Raise the engine cover at points -1 -and remove the engine cover by moving it forward in the -direction of the arrow-.
Unscrew heat shield above turbocharger -arrow-. Remove air filter.
Open and close the expansion tank cap to relieve pressure in the cooling system. Drain coolant. Unlock hose guides -arrows- and detach coolant hose -1- from coolant filler.
Detach hose -2- from activated charcoal filter solenoid valve 1 -N80- to activated charcoal filter. Disconnect fuel supply line -1- and line to activated charcoal filter -2-. To do this, press the release buttons. To prevent contamination from entering the fuel system, plug the openings of the fuel lines. Comply with cleanliness standards. Depending on the vehicle equipment, remove the noise insulation or the underrun protection bar. Remove the front right and left fender liner. Move radiator frame to service position. The engine is removed together with the gearbox down. Disconnect battery. Remove the battery and battery holder frame. After installing the motor, it is necessary to reinstall all cable ties that are removed or cut off during dismantling. Disconnect all wires from gearbox, alternator and starter and lay them aside. Disconnect all other wires from the engine that need to be disconnected and set them aside.
WARNING: The fuel in the pressure line is under pressure!
Disconnect the vacuum and ventilation hoses from the engine; Disconnect the connector from the thermal switch and radiator fan. Remove wiper arms. Remove the plenum box cover. Removal and installation of the anti-theft engine control unit. Unlock all line route locks -arrows-.
Remove wiring from engine control unit. Secure the wiring to the motor with a cable tie. Remove wiring for lambda probe downstream of catalytic converter -G130- and alternator from line routing arrows-.
Remove connector for lambda probe downstream of catalytic converter -G130-. Remove lambda probe after catalytic converter -G130- -1-. Release hose clamp -3- and remove charge air connection -2-. Unscrew exhaust pipe at main catalytic converter -arrows-.
Remove both drive shafts. Unscrew securing bolts -1- and -2- for exhaust pipe support. Pull down the exhaust pipe support.
Unscrew the nuts of the double clamp -arrows- and move it forwards along the exhaust pipe -1-.
Unscrew nuts -arrows- and pull exhaust pipe back. Press exhaust pipe back out of hanger -1-.
Unscrew rocker support -arrows-.
Unscrew the fastening bolts for the cardan shaft on the bevel box. Press the cardan shaft to the side. Lower the subframe. Remove the exhaust pipe towards the front. Remove gearbox bracket from bevel box. Unscrew the gearshift drive from the gearbox. Detach hose -1- for hydraulic clutch slave cylinder.
Instructions: Do not press the clutch pedal.
Removing the V-ribbed belt. Remove air conditioner compressor.
Instructions: The lines of the air conditioning system must not be opened.
Attach the air conditioner compressor to the radiator frame. Check that the hoses are not pinched. Observe additional notes and assembly work. Move radiator frame to service position. To be able to lower the engine with gearbox, engine bracket -T40075A- with adapters -/4-, -15- and -/6- is required.
Screw adapter T40075A/4 into the engine crankcase as far as it will go. Fit engine bracket -T40075A- with adapters -15- and -/6- to crankcase.
Fasten engine bracket -T40075A- with hand-tight screw into engine crankcase.
Tighten all screws on engine bracket -T40075A- to 20 Nm. Raise power unit slightly with engine and gearbox jack -VAG 1383 A-.
Unscrew the assembly support on the engine side from above -arrows.
Unbolt assembly support on gearbox side from above -arrows-.
Instructions: Use a ladder -VAS 5085- when loosening the securing bolts. Raise the power unit carefully to avoid damage to the body.
Carefully lower the engine and gearbox down.
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