Transmission, Installing
Special tools and workshop equipment required
- All special tools, testing and measuring, and those necessary for removing the transmission are needed. In addition, the following tools will also be needed.
- Vehicle Diagnostic Tester
- Torque Wrench 1332 Insert - Ring Wrench - 16mm VAG1332/14
- Clutch Module Transportation Lock T40170
Procedure
Deadly high voltage!
Electrocution can cause death or very serious personal injury.
- Work on the high voltage system may only be performed by an electrically trained person (EuP). Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .
- Work on high voltage systems must only be performed if the vehicle is clearly marked with the information and warning signs as disabled and safety measures have been taken to prevent the vehicle from starting again.
Follow the High Voltage System General Warnings, refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .
Replace any bolts that were tightened with an additional turn. Aluminum bolts used for attaching the transmission to the engine may be used one time only, refer to TRANSMISSION TIGHTENING SPECIFICATIONS - "The aluminum bolts -2 to 11- may be used twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have been used the first time -arrow- " (See Figure).
Replace self-locking nuts and bolts and seals, gaskets and O-rings.
Secure all hose connections with correct hose clamps .
When installing, bring all cable ties back to same positions.
Transmission installation tightening specifications, refer to TRANSMISSION TIGHTENING SPECIFICATIONS .
-- Before installing a replacement transmission, always clean out the ATF cooler and ATF pipes using compressed air (maximum 10 bar (145 psi)), refer to AUTOMATIC TRANSMISSION FLUID LINES, CLEANING .
-- Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.
-- When installing a replacement transmission, install the transmission support, the transmission mounting and the tunnel crossmember on the new transmission, refer to OVERVIEW - SUBFRAME MOUNT .
-- Install the cable bracket on the new transmission if it is not present, refer to OVERVIEW - SELECTOR LEVER CABLE .
Danger of leaks in the ATF pan.
- The Gearbox Support T40173 must not be set on the ATF pan.
-- Mount the transmission onto the prepared Gearbox Support T40173 and secure it using the tension strap -1- as illustrated (refer to "Preparing the Gearbox Support T40173: " (See Figure)).
-- Secure the transmission with a tensioning strap -1-.
-- The following preparations must be made before connecting the engine and transmission:
-- Turn the Electro-Drive Drive Motor -V141- so that the hold next to the notch -arrow- is visible inside the transmission housing in the lower opening, as illustrated.
If the notch is present only once, turn the Electro-Drive Drive Motor -V141-.
-- Insert the Clutch Module Transportation Lock T40170 in the transmission housing from below and secure it on the flange shaft -1-.
-- Check if the alignment sleeves -A- for centering the engine/transmission are in the cylinder block and insert them if they are not.
-- Inspect the aluminum bolts used to connect the engine to the transmission to see if they can be used again and mark them, if necessary, refer to TRANSMISSION TIGHTENING SPECIFICATIONS - "The aluminum bolts -2 to 11- may be used twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have been used the first time -arrow- " (See Figure).
-- Position the transmission on the engine and tighten the bolts -6 through 11-.
-- Remove the Clutch Module Transportation Lock T40170.
-- Raise the transmission and tighten the tunnel crossmember bolts -arrows-, refer to OVERVIEW - SUBFRAME MOUNT .
-- Loosen the tensioning strap and guide the Engine and Gearbox Jack VAS6931 with the Gearbox Support T40173 under the transmission.
-- Clip the locking piece -1- into the starter opening.
- Make sure locking piece -1- is installed correctly before installing the starter -arrows-.
Apply some grease to the locking piece if it is difficult to install the starter.
-- Install the starter. While doing this, install the spacer -arrow- on the bolt -2- between the starter and the transmission, refer to OVERVIEW - STARTER .
-- Push the Electro-Drive Drive Motor -V141- against the engine drive plate a little bit.
-- Tighten the Electro-Drive Drive Motor -V141- to the drive plate as follows:
Use the Torque Wrench 1332 Insert - Ring Wrench - 16mm VAG1332/14 to tighten the bolts.
-- Install the first bolt -arrow- and tighten by hand (2 Nm).
-- Continue turning the crankshaft on the vibration damper 240° in direction of engine rotation using the Counterhold - Vibration Damper T10355.
-- With the crankshaft in this position, tighten the bolt -arrow- to the tightening specification, refer to OVERVIEW - ELECTRO-DRIVE DRIVE MOTOR -item 12-, Bolt.
-- Continue turning the crankshaft 120° and tighten the remaining 2 bolts to the tightening specification, refer to OVERVIEW - ELECTRO-DRIVE DRIVE MOTOR -item 12-, Bolt.
-- Tighten the remaining engine/transmission connecting bolts -3 through 5-.
The bolts -3 and 5- also attach the wire bracket on the transmission.
-- Attach the coolant hoses -1 and 2- at the connection supports for the hybrid engine and remove the Hose Clamps - Up To 25mm 3094.
