Note: The engine is removed downwards together with the gearbox. When reassembling, restore all cable ties in their original positions.
Remove both front wheels. Remove soundproof cover. Remove both front fender liner. Remove the plenum box cover. Remove engine cover.
Attention! Risk of injury from fuel under very high pressure. Before opening the high pressure circuit of the injection system, the fuel pressure must be reduced to residual pressure.
Release of pressure of fuel in a contour of a high pressure. Drain coolant.
Carefully! Only install a used belt in the same direction of travel. Incorrect installation can lead to the destruction of the belt! Before removing the poly V-belt, mark the direction of its travel with chalk or a felt-tip pen.
Vehicles with air conditioning
To loosen the poly V-belt, move the tensioner in -direction of the arrow- (counterclock-wise) and remove the V-ribbed belt from the pulley. air conditioner pressor. Lock tensioner with lock -T10060A-. Remove poly V-belt.
Attention! The coolant is dangerous. Open air conditioner refrigerant circuit.
Unplug connector -1- at air conditioner compressor regulating valve -N280-. Unscrew bolts -arrows- for air conditioner compressor.
Carefully! Risk of damage to compressor and refrigerant hoses. Do not stretch, bend or kink pipes and refrigerant hoses.
Remove air conditioner compressor together with refrigerant hoses, move to right and tie up.
All
Loosen clamp -1- and remove air pipe. Release screws -2- on left and right. Detach from the front support panel and remove the air duct.
Disconnect the connector -1 - of the radiator fan, to do this push the catch -arrow A- back and push the release button down. Simultaneously press the latches on the fan cowl -arrow B- on the left and right and remove the fan cowl from the radiator towards the top. Remove the battery and its bracket.
Unlock catch -arrow- and detach vacuum hose -1-. Detach vacuum hose from mounts on air duct -2-.
Vehicles without auxiliary heater
Raise clips -arrows- and disconnect coolant hoses from heater heat exchanger.
Vehicles with auxiliary heater
Raise the retaining clip and loosen the clamp and detach both coolant hoses -arrows-.
All
Unscrew screw -2- and remove screw clamp. Remove screw -1-. Remove nut -arrows- and tie up catalytic converter.
Release screws -arrows- and remove bracket.
Loosen clamp -1- and detach coolant hose.
Carefully! Danger of contamination. When working on the power system, observe the rules for maintaining cleanliness.
Disconnect fuel pressure line -1- and line to canister -2-.
Raise clamp -arrow- and detach upper right hose from charge air cooler. Remove the air filter housing.
Raise clip -arrow- and disconnect upper left coolant hose from radiator.
Note: For subsequent operations, use door trim remover -MP8-602/1- to release the retainers.
Unplug connector -1- from engine control unit -J623-. Remove connectors -2 and 3- from holder and disconnect. Hang wires.
Disconnect the connector -2-, Remove the protective cap of the B+ contact -1- and disconnect the B+ wire from the starter solenoid. Disconnect ground wire from body. Disconnect the upper connectors from the engine control unit.
Unlock catches -arrows- and remove cover -1- for electronics box in engine compartment.
Unlock catch with a screwdriver -arrow- and lift cover -1- of electronics box in engine compartment upwards.
Loosen nut -arrow-, detach and hang cable.
Disconnect connectors -1- and -2-.
Vehicles with manual gearbox
Disconnect the shift mechanism from the gearbox. Remove the slave cylinder.
Vehicles with automatic transmission DSG
Remove the selector cable, disconnect the connector of the mechatronic unit and disconnect all brackets from the gearbox.
All
Loosen screws -arrows- for engine support by approx. 2 turns.
Unscrew bolts -arrows- for gearbox support by approx. 2 turns.
Unplug connector -1- for oil level and oil temperature sender -G266-. Release wire from holder -2-.
Loosen nuts -1 - of stabilizer struts -3- on left and right side of stabilizer bar -2-.
Loosen screws -1, 2, 3- and remove power unit bottom support.
Unscrew bolts -arrows- and remove heat shield for right drive shaft.
For vehicles with automatic transmission DSG
Remove attachment bracket.
All
Unscrew nuts -arrows- on ball joints on left and right.
If fitted, unscrew nut -arrow- from front left vehicle level sender -G78-. Detach ball joints on left and right from control arms. Disconnect the left and right drive shafts from the gearbox and tie up.
Note: Take care not to damage the protective coating on the drive shaft.
Turn the left shock absorber strut outward and support it with extension -2024 AL - as shown in the illustration.
Attention! Risk of injury due to loose parts of this support. Secure retainer and ball joint with pin -arrow- and nut -1-.
Attach right ball joint -2- to transverse link -1- with nut -arrow- as shown.
Install clamp T10497/2 on the rib of the cylinder block as shown in the figure. Position engine bracket -T10497- with pins T10497/1 on cylinder block. Attach clamp T10497/2 with screw -1- to engine support bracket T10497 and tighten to 20 Nm.
Fit adapter -T10497/3- to engine bracket -T10497- and tighten bolt -1- to 20 Nm. Attach engine support bracket -T10497- to engine and gearbox jack -VAG 1383A- and raise engine slightly.
Note: Use a stepladder, eg -VAS5036-, when loosening the bolts of the power unit supports.
Completely unscrew bolts -arrows- for engine support. Unscrew bolts -arrows- for gearbox support completely.
Carefully! Risk of damage to vacuum hoses and electrical wires, as well as parts of the engine compartment. Check that all vacuum lines and electrical wires connecting the engine, gearbox, subframe and body are disconnected. When removing the power unit from the engine compartment, be careful.
Slightly lower the power unit. Then turn the side of the gearbox of the power unit forward and only then slowly and carefully lower it.