Caution! When installing a new, incomplete engine, it is essential to tighten the clamping brackets of the injection modules to the specified tightening torque after installing the high-pressure lines. To align the injection modules when installing the high-pressure lines, the clamping brackets are only screwed in as far as they will go upon delivery. Failure to comply may result in engine damage. The engine is removed without the gearbox upwards. When reassembling, install all cable ties in the locations where they were originally installed.
Turn off the ignition. Disconnect the ground wire "arrow" from the battery terminal.
Remove the engine cover "arrows".
Open the expansion tank cap. Remove the front wheels on the left and right. Remove the front right and front left fender liner.
Remove noise insulation screens "1" and "2".
Front-wheel drive vehicles: Move the lock mounting beam to the service position.
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Install the tray for the service taps "VAS 6208" under the engine. Screw the drain tap "1" to the nipple and drain the coolant, then remove the nipple "2" from the radiator by lifting the fastening bracket. Release the coolant hose on the side member.
Remove the air duct hose and push it to the side; to do this, loosen the "arrow" clamp.
Unscrew the exhaust pipe "arrow" nuts.
Vehicles with SCR catalytic converter: Disconnect electrical plug connection "2" and release the electrical wire. Disconnect clamp "3" and remove reducing agent injector "N474". Ignore "Pos. 1".
Release the exhaust pipe at the mount "2". Ignore "Pos. 1".
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Unscrew the threaded connections "arrows", move the clamping sleeve back and remove the exhaust pipe.
Unscrew bolt "2" of the diesel particulate filter hanger. Ignore "Pos. 1".
Disconnect the electrical plug connection "arrow" from the steering gear.
Front-wheel drive vehicles: Unscrew bolts "1" and remove the front engine mount. Unscrew bolts on the left and right "2" and remove the crossmember.
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Remove cover "1" from the bottom of the "arrow" gearbox.
Remove the cap from the vibration damper. Unscrew the 3 bolts "arrow" of the driven disk, to do this, turn the crankshaft by the central bolt of the vibration damper in increments of 120° in the direction of engine rotation.
Cars with manual transmission: Unscrew the bolts "1, 7, 8, 9, 10" engine and gearbox connections. "Pos. A" should not be taken into account.
Cars with dual-clutch gearbox 0B5: Unscrew bolt "1" of the starter. Remove the starter from the gearbox and leave it in the installation position. Unscrew the remaining bolts "6...9" securing the gearbox to the engine. Do not take "Pos. A" into account.
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Turn the tension element clockwise "arrow", remove the compressor V-belt from the pulley and secure the tension element with the "T40098" lock. Remove the poly V-belt.
Disconnect the electrical plug connections "1" and "2" and release the electrical wires. Unscrew the air conditioner compressor "arrow" bolts. Tie the compressor with the connected lines to the side. Do not take "Pos. 3" into account.
Vehicles with dual clutch transmission 0B5: Disconnect electrical plug connection "2" of oil level and temperature sensor "G266". Disregard "Pos. 1".
Install a device for pumping out and collecting waste oil under the disconnection points. Unscrew the union nuts "1" and "2". Unscrew the bolts "arrows" of the ATF lines.
Unscrew the bolt "arrow", disconnect the ATF lines "1,2" from the gearbox and push aside. Close the open lines and pipes with clean plugs from the plug kit for the "VAS 6122" engine.
Caution! Risk of damage to the gearbox control unit (Mechatronik) due to static discharge. Therefore, before working with electrical plug connections, it is necessary to "remove the electrostatic charge" from the mechanic. To do this, simply touch the car body, heater or lift with your hand. Do not touch the contacts of the gearbox plug with your hands.
Disconnect the electrical plug connection from the gearbox by turning the rotary lock counterclockwise "arrow". Release the bundle of electrical wires.
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Remove the electrical plug connection "1" of the radiator fan from the mount, to do this, move the lock back "arrow" and press the stopper down. Release the bundle of electrical wires of the radiator fan control unit.
All-wheel drive vehicles: Unscrew the bolt "arrow", unlock the retainer and put aside the radiator fan control unit "J293" "pos. 1". Ignore "pos. 2, 3".
Unscrew the "arrow" bolts, while holding the central bolt. Remove the vibration damper.
Remove the intermediate roller cap. Unscrew the "arrow" bolt and remove the intermediate roller.
Unscrew the "arrow" bolts and put the "1" fastener back.
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Unscrew the "arrow" nut on the right side member and release the ground wires.
Remove the coolant hoses by loosening the fastening clamps "1" and "3". Ignore "Pos. 2" and "arrows".
Remove the air duct hose by loosening the hose clamps "arrows". Disconnect the electrical plug connection of the boost pressure sensor "G31" / intake manifold air temperature sensor "G42" "pos. 1" and release the electrical wire.
Car with all-wheel drive: Unscrew bolts "1,2". Remove the coolant hose by loosening the hose clamp "3".
