Instructions: The engine is removed together with the gearbox downwards. After installing the engine, it is necessary to reinstall all cable ties that were removed or cut during dismantling.
ATTENTION: When performing installation work, especially in the engine compartment due to its dense layout, the following rules must be observed. All types of lines (for example, fuel, hydraulic, activated carbon absorber, cooling system, air conditioning system circuit, brake system, vacuum), and electrical wires must be laid as they were originally laid. Sufficient space must be provided when working with all moving or heated components.
With the ignition off, disconnect the ground wire from the battery. Remove the battery and battery mounting platform. Remove the engine casing. Remove the air filter housing with the air flow meter and connecting pipe. Remove the fuel filter and additional fuel pump "V393". Pump out the refrigerant from the air conditioning circuit. Remove the sound-absorbing pan. Remove the windshield wiper arms. Remove the water drain box casing. Remove the plastic cover above the engine control unit. Bend the protruding ends "1" of the retaining bracket outward. Unscrew the shear bolts "2" with a hand vice and remove the retaining bracket.
Disconnect the "arrow" wiring harness connector from the engine control unit.
Unlock the cable channel clamps on the side member. Disconnect the electrical connector "arrow" of the engine wiring harness below the left headlight. Remove the engine wiring harness from the cable channel and place it on the engine.
Disconnect connector "1" and unscrew ground cable "2" from the side member.
Unscrew the positive starter cable "arrow" from the on-board network control unit and place it on the engine.
With dual clutch transmission
Remove the control lever from the gearbox. Unlock the Mechatronic connector lock "arrow" by turning and disconnect the connector.
With manual transmission
Remove the control lever from the gearbox. Remove the hose line or plastic line from the clutch slave cylinder.
With automatic transmission
Remove the control lever from the gearbox. Disconnect connector "3" on the gearbox. Ignore positions 1 and 2.
Disconnect the "arrow" connector from the starter.
Disconnect connectors "1" and "2" and unscrew the screws securing the pipelines to the gearbox oil cooler "3". Disconnect the pipelines from the gearbox oil cooler, collect the leaking oil.
All
Unscrew the pipelines of the air conditioning system "arrow" from the air conditioning compressor.
Disconnect connector "1", loosen clamp "2" and disconnect the connecting hose. Remove the boost pressure control valve from the front wall of the water drainage box and place it together with the vacuum lines on the engine. Disconnect the vacuum line from the vacuum pump. Remove the subframe with the steering gear. Disconnect the drive shafts from the gearbox.
Remove the diesel particulate filter.
All-wheel drive vehicles
Remove the rear part of the exhaust system. Remove the rear axle drive shaft.
All
Drain the coolant. Disconnect the lower boost air pipes from the intercooler. Disconnect the quick-release fittings on the radiator. Disconnect the quick-release fittings from the "arrow" heat exchanger on the front wall of the water drain box. Remove the sound insulation from the oil pan. Unscrew the screws securing the boost air pipe leading to the air damper and remove it.
Unscrew the screw securing the "arrow" of the coolant bleeding system pump after turning off the engine.
Fasten the bracket "T10012" to the cylinder block using a nut and bolt M10x25, strength class 8.8, tightening torque 40 Nm. Install the bracket "T10012" on the tilter -VAG 1383 A-. Slightly lift the crankshaft unit using the tilter -VAG 1383 A-.
Instructions: Unscrew the mounting bolts from the stepladder -VAS 5085-.
Unscrew the bolts from above that connect the power unit support on the engine side to the "arrow" engine support.
Unscrew the bolts from above that secure the power unit support to the gearbox bracket "arrows".
Carefully lower the engine from the gearbox.
Instructions: Lower the power unit carefully to avoid damage to the body.
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