Removal and installation
Note: The engine is removed from under the engine compartment down along with the transmission.
1. Remove the engine top cover. To do this, sequentially pull it out of the supporting hinge sockets (1-4 in illustration 34.1a), by grasping the edges of the lid as far as possible. To install, press the cover into the slots until you feel it click into place. Before installation, it may be necessary to set the hinge sockets to the correct position (see illustration 34.1b).
34.1a Removing the engine top cover
34.1b Correct (from below) and wrong (above) position of the socket for the top cover of the engine
2. Remove the battery and its holder (see chapter 5).
3. Remove the air cleaner along with the MAF sensor and suction tube (see chapter 4).
4. On CFFB and CFGB engines, disconnect the following connectors on the bulkhead of the engine compartment (see resist. illustration): sensor "G648" EGR №4 (2, orange), sensor "G235" EGR No. 1 or temperature sensor after the turbocharger "G507" (3, black), Lambda probe "G39" (4, black) and EGR sensor No. 3 "G495" (6, brown).
34.4 Sensors and vacuum hose on bulkhead of engine compartment
5. Disconnect the vacuum hose (5 in illustration 34.4) from e/m valve "N75" boost pressure adjustment.
6. Blow the coolant (see chapter 3).
7. Disconnect the connector (1 in illustration 5.16) sensor "G266" engine oil level and temperature. Remove bracket (2) the electrical wiring of the G266 sensor from the support of the power unit.
8. If equipped, remove the right drive shaft heat shield (see illustration 23.4).
9. Remove the lockers of both front wheel arches (see chapter 11).
10. Disconnect the left drive shaft from the transmission flange halyard (see chapter 8).
11. Remove the exhaust pipe with particulate filter (see chapter 4).
12. On AWD models, separate the cardan shaft from the manual transmission / DSG (see chapter 8).
13. Give a nut of the left stabilizer strut (2 in illustration 5.5) and push it away from the stabilizer. Then give three nuts (3) ball joint and separate it from the suspension arm. If equipped, remove the front left suspension height sensor. Turn the steering wheel all the way to the left, pull the ball joint outward and use a suitable belt to (A) fasten the left drive shaft (1) on the suspension strut so that the CV joint does not bend too much. Insert a pin into the suspension arm to stabilize the ball joint.
14. Remove the radiator (see chapter 3), remove the bolts (arrows on resist. illustrations), release the coolant hose (1), loosen clamp (3), disconnect the connector (2) sensor ''G31" and remove the right pressure air tube.
34.14 Removing the right pressure air tube
15. Remove the bolt (arrow on resist illustrations) and remove the coolant circulation pump No. 2 "V178" to the side.
34.15 Pump fixing "V178"
16. Remove the vacuum hose (2) from the turbocharger vacuum element and disconnect the vacuum hose (3).
34.16 Vacuum hoses
17. Remove the vacuum hose from the vacuum brake booster (see resist. illustration).
34.17 Vacuum hose on the brake booster
18. Disconnect the supply (2 to resist. illustrations) and return fuel lines.
34.18 Fuel lines
19. Disconnect the connector (4 to resist. illustrations) sensor ''G81" fuel temperature, loosen clamps (2 and 3) and remove the supply and return fuel lines.
34.19 Sensor connector "G81" and fuel lines
20. Remove the bolt (1 per resist. illustrations) and move the neck to the side (2) washer fluid reservoir along with the tube.
34.20 Removing the neck of the washer fluid reservoir
21. Release the fuel hose (2 to resist. illustrations) from the bracket. Remove the fuel line bracket upwards in the direction of the arrow and place it on the side. Disconnect connector (1) additional fuel pump "V393" and remove the bolts (3).
34.21 Bracket for fuel lines and connector for additional fuel pump
22. Loosen the bolt (1 per resist. illustrations) 2 turns, unscrew the bolt (2) and give the nut (3). Separate the coolant line bracket from the fuel filter. Remove the fuel filter together with the connected hoses and remove the bracket together with the pump "V393".
34.22 Removing the fuel filter and additional fuel pump
23. Remove the accessory drive belt (see Section 35) and the climate system compressor without disconnecting the refrigerant lines from it (see chapter 3). Attach the compressor to the hood latch holder with wire so that the refrigerant lines are not stretched or kinked (see resist. illustration).
34.23 Fixing the compressor on the hood lock holder
24. Remove the fuse and disconnect the front ECM connector (see chapter 5).
25. Remove the wiring harness guide plate (see illustration 5.17) and pull it up from the bulkhead at the expansion tank.
