce the pressure in the fuel system, wrap a clean cloth around the connection and carefully loosen the connection. — Disconnect fuel supply line (1) and fuel return line (2) from plenum chamber partition panel.
46. Remove electrical connector (1) for exhaust gas temperature sender 2G448 and (2) for Lambda probe G39 from bracket and unplug.
47. Move electrical wiring clear. [Note: Disregard (items 3, 4).]
48. Unscrew Lambda probe G39(item 5).
49. Remove NOx sender G295(item 4) and move electrical wiring clear.
50. Tie NOx sender onto body. [Note: Disregard (items 1, 2, 3).]
51. Remove wiper arms (1) and (3)Electrical system92.
52. ⚠ Risk of damage to plenum chamber cover. Apply a small quantity of soap solution to the transition between the windscreen and the plenum chamber cover. Then pull the plenum chamber cover vertically up and out of the windscreen surround, starting at the edge of windscreen. — Remove seal (5).
53. Pull plenum chamber covers (2) and (4) carefully off retainers at windscreen.
54. Remove cover for electronics box in plenum chamber (arrows).
55. Unplug electrical connectors (1, 2, 3) at connector point in electronics box in plenum chamber and move wiring harness clear.
56. Unplug electrical connector (arrow).
57. Remove nut (2) for earth connection.
58. Remove engine control unit (1)23.
59. Move engine wiring harness clear.
60. Loosen nut for upper link several turns and use ball joint puller T10187 to press off joint.

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