Unscrew terminal 30/V+ "pos. 1". Disconnect electrical plug connection "2".
Unscrew the bolts "arrows". Remove the generator "1", for which the coolant pipe at the top left is pressed aside. If the generator is jammed in the holder, screw the bolts back in up to 2 turns. Carefully tap the flat end of the hammer on the bolt head, this way you can loosen the generator mounting bushings.
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For reinstallation, mark the position of the poly V-belt pulley of the vane pump in relation to the hub "arrow".
Unscrew the "arrow" bolts and remove the poly-V belt pulley of the vane pump.
Unscrew the "arrow" bolts and tie the vane pump with the connected hydraulic lines to the side.
Remove the coolant hose by loosening the fastening clamp "2". Ignore "Pos. 1".
Car with all-wheel drive: 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.
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Remove the air duct "arrow".
Disconnect the electrical plug connection "3" of the air flow meter "G70". Remove the air duct hose from the air flow meter "G70" by loosening the hose clamp "4". Disconnect the vacuum hose "arrow". Remove the air filter housing "2" and, if present, disconnect the electrical plug connection "1" on its back from the air filter bypass flap valve "N₂75".
Disconnect the supply "3" and return "1,2" fuel lines.
Remove the stretch.
Remove the foam elements "1" and "2" from the left and right in an upward direction.
Remove the gasket "3". Release the fastening clamps "1" from the fasteners and remove the cover of the water drainage box "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 distributor 2 cl. 30 "TV22" from the front wall of the water drainage box "arrow".
If present, disconnect the electrical plug connection from the brake booster pressure sensor "G294" "arrow".
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 bundle of wires "3" to the generator and starter with the push-up lever "80-200".
Open cable channel "1" by unlocking the "arrow" lock and releasing the bundle of electrical wires.
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".
Unlock the clamps "arrow A" and remove the engine control unit "arrow B".
Disconnect (if available) el. plug connection "2". Disconnect el. plug connections "4" and unscrew el. wire "3". Unlock latches "arrow" and remove fuse block B "SB" "pos. 1". Disconnect and release the motor wire harness from the switching block.
Unlock the clamps "arrow A" and remove the cable guide "2" in the upward direction "arrow B". Release the bundle of wires, place it on the engine and secure the engine control unit from falling. Ignore "Pos. 1".
Cars without independent heater: Unscrew nut "5". Remove coolant hoses, to do this, loosen fastening clamps "1,2". Route coolant hoses through the front wall of the water drain box.
Cars with independent heater: Unscrew nut "3". Remove coolant hoses by loosening hose clamps "1,2". Route coolant hoses through the front wall of the water drain box and release them.
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Remove the front wall of the water drainage box. Disconnect the electrical plug connection "3" of the differential pressure sensor "G505". Unscrew the bolt "2" and release the hoses "1" from the holder. Put the differential pressure sensor "G505" back.
Release the bundle of electrical wires "arrow". Unscrew the nuts "1" and remove the holder "2".
Remove from the holder and disconnect the electrical plug connections.
3. Lambda probe "G39"
4. Exhaust gas temperature sensor 3 "G495"
"Pos. 1, 2" do not take into account. Remove the lambda probe "G39" "pos. 1".
Unscrew the "arrow" nuts and put the particulate filter back.
Vehicles with manual transmission: Disconnect the electrical plug connection "2" from the reversing light switch "F4" and release the electrical wire. "Pos. 1,3" do not take into account.
Unclip the electrical wire from the gearbox and disconnect the electrical plug connection "C". Ignore "Pos. B".
Disconnect the electrical plug connection "arrow" from the neutral gear sensor "G701" and release the electrical wire.
Unscrew bolts "2...6" connecting the gearbox and engine. Remove 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 strut cups on the left and right, as shown in the figure. Secure the gearbox mount "3147" to the gearbox and, using the additional hook "10 - 222 A/2", to the hook "10 - 222 A/10". For better representation, the installation position is shown with the engine removed.
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Slightly tighten the engine using the lead screw of the crosshead. Remove the eye of the suspension device "2024 A" by disconnecting the stud and pressing in the bolt. Reinstall the eye in the 4th hole at the front of the suspension device. Secure the bolt with the stud. Suspend the suspension device "2024 A" on the engine and the service crane "VAS 6100" as shown in the figure.
Unscrew the bolts "1" of the engine mount on the left and right. Unscrew the nut "2" and release the holder with the electric wires. If present, remove the left and right electric plug connection "arrow" from the holder and disconnect them. Raise the engine enough to release the engine mounts. Tighten the lead screw of the crossmember "10 - 222 A" further. Risk of damage to the 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. Exercise caution when removing the engine from the engine compartment. When removing the engine, the second mechanic must carefully open the hood, ensuring the maximum opening angle. To do this, lightly 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 upwards from the engine compartment. Press the gas-filled shock absorbers back into the ball joints.
(Information obtained from this resource AudiManual.ru)