Withdrawal
Instruction. The engine is removed together with downwards. All cable clamps that are removed or cut during dismantling must be reinstalled in the same places during installation. The battery is located in a hidden niche in the trunk.
Switch off the ignition and remove the key from the ignition switch.
Disconnect earth wire -arrow- from battery. Remove the hood.
Attention! When opening the coolant can, hot steam or hot coolant may come out, cover the lid with a cloth and carefully open it.
Open cap -arrow- of expansion tank. Remove front wheels. Remove noise insulation -arrows-. Place a pallet for service cranes -VAS 6208- under the engine. Unplug electrical connector -1- for coolant temperature gauge sender at radiator outlet -G83-. Detach lower coolant hose -arrow- from radiator and drain off coolant.
Detach coolant hose -arrow- from oil cooler, fold down and drain remaining coolant.
Remove all nuts -arrows- from the exhaust system to the turbocharger.
Instruction. The detachable element must not be bent more than 10°. Danger of damage!
Support the detachable element with the retainer -T40035-. Unscrew heat shield for exhaust system -arrows-.
On vehicles with a detachable exhaust system, loosen the nuts on the adapter sleeve -4- and push the adapter sleeve back to release the exhaust system.
On vehicles with a non-detachable exhaust system, cut the exhaust pipe at a right angle at the connector -2- using a chain pipe cutter -VAS 6254-. Pos. -1- and -3- are ignored.
Loosen bolt -1- of suspension arm strut -2-.
Unscrew heat shield for left drive shaft -arrows-. Unbolt the left drive shaft from the gearbox flange shaft and hang it up. Remove right drive shaft.
Vehicles with code letter AMF
Detach air hose -6- from turbocharger. Detach hoses -5- for charge pressure control from turbocharger and charge pressure control air element. Disconnect ventilation hose -4-. Remove bolts -3- and remove air pipe from turbocharger.
Instruction. The air guide tube remains in the installation position and can be removed upwards later. Pos. -1- and -2- are ignored.
Vehicles with letter designation ATL, BHC
Remove the vacuum hose -1st of the boost pressure control vacuum element and set it aside. Loosen bolts -2- and remove air duct from turbocharger. Detach air hose -3- from turbocharger.
Instruction. The air guide tube remains in the installation position and can be removed upwards later.
Bracket for air pipe removed from oil sump -arrows-.
Remove right air hose -2nd intercooler. Pos. -1- ignore. Unplug electrical connector -arrow- for oil level and oil temperature sender -G266-. Unfasten electrical wiring.
Instruction. Depending on the version, the oil level and oil temperature sender -G266- can be located at the front on the oil sump.
If present, unfasten the bracket. Remove engine cover -arrows-. Remove the sound insulation underneath.
Pry up caps -3 and 4- of both parts of wiper arm with a screwdriver. Loosen the nuts on both parts of the wiper arm with a few turns. Alternately loosen wiper arms -1 and 2- on axles by lightly rocking them. Completely unscrew the nuts and remove both parts of the wiper arm.
Instruction. If it is not possible to remove the lever in this way, then in this case it is necessary to use a standard puller.
Disconnect washer fluid pipe -3-. If fitted, unplug electrical connectors -4 and 5- for heated washer jets. Loosen hose clamp -6- using hose clamp pliers -VAG 1921- and remove drain hose from deflector grille. Remove rubber seal -1- from deflector grille. Remove air vent grille -2-.
Remove nuts and bolts -arrows-. Pull the fresh air duct forward and remove it by turning it towards the right side of the vehicle.
Vehicles with code letter AMF
Detach air/water hose -2- from mechanical exhaust gas recirculation valve. Detach vacuum hose -3- from mechanical exhaust gas recirculation valve. Detach vacuum hose -4- for air intake manifold flap vacuum unit. Pos. -1- ignore.
Detach air hose -2- from intercooler.
Vehicles with code letter ATL
Shine off air hose -3- from intake manifold flap motor -VI57-. To do this, loosen clip -2- slightly. Detach vacuum hose -1- from mechanical EGR valve.
Detach air hose -2- from intercooler. Unplug electrical connector for charge pressure sender -G31- pos. -1-.