26. Open all cable harness guides and set it aside (see resist. illustration).
34.26 Cable harness guides
27. Disconnect the connector (1 in illustration 23.12) and open the bracket (2) under the wiring guide. Loosen the engine harness going to the ECM and lay it on top of the engine.
28. Disconnect the connector on the lower left side member (see resist. illustration).
34.28 Connector on the left side member
29. Remove the clamp (arrow in illustration 23.15) protective cap (in the presence of), disconnect the ground wire (1), disconnect the connector (2), pull back the protective cap and disconnect the B+ wire from the starter valve solenoid bracket.
30. Disconnect all remaining electrical wiring connectors on the engine and transmission, or disconnect the electrical wiring harnesses from them.
31. Disconnect the coolant hoses from the heater core (see resist. illustration), and also disconnect the coolant hose from the expansion tank at the top and bottom.
34.31 Coolant hoses on the heater core
32. On models with an additional heater, disconnect the coolant hoses from it, collecting the escaping liquid.
33. On models with a manual transmission, remove the gearshift mechanism from it and disconnect the pressure line from the breather / clutch slave cylinder (see chapter 6). On models with DSG, remove the shift mechanism from it (see chapter 7).
34. Disconnect all remaining engine and transmission connections, coolant hoses, vacuum and ventilation hoses.
35. Turn out bolts in sequence (1-3 in illustration 5.11) and remove the transmission rocker.
36. Fix the T10012 support to the cylinder block by tightening the nut (2 to resist. illustrations) and bolt (1) with a force of 20 Nm. Insert the transmission jack VAG1383A into the T10012 support and support the engine to unload its supports.
34.36 Support for lifting the power unit
37. Give the bolts from the ladder (see resist. illustrations) fixing right and left brackets (on the engine and transmission).
34.37a Bolts of the right engine mount
34.37b Left engine mount bolts
38. Together with an assistant, carefully lower the power unit from the engine compartment on the jack. Rotate or move the power unit, if necessary, to prevent damage to its parts, as well as components of the engine compartment.
39. Fix the engine on the mounting stand and separate the transmission from the engine (see Chapter 6 or 7).
40. Installation is carried out by analogy with gasoline engines 1.8 / 2.0 l (see Section 23). The pressing depth of the crankshaft needle bearing is 1.5-1.8 mm. A description of the check and adjustment of the power unit supports is given in the subsection below.
Checking and adjusting the power unit supports
41. Details of the fastening of the supports are indicated on the resist. illustrations.
34.41 Details of fastening of supports of the power unit
1 Bolt
2 Bolt, strength class 10.9, to be replaced, 50 Nm then retighten by 90°
3 Engine support bracket
4 Bolt, to be replaced, 40 Nm then retighten by 180°
5 Engine support
6, 10, 15 Bolt, to be replaced, 40 Nm then retighten by 90°
7 Connecting piece
8, 9 Bolt, to be replaced, 20 Nm then retighten by 90°
11, 14 Bolt, to be replaced, 60 Nm then retighten by 90°
12 Oscillating support
13 Bolt, to be replaced, 100 Nm then retighten by 90°
16 Transmission support
17 Bolt
18 Bolt, only on models with transmission "DQ250"
19 Transmission support bracket
42. When attaching the engine mount to the cylinder block, tighten the bolts in the sequence (1-3 per resist. illustrations) in three stages: first by hand, then - with a force of 40 Nm, and finally - tighten them at an angle of 180°.
34.42 Engine mount bolt tightening sequence
43. To check the installation of the bracket, measure the distance (and in the illustration 15.45) between the bracket and the support - it should be 10-13 mm. Cast support edge (2) must be parallel to the support arm (1), i.e. distance (X) should be the same front and back. If the engine or transmission hits the side member while cornering and the distance (A) is not 10-13 mm, adjust the bracket as described below.
44. Remove the battery and its holder (see chapter 5).
45. Remove the front hood buffers from the upper sides of both front fenders. Insert plates T10311 on the right (And in illustration 5.47) and left (IN) sides in the direction of the arrows as far as it will go so that the arrows "R" And "L" on the plates pointed back. These plates are needed in order not to damage the wings.
46. Install support MP9-200 with spindles MP9-200/10 (see illustration 5.48). The heel of the support must rest against the buffers. Unload the power unit mounts evenly by rotating both spindles.
47. Loosen the bolts of the right and left brackets (see illustrations 34.37a-b) about 1 turn. If the bracket bolts have not yet been replaced when installing the engine, screw in new bolts one by one.
48. Move the power unit using the lever installed between the support arm (1 in illustration 15.45) and support (2), to distance (A) was 10 mm, and the distance (X) was the same front and back.
49. Tighten the support bolts (see illustration 34.41).
50. Install the remaining parts.