Removing
Note: The engine is removed from under the engine compartment down along with the transmission.
1. Remove the air cleaner (see chapter 4).
2. Remove the PCV tube (1 per resist. illustrations), remove the bolt (arrow) and remove the inlet pipe by loosening the clamp (2). Plug the turbocharger intake port to keep dirt out.
23.2 Removing the intake tube
3. Remove the battery and its holder (see chapter 5).
4. Remove the locker of the front right wheel arch (see chapter 11). On FWD models, release the right drive shaft heat shield fastener (see resist. illustration).
23.4 Fixing the heat shield of the right drive shaft
5. Remove the right drive shaft (see chapter 8).
6. Loosen the left drive shaft fastener to the manual transmission/DSG flange shaft and tie up the drive shaft so that it does not hang down under its own weight.
7. Remove the intake exhaust pipe (see Section 4) and cardan shaft (on AWD models, see chapter 8).
8. Remove the radiator fan shroud and bleed the coolant (see chapter 3). Disconnect the coolant hoses from the radiator, heater core and expansion tank.
9. Disconnect the engine wiring harness connector from the ECM (see chapter 5).
10. Remove the wiring harness guide plate (see illustration 15.17) and pull it up. Pull the rear left engine wiring harness out of the bulkhead.
11. Open the wiring guide bracket (see illustration 5.23).
12. Disconnect the connector (1 per resist. illustrations) and open the bracket (2) under the wiring guide. Disconnect the engine harness to the ECM, disconnect all engine/body harness connectors.
23.12 Connector (1) and bracket (2)
13. On models with DSG, remove the selector lever cable from it (see chapter 7).
14. On models with a manual transmission, remove the select and shift cables from it, remove the rack (1 per resist. illustrations), remove the slave cylinder (arrows) clutch and tie it aside without opening the clutch circuit.
Note: Do not depress the clutch pedal after removing the clutch slave cylinder.
23.14 Stance (1) and fasteners (arrows) executive cylinder
15. Remove the clamp (arrow on resist illustrations) 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.
23.15 Starter wiring connections
16. Loosen clamp (2 to resist. illustrations), remove the bolt (4), disconnect the connector (arrow) and pull out the wire. Remove the bolt (1) and remove the pressure tube downwards.
23.16 Pressure tube
17. Remove the right pressure hose (see resist. illustration).
23.17 Right pressure hose
18. On models with an additional heater, loosen the clamp (1 in illustration 5.14), remove the bolt (2) and remove the auxiliary heater muffler.
19. Disconnect the connector (2 to resist. illustrations) sensor "G83" coolant temperature at the radiator outlet and connection (1).
23.19 Sensor (2) coolant temperature at the radiator outlet
20. Remove the fuel supply line (2 to resist. illustrations), by pushing the retaining ring upwards and collect the escaping fuel.
23.20 Ventilation line
21. Loosen the bolts (see resist. illustrations) brackets of the right and left engine mounts by no more than 1 turn.
23.21a Bolts of the right engine bracket
23.21b Left engine bracket bolts
22. Remove the drive belt (see Section 24).
23. 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 fix it on the side member holder (2 to resist. illustrations) on the wire so that the refrigerant lines are not stretched or kinked.
23.23 Fixing the compressor to the side member holder
24. Disconnect the connector (1 in illustration 5.16) sensor "G266" engine oil level and temperature. Unhook the bracket (2) G266 sensor wiring from the holder on the power unit support.
25. Remove/disengage any remaining wiring from the engine and transmission; Disconnect the coolant, vacuum and ventilation hoses from the engine.
26. Remove the bolt (2 to resist. illustrations) on coolant circulation pump bracket "V51".
23.26 Circulation pump "V51"
27. Loosen the oscillator fasteners in sequence (1-3 in illustration 5.11) and take it off.
28. Fix the T10359 support to the cylinder block by tightening the bolt (1 per resist. illustrations) in the hole for fixing the circulation pump ''V51" with a force of 20 Nm. Insert the transmission jack VAG1383A into the T10359 support and support the engine to unload its supports.
23.28 Tools for lifting the power unit
29. Make sure that all hoses and electrical wiring between the engine, transmission and body are disconnected. Give the bolts from the ladder (see illustrations 23.21a-b) fixing right and left brackets (on the engine and transmission).