Attention! Risk of burns from contact with fuel lines or fuel heated to 100°C. Wait until the fuel has cooled down before opening the fuel line connections.
Mark and disconnect fuel pre-supply line -2- and fuel return line -1-. Unfasten the fuel lines.
Detach air hose -1- from air mass meter -G70-. Unplug electrical connector -3- for air mass meter -G70-. Loosen nut -2-. Remove hose -4- for crankcase breather from cylinder head cover. Pull out air pipe together with air mass meter -G70-.
If fitted, unplug electrical connector -arrow- for crankcase breather heating coil -N79-. Remove the air guide pipe.
Vehicles with code letter ATL
Unplug electrical connector -arrow- for intake manifold flap motor -VI57-. Unfasten electrical wiring.
Remove the dipstick from the guide tube. Remove guide tube for oil dipstick -1-. Remove oil filler tube -2- from oil filler tank.
Remove drain hose -2-. Remove water tank -1-.
Remove upper left coolant hose -pos. 1 and 2-.
Disconnect the engine coolant hose -arrow- from the front connector.
Pull coolant hose out of bracket -1- and remove. Pos. -2- ignore.
Mark coolant pre-flow hose -1- and coolant return hose -2- to heater heat exchanger and remove coolant hoses from bulkhead.
Vehicles with letter designation ATL, BHC
Detach vacuum hose -1-.
Detach vacuum hose -2- from tandem pump to brake servo. Unfasten the vacuum hoses.
Detach coolant hoses from expansion tank -arrows- and unclip upper coolant hose.
Open cable tie -2- and remove cover -3- from solenoid -1- upwards.
Unplug electrical connector -4- for reversing light switch -F4-. Unfasten electrical wiring. Disconnect plug connector from terminal 50 -pos. 3 - solenoid starter relay. Loosen nut -2- and remove B+ wire. Loosen nut -1- and remove ground wire.
Unplug electrical connector -1- for air conditioner compressor solenoid clutch. -arrows- disregard.
Disconnect plug connector from terminal D+ -pos. 1- generator. Unplug electrical connectors -2- for glow plugs. Pull out the release pin and unscrew the knurled nut -3- of the central connector of the unit injector modules.
Unplug electrical connector for Hall sender -G40- pos. -4- and engine speed sender -G28- pos. -5-. Unplug electrical connector -6- for oil pressure sender -F1-. Unplug electrical connector -7- for fuel temperature sender -G81-.
Unplug electrical connector -arrow- for coolant temperature gauge sender -G62-.
Unbolt bracket for wiring harness from coolant connection -arrow-. Unfasten the wiring harness to the engine.
Remove cross support -A-, to do this unscrew nut -1- and bolt -2-.
Unbolt cable carrier -arrows- from gearbox.
Carefully! The cable retainers must not be removed with the selector shaft lever or intermediate lever. If the cable clamps have been removed, they must be replaced.
Unlock lock of selector and shift cables, to do this push movable sleeve -in direction of arrow- as far as it will go- and then lock by turning to left -in direction of arrow 3-. Pull cables -1- out of cable retainer.
Remove bolts -arrows-. Remove the line bracket and move the clutch slave cylinder to the side; do not disconnect pipelines.
Carefully! After removing the clutch slave cylinder, do not press the clutch pedal again. Use stepladder -VAS 5085- to loosen bolts of securing elements.
Vehicles with cover for engine mounting
Remove the cover of the engine mounting, to do this unscrew the bolts -1 and 2-.
Loosen bolts -1 and 3- by approx. 2 turns. Pos. -2- ignore.
Vehicles without engine mount cover
Loosen bolts -1 and 2- by approx. 2 turns. The nut -3- may only be loosened to replace the engine mount.
Loosen bolts -arrows- for gearbox support by approx. 2 turns.
Instruction. Mark the direction of rotation of the V-ribbed belt with chalk or felt-tip pen. Installing a belt that has already been running in the opposite direction of rotation can lead to its destruction.
To loosen the V-ribbed belt, turn the belt loosening tool with the spanner -in the direction of the arrow-. Lock the belt tensioner by inserting the pin -T10060 A- into the locking holes. Remove poly V-belt.
