Unscrew heat shield above turbocharger -arrows-. Remove air filter.
Open and close expansion tank cap to relieve pressure in cooling system. Drain coolant.
Instruction: Detach coolant hoses from engine using clamp pliers -VAS 6340-.
Unlock hose guides -arrows- and detach coolant hose -1- from coolant expansion tank.
Detach hose -2- from activated charcoal filter solenoid valve 1 -NBD- to activated charcoal filter.
WARNING: The fuel in the pressure line is under pressure!
Disconnect fuel supply line -1- and line to activated charcoal filter -2-. To do this, press the locking tabs. To prevent contamination from entering the fuel system, plug the openings of the fuel lines. Follow the rules for maintaining cleanliness. Depending on the vehicle's equipment, remove the noise insulation or the underride guard. 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 terminals. Remove the battery and battery holder frame. When installing the engine, it is necessary to reinstall all cable ties that are removed or cut off when removed, in the same places. Disconnect all wires from gearbox, alternator and starter and move clear. Disconnect all other wires from the engine that need to be disconnected and set them aside. Disconnect the vacuum and vent hoses from the engine. Remove the temperature sensor and radiator fan connector. Remove wiper arms. Remove the water box cover. Remove engine control unit -J623-. Unlock all retainers of cable box -arrows-.
Remove wiring from engine control unit. Secure the wiring to the motor with a cable tie. Pull out lambda probe wiring after catalytic converter -G130- and alternator wiring duct -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 catalytic converter -arrows-.
All wheel drive vehicles
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 slide it forward along the exhaust pipe.
Unscrew nuts -arrows- and pull exhaust pipe back.
Press exhaust pipe back out of hanger -1-. 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
Front wheel drive vehicles
Unscrew exhaust pipe with split piece -arrows-.
Loosen double bracket bolts -arrows- and pull exhaust pipe back.
Continuation for all cars
Unscrew pendulum support -arrows-.
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. Do not kink lines. Observe additional notes and assembly work. To lower the engine with gearbox, you will need the T40075A- engine bracket with -/4-, -/5- and -/5- adapters.
Screw adapter Т40075А /4 into the engine crankcase as far as it will go. Fit engine bracket -T40075A- with adapters -/5- and -/6- to crankcase.
Attach engine bracket -T40075A- to engine crankcase using bolt -1- hand-tight.
Tighten all bolts on engine bracket -T40075A- to 20 Nm. Raise power unit slightly with engine jack -VAG 1383 A-.
Unbolt the assembly support on the engine side from above -arrows-.
Unbolt assembly support on gearbox side from above -arrows-.
Raise the power unit carefully to avoid damage to the body. Carefully lower the engine and gearbox down.
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