-- Install the bolts -arrows- for the cold water control mount by hand on the right transmission side.
-- Secure the engine wiring harness mount -B- on the left side of the transmission and secure the cold water control -A- with the bolts -arrows-. Tighten the bolts for the cold water control mount to the right side of the transmission .
-- Attach the ATF pipes to the transmission with the bolts -1 and 2-, refer to ATF CIRCUIT .
Handling the high voltage cables:
- Do not stand on or place tools on the high voltage cables or their components. This may damage the insulation.
- Do not bend or kink high voltage cables as this may damage the insulation.
- The round high voltage connectors are color coded with an exterior colored ring and mechanically coded with guide or code tabs. Observe the coding when connecting the round high voltage connector in order to avoid mechanical damage to the high voltage connector.
-- Connect the Drive Motor High Voltage Wiring Harness -PX2- -1- to the connection box and install the connection box cover, refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .
The bolts -2- secure the Drive Motor High Voltage Wiring Harness -PX2- to the Electro-Drive Drive Motor -V141-.
-- Install the catalytic converter, refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING, NON-HYBRID VEHICLES or CATALYTIC CONVERTER, REMOVING AND INSTALLING, HYBRID VEHICLES .
-- Connect the connector -A- to the Drive Motor High Voltage Wiring Harness -PX2- and the connector -B- to the Drive Motor Rotor Position Sensor 1 -G713- on the upper left side of the transmission.
-- Connect the connector -C- for the Oxygen Sensor after Three Way Catalytic Converter -G130- and install the cable tie -arrow-.
-- Attach the potential equalization cable -2- with the bolt -3- to the transmission, refer to POTENTIAL EQUALIZATION CABLES .
-- Install the torque crossbrace -3- (bolts -2-) and torque support (bolts -1-), refer to TORQUE SUPPORT AND CROSSMEMBER, REMOVING AND INSTALLING .
Install in reverse order of removal. Note the following:
-- Attach the selector lever cable to the transmission, refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING .
-- Attach the steering column to the steering gear, refer to OVERVIEW - STEERING COLUMN .
-- Tighten the left and right drive axles on the transmission flange shafts, refer to INSTALLING , also see OVERVIEW - WHEEL BEARING HOUSING AND WHEEL BEARING UNIT -item 22-. .
-- Install the subframe crossbrace, refer to INSTALLING .
-- Install the right drive axle heat shield and tighten the bolts -arrows- to 23 Nm.
-- Install the right subframe shield under the right drive axle, refer to SUBFRAME HEAT SHIELD, REMOVING AND INSTALLING .
-- Install the driveshaft and attach the driveshaft heat shield to the transmission, refer to DRIVESHAFT, REMOVING AND INSTALLING (See Figure) .
-- Reconnect exhaust system making sure it is not under stress, refer to EXHAUST SYSTEM, INSTALLING WITHOUT TENSION .
-- Install the noise insulations, refer to OVERVIEW - NOISE INSULATION .
-- Install the front wheels, wheel bolt tightening specification: 140 Nm. Also refer to WHEEL BOLT TIGHTENING SPECIFICATIONS .
Energizing High Voltage System
Restarting the high voltage system must be performed only by using Guided Fault Finding on the Vehicle Diagnostic Tester.
Extremely dangerous high voltage
Severe bodily injury or death by electrocution
- The high voltage system may only be restarted by a qualified person (Audi high voltage technician).
- Only the Vehicle Diagnostic Tester via the "Guided Fault Finding " can guarantee if the voltage has been re-energized.
- Qualified personnel (Audi high voltage technician) restart the vehicle.
- The qualified personnel (Audi high voltage technicians) mark the vehicle with a label.
Energizing the high voltage system:
Connect the Vehicle Diagnostic Tester
Select the Guided Fault Finding mode
Using the Go To button, move through the following menu points
Function/Component Selection
Body
Electrical Equipment
OBD-Capable System
8C - Hybrid Battery Management -J840
8C - Hybrid Battery Management, Functions
51 - High Voltage Restart
-- Follow all steps after connecting the battery, refer to battery - CONNECTING .
There is a risk of destroying control modules due to the excess voltage.
- Do not use a charger to jump start.
-- Check and adjust the selector lever cable, refer to SELECTOR LEVER CABLE, CHECKING AND ADJUSTING .
-- Check the ATF level and correct if necessary, refer to ATF LEVEL, CHECKING .
-- Check the coolant level and add if necessary, refer to COOLANT, DRAINING AND FILLING, NON-HYBRID VEHICLES or COOLANT, DRAINING AND FILLING, HYBRID VEHICLES .
-- Check if the basic setting for the Electro-Drive Drive Motor -V141- needs to be performed, and perform if necessary, refer to ELECTRO-DRIVE DRIVE MOTOR, PERFORMING BASIC SETTING .