Carefully! Do not open the air conditioning circuit of the air conditioner. To avoid damage to the air conditioning compressor, as well as pipelines and hoses of the air conditioning circuit, it is necessary to ensure that the lines and hoses are laid without interference, kinks or kinks.
Unscrew bolts -arrows- for air conditioner compressor. Hang the A/C compressor to the radiator frame. Pos. -1- ignore.
Unscrew bolts -arrows- and remove pendulum support.
Remove screw -2-. Pos. -1- ignore.
Remove screw -2-. Screw engine holder -T40076- with bolt -1- to approx. 20 Nm to cylinder block. Insert bolts of engine support -T40076- into cylinder block and secure bolt -T40076/2-. To do this, tighten nut to approx. 20 Nm. Insert engine and gearbox jack -VAG 1383 A- into engine holder. Slightly raise the engine together with the gearbox. Use stepladder -VAS 5085- to loosen securing bolts.
Vehicles with cover for engine mounting
Loosen bolts -1 and 3- and remove bracket with engine mounting -2-.
Vehicles without engine mount cover
The nut -3- may only be loosened to replace the engine mount. Remove bolts -1 and 3- and remove bracket with engine mount.
'Remove bolts -arrows- on gearbox support.
Instruction. Check that all hoses and wires between the engine, gearbox and body are disconnected. Lower the engine with the gearbox carefully to avoid damage. Make sure that the A/C compressor or the area between the drive shaft and the turbocharger is easily accessible.
Lower engine with gearbox and engine and gearbox jack -VAG 1383 A- slowly.
Separation of the engine and gearbox
The engine together with the gearbox has been removed and installed on the engine holder -T40076-. Loosen bolts -1...5- connecting engine to gearbox. Remove starter. Move the gearbox away from the engine.
Engine installation
The engine is mounted on engine holder -T40076-. Install in reverse order, note: when installing, replace self-locking nuts and bolts. Replace bolts tightened to a certain angle, as well as cuffs and seals. The hoses and hose fittings of the charge air system must be free of oil and grease before installation. Never use lubricants. Use clamps of the appropriate series to fasten all hose connections. When assembling, install all cable ties in their original places. Clean the splines of the input shaft of the gearbox and the splines of the bushings of the clutch discs that have already been used, remove corrosion and apply a thin layer of grease for the splines of the clutch discs to the splines. Do not lubricate the guide bush. Check the centering of the clutch disc. Check clutch release bearing for wear, replace if necessary. Check the presence of centering sleeves in the cylinder block for centering the engine and gearbox, insert sleeves if necessary. Make sure that the intermediate plate is placed on the sealing flange and inserted into the dowel sleeves -arrows-. Screw gearbox to engine.
Instruction. The specified tightening torques are valid for lightly oiled, phosphated. or oxidized nuts and bolts. It is allowed to use additional lubricants, such as motor or transmission oils, except for those containing graphite. Do not use degreased parts. Torque tolerance is±15%.
Fixing the Engine/Gearbox
1 1), 2 | М12х55 | 80 |
3 | M10x50 | 40 |
4 1) 2) | N112x150 | 80 |
5 3) | N16x12 | 10 |
A, B | Centering bushings |
1) Bolt with threaded pin M8.
2) Additionally for the starter to the gearbox.
3) Protective sheet for dual mass flywheel.
Start the engine together with the gearbox in the engine compartment of the body. First tighten bolts -1 and 2- on engine by hand. Pos. -03- ignore.
First screw the bolts -arrows- of the fasteners onto the gearbox by hand. Use new bolts for fastening. Remove engine holder -T40076- from engine. Install drive shafts. Install the ball joint. Install catalytic converter. Install pendulum support. Install the air conditioning compressor. Install starter. Install poly V-belt.
Before installing the clutch slave cylinder, do not press the clutch pedal. Install the clutch slave cylinder. Install the gear shift actuator in the gearbox and adjust. Install the cross support. Install the air ducts in the clamps. Install fasteners without mechanical stress. Electrical connectors and their gaskets. Observe precautions after connecting the battery. Install the wiper arm. Check oil level. Do not use the charger to help start the vehicle. There is a risk of damage to the vehicle controls. Fill up the coolant.
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