Remove the trunk tray "3". Remove the Bassbox "2" if present. Unscrew the floor covering "1" above the lid.
Unlock the "arrow" fasteners and install cover "1".
Open cover "1" above the negative pole of the battery. Unscrew the nut a few turns and remove the pole tip "arrow" of the ground cable from the battery terminal.
Remove the engine casing "arrows". When the engine is warm, the cooling system is under excess pressure. To relieve excess pressure, place a rag around the coolant expansion tank cap and carefully open it. Open the expansion tank cap. Remove the front wheels: right and left. Remove the front right and left fender liner.
Remove noise insulation screens "1" and "2"
Install the tray for the service taps "VAS 6208" under the engine. Screw the drain tap "1" onto the nipple and drain the coolant, then remove the nipple "2" from the radiator, to do this, lift the clamp bracket.
Disconnect the hose clamp "arrow", remove the air duct hose and set it aside.
Loosen the "arrow" nut on the right side member and release the ground cables.
Unscrew the exhaust pipe "arrow" nuts.
Unscrew the threaded connections "arrows", move the clamping sleeve back and remove the exhaust pipe.
Unscrew the threaded connection "1".
"Pos. 2" should not be taken into account.
Disconnect the "arrow" connector from the steering gear.
Remove cover "1" from the bottom of the "arrow" gearbox.
Remove the cover from the vibration damper. Unscrew the 3 bolts "arrow" of the driven disk, to do this, turn the crankshaft accordingly through 120° in the direction of engine rotation.
Unscrew the bolts "1,7,8, 9,10" engine and gearbox connections. "Pos. A" should not be taken into account. Risk of damaging a previously used poly V-belt when changing its running direction. For reinstallation, before removing the poly V-belt, mark its running direction with chalk or a felt-tip pen. Turn the tensioner "in the direction of the arrow", remove the poly V-belt from the air conditioning compressor pulley and secure the tensioner with the "T40098" lock. Remove the poly V-belt.
Disconnect and release plug connectors "1" and "2". Unscrew the "arrow" bolts of the air conditioner compressor. Do not overtighten, bend or flex the refrigerant lines and hoses. Tie the compressor with the connected lines to the side. Do not take "Pos. 3" into account.
Remove the electrical connector "1" of the radiator fan from the bracket, to do this, move the lock back "arrow" and press the stopper down. Release the electrical cables to the radiator fan control unit.
Unscrew the bolt "arrow" and put aside the control unit "1" of the radiator fan. "Pos. 2,3" do not take into account.
Unscrew the "arrow" bolts, while holding the central bolt. Remove the vibration damper.
Unscrew the "arrow" bolt and remove the intermediate roller.
Unscrew the bolts "arrows" and put the fastener "1" back. In the figure, the engine compartment is shown from below in the direction of the turbocharger.
Remove the coolant hoses by loosening the fastening clamps "1" and "3". Ignore "Pos. 2" and "arrows".
Loosen the clamps for the "arrow" hose and remove the air duct hose. Disconnect the plug connector of the boost pressure sensor "pos. 1" and release the connector.
Unscrew bolt "1". Ignore "Pos. 2, 3".
Loosen nut "3" and disconnect plug connector "1". Remove EGR radiator pump "V51" "pos. 2" with bracket and set aside with coolant hoses connected.
Unscrew the double bolt "2" and pull the coolant pipe "1" with the connected coolant hoses "in the direction of the arrow".
Unscrew terminal 30/V+ "pos. 1". Disconnect electrical connector "2".
Unscrew the bolts "arrows". If the generator jams in the bracket, screw the mounting bolts back in up to 2 turns. Carefully tap the flat end of the hammer on the head of the bolt - this way you can loosen the generator mounting bushings. Remove the generator "1" by pulling the coolant pipe to the side.
Unscrew the bolts "arrows" and remove the pulley of the poly-V belt of the general hydraulic power steering pump.
Unscrew the "arrow" bolts and secure the pump with the connected hydraulic lines to the side at the top.
Remove the coolant hose by loosening the fastening clamp "2". Ignore "Pos. 1".
Unscrew bolt "1" and remove tension element "2" of the poly V-belt "arrow".
Release the "arrow" clamps and remove the toothed belt protective cover.
Remove the air duct "arrow".
Disconnect the plug connector "3" of the air flow meter "G70". Remove the air duct hose from the air flow meter "G70", loosening the clamp "4" for this. Disconnect the vacuum hose "arrow". Remove the air filter housing "2", on the reverse side disconnect (if available) plug connector "1" of the air intake switching valve "N335".
