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: 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).
• 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.
• Disregard (item 1).

🔧 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 (3) at radiator outlet coolant temperature sender G83.
12. Lift retaining clip (1), disconnect coolant hose (bottom right) from radiator and drain off coolant. [Note: Disregard (item 2).]
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. Open cover over terminal 30 wiring junction 2TV22(arrow).
19. Remove bolt (1).
20. Remove stud (2) on jump start socket U6 and move electrical wiring clear.
21. Release hose clips (arrows) and remove air hose.
22. Unplug electrical connector (3).
23. 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.]
24. Clamp off hydraulic hose (1) for power steering pump using hose clamp 3094 and detach.
25. Seal off open pipes/lines and connections with clean plugs from engine bung set VAS 6122. [Note: Disregard (item 2).]
26. ⚠ 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.
27. Remove bolts (3) and (4) and disconnect refrigerant lines from air conditioner compressor.
28. Seal off open pipes/lines and connections with clean plugs from engine bung set VAS 6122. [Note: Disregard (item 2).]
29. Release hose clips (2, 3) and detach air hoses. [Note: Disregard (item 1).]
30. Release hose clips (arrows) and remove air pipe.
31. Unplug electrical connector (arrow).
32. Disconnect vacuum hose (arrow) going to brake servo.
33. ⚠ 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 lines (2 and 3) from plenum chamber partition panel.
34. Remove electrical connector (2) for Lambda probe G39 from bracket and unplug connector.
35. Move electrical wiring clear. [Note: Disregard (items 1, 3, 4).]
36. Unscrew Lambda probe G39(item 5).
37. Remove NOx sender G295(item 4) and move electrical wiring clear.
38. Tie NOx sender onto body. [Note: Disregard (items 1, 2, 3).]
39. Remove wiper arms (1) and (3)Electrical system92.
40. ⚠ 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).
41. Pull plenum chamber covers (2) and (4) carefully off retainers at windscreen.
42. Remove cover for electronics box in plenum chamber (arrows).
43. Unplug electrical connectors (1, 2, 3) at connector point in electronics box in plenum chamber and move wiring harness clear.
44. Remove nut (2) for earth connection.
45. Remove engine control unit (1)23.
46. Move engine wiring harness clear.
47. Loosen nut for upper link several turns and use ball joint puller T10187 to press off joint.
48. Remove nut for link completely.
49. Perform the same work steps on the other side of the vehicle.
50. Unplug electrical connectors (arrow) at front wheel speed sensors on both sides.
51. Remove bolts (arrows) for wiring retainer.
52. Remove bolts (1) for brake caliper. [Note: Do not bend brake pipes to a different shape.]
53. Use wire to tie up brake caliper in wheel housing.
54. ⚠ Avoid damage to brake pistons. Do not operate brake pedal with brake caliper removed. — Perform the same work steps on the other side of the vehicle.
55. Unfasten bottom bolt connection (2) on anti-roll bar (left and right).
56. Remove nuts from bolts (1) on suspension strut (left and right). [Note: The bolts (1) are removed at a later stage.]
57. Disconnect exhaust system at clamp (arrows).
58. Remove NOx sender 2G687(item 3) and move electrical wiring harness clear at transfer box.
59. Unplug electrical connector (5) and move electrical wire clear.
60. Release retaining clip (arrow) and detach injector for reducing agent N474.

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