30. Together with an assistant, slightly lower the power unit, pull it 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.
31. Fix the engine on the mounting stand and separate the transmission from the engine (see Chapter 6 or 7).
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.
32. Installation is carried out in the reverse order. Pay attention to the following features.
33. Use new self-locking nuts and bolts that need to be tightened to a certain angle. Use new seals and gaskets.
34. On models with a manual transmission, clean the splines of the transmission input shaft 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 input shaft splines. Move the clutch disc on the shaft until the disc travels smoothly, and then remove excess grease. Check the clutch release bearing for wear; replace if necessary. Make sure the clutch is centered (see chapter 6).
35. On models with DSG, replace the crankshaft needle bearing as described in Section 14. Note: Press in the bearing to a depth (and in illustration 14.Зb) - 2.0 mm.
36. Make sure that the centering sleeves for the transmission are inserted into the cylinder block. Attach the transmission to the engine (see chapter 6 or 7).
37. Fix the power unit on the transmission jack using the T10359 support, drive it into the engine compartment and screw in the new bolts of the power unit brackets by hand. Adjust the brackets and tighten their mounting bolts (see subsection below).
38. Install the oscillator (see subsection below) and drive shafts (see chapter 8).
39. Install the compressor and accessory drive belt.
40. On models with a manual transmission, install the clutch slave cylinder and gearshift mechanism, and then adjust it.
41. On models with DSG, attach the selector cable to it.
42. Lay the engine wiring harness, dock it with the ECM.
43. Install the exhaust pipe.
44. On AWD models, install the driveshaft.
45. Connect the battery wiring.
46. Fill the engine cooling system (see chapter 3).
47. Clear the ECM memory of any DTCs that occurred during removal/installation of the engine and verify that the ECM has generated a readiness code.
48. Do a road test (see chapter 1) and fix any errors you find.
Checking and adjusting the power unit supports
49. Details of the fastening of the supports are indicated on the resist. illustrations.
23.49 Details of fastening of supports of the power unit
1 Support bracket 3
2 Bolt, to be replaced, 40 Nm, then retighten 180°
3 Right engine mount
4, 8, 14 Bolt, to be replaced, 40 Nm, then retighten 90°
5 Connecting piece
6, 7 Bolt, to be replaced, 20 Nm, then retighten 90°
9, 13 Bolt, to be replaced, 60 Nm, then retighten by 90°
10 Oscillating bearing, remove bolts in sequence 11-12 and install in sequence 12-11
11 Bolt, to be replaced, 100 Nm, then retighten by 90°
12 Bolts to be replaced 40 Nm (strength class 8.8) or 50 Nm (strength class 10.9), then tighten to 90°; on models with manual transmission "MQ350" (code "02Q") after repairing the thread, only bolts of strength class 10.9 may be used
15 Left engine mount
16 Support bracket 15
17 Bolt
50. To check the installation of the bracket, make sure that the heads of both bolts (2 in illustration 23.21a) parallel to the edge of the support arm (3), and the distance between the bracket (1) and support (4) is 10-13 mm. If the engine or transmission hits the side member while cornering and the distance (X) is not 10-13 mm, adjust the bracket as described below.
51. Remove the battery and its holder (see chapter 5).
52. Install support MP9-200 (№10-222A) with two spindles MP9-200/10 (№10-222А/1 0) (see illustration 15.45) and evenly relieve the power unit mounts by rotating both spindles.
53. Loosen the bolts (2 in illustration 23.21a) fixing the right bracket and slightly (no more than 1 turn) loosen the bolts (see illustration 23.21b) left bracket mounting.
54. If, when installing the engine, the bracket bolts have not yet been replaced, screw in new bolts one by one.
55. Move the power unit using the lever installed between the support arm (3 in illustration 23.21a) and support (1), to the bolt heads (2) were parallel to the edge of the support arm, and the distance (X) was 10 mm. Tighten the bolts of the right support (see illustration 23.49).
56. Make sure that on the side of the 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 bracket mounting bolts (see illustration 23.33).
23.56 Checking the installation of the left support
57. Install the remaining parts.