Removal
Note: The engine is removed downwards together with the DSG.
1. Remove the battery (see Chapter 5).
2. Loosen the front right wheel hub bolt no more than 90°.
3. Remove the front wheels and front wheel arch liners.
4. Remove the front right drive shaft (see Chapter 8).
5. Separate the left drive shaft (1 on the accompanying illustration) from the DSG flange shaft (see Chapter 8). Loosen the nut of the left stabilizer bar (2) and separate it from the stabilizer. Then loosen the three nuts (3) of the left ball joint and press it out of the suspension arm.
5.5 Fixing the left drive shaft to the suspension strut
6. If there is a suspension height sensor, loosen the nut (2 on the accompanying illustration) its fastening to the lever. Turn the steering wheel all the way to the left, pull the ball joint outward and, using a suitable belt, (And in illustration 5.5) secure the left drive shaft to the suspension strut to prevent the CV joint from bending too much. Insert a stud into the suspension arm to stabilize the ball joint.
5.6 Nut (2) for securing the suspension level sensor
7. Remove the air cleaner together with the hose going to the throttle module (see Chapter 4). Unscrew the bolts (see accompanying illustration) and remove the air cleaner bracket.
5.7 Air cleaner bracket fastening
8. Remove the upper part of the intake manifold (see Chapter 4). Give me the fasteners (arrows in the accompanying illustration) coolant pipes to the casing, then unscrew the bolts (1) and remove the casing together with the intake manifold support.
5.8 Fastening of coolant pipe (arrows) and bolts (1) of casing
9. Loosen the nuts securing the exhaust pipe to the exhaust manifolds (see accompanying illustration) and move it back slightly.
5.9 Fastening the exhaust pipe to the manifolds
Note: Do not allow flexible sections to bend at an angle greater than 20° to avoid damage.
10. Remove the accessory drive belt (see Section 6). To do this, first completely remove the EVAP canister with the purge solenoid valve (see Chapter 4).
11. Loosen the swing support fasteners in the following sequence: (1-3 on the accompanying illustration) and take it off.
5.11 Fastening of the swing support
12. Remove the radiator fan shroud "V7" and "V35", drain the coolant and remove the lower radiator support (see Chapter 3).
13. Disconnect the connector (1 in illustration 5.13a) compressor magnetic clutch and unscrew the bolts (arrows). Remove the air conditioning compressor without disconnecting the refrigerant lines from it and secure it to the hood lock holder with a wire (And in illustration 5.13b) so that the refrigerant lines are not stretched or kinked.
5.13a Connector (1) and fasteners (arrows) of the refrigeration unit compressor
5.13b Compressor Securing
14. On models with additional heating, loosen the clamp (1 on the accompanying illustration), unscrew the bolt (2) and remove the outlet pipe of the additional heater. Disconnect the existing lines on the coolant pipe and on the shut-off valve "N₂79" of the heating system.
5.14 Removing the auxiliary heater outlet pipe
15. Loosen the fastening of the flexible disk of the propeller shaft to the DSG (see Chapter 8).
16. Disconnect the connector (1 on the accompanying illustration) sensor "G266" of the engine oil level and temperature. Remove the bracket (2) of the electrical wiring of the sensor G266 from the support of the power unit.
5.16 Wiring of the G266 sensor
17. Disconnect the coolant lines from the radiator, expansion tank and heater core (see Chapter 3).
18. Remove the selector lever cable from the DSG (see Chapter 7).
19. Press the retaining ring and separate the fuel supply line (2 on the accompanying illustration).
5.19 Fuel supply line (2) and vent line (1)
20. Disconnect the engine wiring harness connector from the ECM (front connector).
21. Release the guide plate (2 on the accompanying illustration) wiring harness and pull it up. Cut the ties (4), Unscrew the bolts (3) on the wall (1) of the air intake chamber. Lift the left side of the wall and pull out the wiring harness.
5.21 Releasing the wiring harness
22. Give the nut (see accompanying illustration) and disconnect the generator wire from the mounting block.
5.22 Generator wire on the mounting block
23. Open all the protection of the engine wiring harness on the side member (see accompanying illustration). Open the other connections of the engine wiring harness, remove it, place it on the engine and secure it with clamps.
5.23 Protection of electrical wiring harnesses
24. Remove the protective cap and disconnect the wire (1 on the accompanying illustration) from the starter solenoid valve. Disconnect the connector (2) on the solenoid valve and disconnect the ground wire (3) from the DSG console. Remove any static charge by touching the body ground with your bare hand, then turn the DSG connector lock (4) and disconnect it.
5.24 Starter wiring
25. Disconnect/release all other interfering engine and transmission wiring. Remove the vacuum line from the brake booster.
26. Install the T40074 engine support on the VAG1383A transmission jack, remove the T40074/1 adapter from it and secure this adapter to the cylinder block with a nut (1 on the accompanying illustration). Then lift the support and reattach the adapter (2) to it.
