Removing
Note: The engine is removed from under the engine compartment down together with the manual transmission.
1. Relieve pressure in the fuel supply system and remove the air cleaner (see chapter 4).
2. Remove the engine top cover. To do this, remove the screws (1 per resist. illustrations), unhook the coolant hoses (2) and pull the cover up.
Note: When installing, tighten the bolts to 8 Nm.
15.2 Details of fastening of the top cover of the engine
3. Remove the air cleaner (see chapter 4).
4. Follow the steps in paragraphs 2-6 of Section 5.
Note: The coolant must be drained from both the engine cooling system and the intercooler.
5. Disconnect the fuel supply line (1 per resist. illustrations) and hose (2), leading to the EVAP canister by squeezing the retaining ring. Remove the hose (3), going to the adsorber from the e / m valve No. 1 purge adsorber. Remove the adsorber upwards and unscrew the bolts (arrows) from the bracket. Remove coolant hoses (4).
15.5 Removing the EVAP canister
6. Disconnect the coolant hose from the radiator of the engine cooling system, top left (see resist. illustration).
15.6 Upper radiator hose
7. Disconnect coolant hoses (1 and 2 on resist. illustrations) from the heater core.
15.7 Hoses on the heater core
8. Turn out bolts and remove a thermofilter of a turbocharger (see resist. illustration).
15.8 Fixing the heat shield
9. Give the nuts on the turbocharger (see resist. illustration).
15.9 Nuts on the turbocharger
10. Remove the coolant pipe (2 to resist. illustrations).
15.10 Coolant pipes
11. 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.
12. On models with an additional heater, loosen the clamp (1 in illustration 5.14), remove the bolt (2) and remove the auxiliary heater exhaust pipe. If necessary, disconnect the interfering connections of the coolant pipe.
13. Pull out the wiring (1 per resist. illustrations) on the catalytic converter, disconnect the connector (2), give nuts (3) and remove the gasket. Remove the catalytic converter downwards.
15.13 Removing the catalytic converter
14. Give nuts (2 and 3 on resist. illustrations) and remove the gasket. Remove the bolts (1 and 5) and remove the intake exhaust pipe with bracket (4).
15.14 Removing the exhaust pipe
15. Loosen clamp bolts (see resist. illustration) and pull the intermediate exhaust pipe back. Remove or release all electrical wiring from the manual transmission, alternator and starter, as well as other engine wiring. Remove the vacuum and vent hoses from the engine.
15.15 Exhaust pipe clamp
16. Disconnect the connector (1 per resist. illustrations) thermostatic switch and radiator fan. Disconnect the engine wiring harness connector at the ECM (front connector).
15.16 Connector (1) thermal switch and radiator fan
17. Remove the wiring harness guide plate (see resist. illustration) and pull it up out of the bulkhead.
15.17 Wiring guide plate retainer
18. Open the entire engine wiring harness protection on the side member (see illustration 5.23). Open other connections of the engine wiring harness, remove it, lay it on the engine and secure with clamps.
19. Loosen the oscillator fasteners in sequence (1-3 in illustration 5.11) and take it off.
20. Remove the gearshift mechanism and clutch slave cylinder from the manual transmission without opening the clutch hydraulic circuit (see chapter 6). Hang the slave cylinder aside.
Note: After removing the clutch slave cylinder, do not depress the clutch pedal.
21. Set the hood lock holder to the service position (see chapter 11).
22. Disconnect the connector (3 on resist. illustrations) coolant circulation pump "V50". Loosen the clamps (arrows) and disconnect coolant hoses. Remove the bolt (2) and remove the pump from the bracket. Remove the bolts (1) pump bracket from the cylinder block.
15.22 Removing the coolant circulation pump and its bracket
23. Remove the drive belt (see Section 16).
24. Disconnect the connector (1 in illustration 5.13a) magnetic clutch of the compressor and remove the bolts (arrows). Remove the climate system compressor without disconnecting the refrigerant lines from it, and secure it to the hood lock holder with a wire so that the refrigerant lines are not stretched or kinked.
25. To lower the power unit, prepare support T40075A with adapters -/1, -/2 and -/3 (see resist. illustration).
15.25 Tool for removing the power unit
26. Screw the adapter Т40075/1 into the cylinder block until it stops (see resist. illustration).
15.26 Adapter Т40075/1
27. Position the T40075A support with adapters -/2 and -/3 on the cylinder block and fix the adapter -/1 with a bolt (3 on resist. illustrations). Between the cylinder block and the T40075A support, install two M10 nuts (2) and fix the support by screwing the M8x35 bolt by hand (1). Tighten all the mounting bolts of the support with a force of 20 Nm, place the VAG1383A jack under the T10416 support and slightly raise the power unit on it to unload its supports.