Disconnect the supply "1" and return "2" fuel lines.
Unscrew bolts "1" and nuts "2", remove the tensioner.
Remove the foam elements "1" and "2" from the left and right in an upward direction.
Remove seal "3". Release fastening clamps "1" from fasteners and remove water drainage box cover "2".
Unlock the lock "arrow A" and open the cover "arrow B".
Unscrew nuts "1...3" of the electrical wires. Remove the electrical plug connection "4" from the holder and disconnect it. Unscrew bolt "5" and remove the 2-key 30 "TV22" branch pipe from the front wall of the "arrow" water drainage box.
Unlock the wheel arch latches with a 5.5 union wrench "pos. 1" and remove the cable gland "2" in the upward direction. Release the wiring harness "3" going to the alternator and starter with the "80-200" release lever.
Release the cable channel by unlocking the lock "arrow B" and pulling the cable channel upwards "arrow A".
Remove the vacuum pipe "1" from the end wall of the water drain box, to do this, disconnect the vacuum hose "2" on the back side of the "arrow".
Unscrew bolt "2" and nut "3". Remove filler neck "1" with filler tube from washer reservoir, passing it through body opening "arrow".
Unscrew nut "5" and release the ground wire. Unscrew bolts "1,2,4" and remove cover "3" of the switching unit of the engine compartment "arrow".
Remove the clamps "arrow A" and open the cover "arrow B" of the engine control unit.
If present, disconnect electrical connector "2". Disconnect plug connectors "4" and unscrew electrical wiring "3". Unlock the "arrow" latches and remove fuse block B "SB" "pos. 1". Remove and release the engine wiring harness secured in the switching block.
Unlock the clamps "arrow A" and remove the cable guide "2" in the upward direction "arrow B". Release the wiring harness, place it on the engine and secure the engine control unit from falling. Ignore "Pos. 1".
Remove vacuum hose "6". Unscrew nut "1". Disconnect coolant hoses by loosening hose clamps "2" and "5" and pressing fastening brackets "4" and "3". Remove front wall of water drainage box.
Disconnect and release plug connector "1" of lambda probe "G39" and connector "2" of temperature sensor before particulate filter. Disconnect electrical connector "3" of exhaust gas pressure sensor 1 "G450". Do not take "Pos. 4" into account.
Unscrew nuts "1", remove bracket "2" and put aside together with exhaust gas pressure sensor 1 "G450".
Unscrew nuts "1, 2, 3" of the turbocharger and put the particulate filter back.
Disconnect and release the plug connector "2" of the reversing light switch "F4". "Pos. 1,3" is not taken into account.
Unfasten the electrical wire "A" from the gearbox and disconnect the electrical connector "C". Ignore "Pos. B".
Unscrew bolts "2...6" connecting the gearbox and engine. Disconnect the starter from the gearbox and leave it in the mounting position. "Pos. A" is not taken into account. Bolt "2" secures the starter to the gearbox and has an additional spacer sleeve "arrow".
Install the crossmember "10-222 A" on the shock absorber cups on the left and right, as shown in the figure. Connect the gearbox and the lead screw with the cargo clamp "10-222 A/12" and the additional hook "10-222 A/2". For a better idea, the installation position is shown with the engine removed. Slightly tighten the engine using the crossmember lead screw.
Remove the eye of the hanging device "2024 A" by disconnecting the pin and pressing in the bolt. Reinstall the eye in the 4th hole at the front of the hanging device. Secure the bolt with the pin. Hang the hanging device "2024 A" on the engine and the service crane "VAS 6100" as shown in the figure. The hooks and locking pins of the hanging device must be secured with stoppers.
Unscrew the bolts "1" of the engine mount on the left and right. Unscrew the nut "2" and remove the wiring bracket. Ignore "Pos. 1" and "arrow".
Raise the engine enough to release the engine mounts. Tighten the lead screw of the crossmember "10-222 A". Risk of damage to hose and wire connections, as well as the engine compartment. Make sure that all hose and wire connections between the engine, gearbox, subframe and body are disconnected. When removing the engine, carefully remove it from the engine compartment.
During engine removal, the second mechanic must carefully open the hood, ensuring the maximum opening angle. To do this, slightly pry the locking spring "arrow" on the left and right with a small screwdriver and remove the gas-filled shock absorber "1" from the top of the ball joints "2". Disconnect the engine from the gearbox and lift it up from the engine compartment. Reinstall the gas struts on the ball joints.