5.26 Support T40074 on transmission jack
27. Secure the T40074 support to the exhaust side of the cylinder block by tightening the bolts (arrows in the accompanying illustration) with a force of 20 Nm. Slightly raise the power unit on the transmission jack. Make sure that all hoses, pipes and wires between the engine, DSG and the body are disconnected.
5.27 Fastening the T40074 support on the exhaust side of the cylinder block
28. Using a stepladder, loosen the bracket mounting bolts on the engine (see illustration 5.28a), and then the bracket mounting bolts on the DSG (2 in illustration 5.28b). With the help of an assistant, pull the power unit forward as far as possible, and then lower it on the jack, being careful not to damage the power unit or engine compartment components. Guide the power unit if necessary. Separate the transmission from the engine (see Chapter 7) and fix it on the mounting stand.
5.28a Engine Bracket Bolts
5.28b DSG bracket bolts
Installation
Note: Place the hoses and wiring in the same position as they were before removal; install all clamps and ties in their original places. Tighten fasteners, depending on the thread, with the following forces: M6 - 9 Nm, M7 - 13 Nm, M8 - 20 Nm, M10 - 40 Nm, M12 - 70 Nm.
29. Before installation, the crankshaft needle bearing should be replaced (see Section 14).
30. Installation is carried out in the reverse order. Please note the following features.
31. Use new self-locking nuts and bolts that require tightening to a certain angle. Use new seals and gaskets.
32. Make sure that the transmission centering bushings are inserted into the cylinder block. Secure the transmission to the engine (see Chapter 6 or 7).
33. Secure the power unit to the transmission jack, move it into the engine compartment and screw in the new power unit bracket mounting bolts by hand. Adjust the brackets and tighten the mounting bolts (see subsection below).
34. Secure the driveshaft (see Chapter 8), install the rocking support (see subsection below) and drive shafts (see Chapter 8).
35. Install the refrigeration compressor and accessory drive belt.
36. Attach the selector cable to the DSG.
37. Place the engine wiring harness and connect it to the ECM.
38. Install the exhaust pipe.
39. Connect the battery wiring.
40. Check and, if necessary, adjust the engine oil level.
41. Fill the engine cooling system (see Chapter 3).
42. Clear all fault codes from the ECM memory that occurred during engine removal/installation and verify that the ECM has generated a readiness code.
43. Perform a road check (see Chapter 1) and fix any errors found.
Checking and adjusting the powertrain supports
44. The details of the support fastenings are shown in the accompanying illustrations.
5.44a Engine bracket mounting bolts, subject to replacement
A 20 Nm, then tighten to an angle of 90°
At 40 Nm, then tighten to an angle of 90°
From 60 Nm, then tighten to an angle of 90°
5.44b DSG bracket mounting bolts, subject to replacement
A 40 Nm, then tighten to an angle of 90°
At 60 Nm, then tighten to an angle of 90°
5.44c Swing support mounting bolts, subject to replacement
A 40 Nm (class 8.8) or 50 Nm (class 10.9), then pull it to a 90° angle
At 100 Nm, then tighten to an angle of 90°
45. To check the installation of the bracket, measure the distance (and in the accompanying illustrations) between the bracket and the support, - it should be 10-13 mm. The cast edge of the support (2) should be parallel to the support arm (1), i.e. the distance (x) should be the same at the front and rear. If the engine or transmission hits the side member when turning and the distance (a) is not 10-13 mm, adjust the bracket as described below.
5.45 Checking the installation of the right bracket
46. Remove the air cleaner together with the hose going to the throttle module (see Chapter 4). Unscrew the bolts (see illustration 5.7) and remove the air cleaner bracket.
47. Remove the front bonnet bumpers from the top sides of both front fenders. Insert the T10311 plates on the right (And on the accompanying illustration) and left (B) sides in the direction of the arrows until they stop so that the arrows "R" and "L" on the plates point to the rear. These plates are needed to prevent damage to the wings.
5.47 Installing protective plates
48. Install the MP9-200 support with the MP9-200/3 and MP9-200/18 adapters (see accompanying illustration). The heel of the support should rest against the buffers (1) and be located on top of the side beam (2). Evenly unload the power unit supports by rotating both spindles.
5.48 Unloading the power unit supports
49. Loosen the bolts (arrows in illustration 5.28a) fastening the right bracket and slightly (less than 1 turn) loosen the bolts (2 in Figure 5.28 B) fastening the left bracket.
50. If the bracket bolts were not yet replaced when installing the engine, screw in the new bolts one by one.
51. Move the power unit using a lever installed between the support lever (1 in illustration 5.45) and support (2) so that the distance (a) is 10 mm and the distance (x) is the same at the front and rear. Tighten the bracket bolts (see illustrations 5.44a-b).
52. Install the remaining parts.