15.27 Installing the jack
28. Make sure that all hoses and electrical wiring between the engine, transmission and body are disconnected. Give the bolts from the ladder (see illustration 5.28a and resp. illustration) fixing right and left brackets (on the engine and transmission).
15.28 Bolts of an arm of the left support of the power unit
29. Together with an assistant, pull the power unit forward as far as possible and carefully lower it from the engine compartment on the jack. Do not damage parts of the power unit and components of the engine compartment.
30. Fix the engine on the mounting stand and separate it from the manual transmission engine (see chapter 6).
Installation
Note: Lay hoses and electrical wiring in the same way as they were located before removal; Install all clamps and ties in their original places. Fasteners, depending on the thread, tighten with the following forces: M6 - 9 Nm, M7 - 13 Nm, M8 - 20 Nm, M10 - 40 Nm, M12 - 70 Nm.
31. Installation is carried out in the reverse order. Pay attention to the following features.
32. Use new self-locking nuts and bolts that need to be tightened to a certain angle. Use new seals and gaskets.
33. Clean the transmission input shaft splines and, if an old clutch disc is used, its splines. Remove any corrosion and apply a very thin coat of G000 100 grease to the splines of the input shaft. Slide the clutch disc on the shaft until the disc runs smoothly, then wipe off excess grease. Check the clutch release bearing for wear; replace if necessary. Make sure the clutch is centered (see chapter 6).
34. Make sure that the centering sleeves for the manual transmission are inserted into the cylinder block. Attach the gearbox to the engine (see chapter 6).
35. Fix the power unit on the transmission jack using the T40075A support, drive it into the engine compartment and screw in new bolts for fastening the power unit brackets by hand. Adjust the brackets and finally tighten the bolts of their fastening (see subsection below).
36. Install the oscillator (see subsection below) and drive shafts (see chapter 8).
37. Install the compressor and accessory drive belt.
38. Install the clutch slave cylinder (see chapter 6).
39. Install the gearshift mechanism and, if necessary, adjust it (see chapter 6).
40. Follow the steps described in paragraphs 37-43 Section 5.
Checking and adjusting the power unit supports
41. Details of the fastening of the supports are indicated on the resist. illustrations.
15.41 Details of fastening of supports of the power unit
1 Gearbox support bracket
2 Bolt
3 Engine support
4 Stud bolt, to be replaced, 40 Nm, then retighten by 90°
5 EVAP canister bracket
6 Bolt, 9 Nm
7 Nut, 9 Nm
8, 9 Bolt, to be replaced, 20 Nm, then retighten by 90°
10 Connecting piece
11, 17 Bolt, to be replaced, 40 Nm then retighten by 90°
12, 16 Bolt, to be replaced, 60 Nm then retighten by 90°
13 Oscillating support, when removing, unscrew the bolts in the sequence 14-15, and when installing - in the sequence 15-14
14 Bolt, to be replaced, 100 Nm, then retighten by 90°
15 Bolts, to be replaced, 40 Nm (strength class 8.8) or 50 Nm (strength class 10.9), then tighten to 90°
18 Gearbox support
42. To check the installation of the bracket, measure the distance (and in illustration 5.45) between the bracket and the support - it should be 10-13 mm. Cast support edge (2) must be parallel to the support arm (1), and the 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.
43. Remove the battery and its holder (see chapter 5).
44. 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.
45. Install support MP9-200 with spindles MP9-200/10 (see resist. illustration). The heel of the support must rest against the buffers. Unload the power unit mounts evenly by rotating both spindles.
15.45 Unloading power unit supports
46. Loosen the bolts (arrows in illustration 5.28a) fixing the right bracket and slightly (less than 1 turn) loosen the bolts (2 in illustration 15.28) left bracket mounting.
47. If, when installing the engine, the bracket bolts have not yet been replaced, screw in new bolts one by one.
48. Move the power unit using the lever installed between the support arm (1 in Figure 5.45) and support (2), to distance (A) was 10 mm, and the distance (X) was the same front and back. Tighten right bracket bolts (see illustration 15.41).
49. Make sure that on the side of the manual transmission, the edges of the support (1 per resist. illustrations) and its support arm (2) are located parallel to each other. Those. distance (X) should be the same on both sides of the support. Tighten the left bracket bolts (see illustration 15.41).
5.49 Checking the installation of the left bracket
50. Install the remaining parts.