Turbo

1. Disconnect battery ground cable.
2. Remove cap from expansion tank and drain coolant by disconnecting lower radiator hose.
3. Remove bolt from coolant pipe.
4. Remove upper radiator hose, disconnect radiator thermoswitch electrical connector and disconnect heater hose at engine.
5. Disconnect vacuum hose at brake booster.
6. Remove belt cover from power steering pump, loosen and remove power steering drive belt, remove power steering pump, leaving hoses connected, and lay pump in cowl.
7. Disconnect electrical connectors from oil pressure switch, temperature sending unit and control pressure regulator.
8. Remove control pressure regulator, leaving fuel lines attached, and loosen vacuum hose adjacent to control pressure regulator.
9. Disconnect accelerator cable and linkage.
10. Remove windshield washer reservoir.
11. Disconnect electrical connectors at throttle valve switch, cold start valve, auxiliary air regulator, boost pressure safety switch, ignition coil, 2-way valve, thermo time switch, and ignition distributor.
12. Disconnect vacuum hoses at thermo pneumatic valve, and the vacuum hose at distributor retard.
13. Remove distributor cap.
14. Disconnect vacuum hoses at intake manifold and delay valve.
15. Remove cold start valve and pull out fuel injectors, leaving fuel lines connected.
16. Remove intake air duct and hose/pipe connection to turbocharger.
17. Disconnect fuel return line.
18. Disconnect fuel supply line at gas filter, then remove the filter.
19. Remove fuel distributor and air flow sensor as an assembly.
20. Remove A/C compressor mounting bolts and tie compressor out of way, leaving hoses connected.
21. Remove front engine mount.
22. Remove upper engine to transmission attaching bolts except the easiest one to reach.
23. Disconnect exhaust pipe at turbocharger and remove heat shield.
24. Disconnect exhaust pipe at wastegate, remove transmission bracket, and disconnect exhaust pipe at catalytic converter.
25. Remove starter and position out of way, leaving wiring connected.
26. Disconnect oil temperature switch electrical connector.
27. On vehicles equipped with automatic transmission, remove torque converter mounting bolts through starter mounting hole.
28. Remove air guide cover for oil cooler and the air guide hose for engine mount.
29. Disconnect oil lines at oil cooler, then remove lower engine to transmission attaching bolts.
30. Remove alternator with bracket and position out of way, leaving wiring connected.
31. Remove left and right engine mount nuts.
32. Install transmission support tool VW785/1 or equivalent with slight preload.
33. Attach suitable lifting device to engine.
34. Loosen ground strap on and remove left engine bracket.
35. Remove remaining upper engine to transmission attaching bolt.
36. Lift engine until wastegate is above water cowl panel, then turn disc of supporting tool until it touches transmission housing.
37. Turn engine toward right while lifting, then turn engine 90° and lift out.
38. On vehicles equipped with automatic transmission, secure torque converter using tool VW540 or equivalent.
39. Reverse procedure to install, noting the following:
a. Tighten engine mounts to side frame while engine is idling.
b. Ensure that metal lip on gasket between manifold and exhaust pipe faces exhaust.
c. Torque bolts and/or nuts as follows: A/C compressor to engine, 29 ft.lbs., alternator to engine and bracket, 14 ft.lbs., cold start valve, 7 ft.lbs., control pressure regulator, 14 ft.lbs., crankshaft bolt, 253 ft.lbs., engine stop on body/block, 32 ft.lbs., engine mounts, 32 ft.lbs., engine to transmission bolts, M8 14 ft.lbs., M10 32 ft.lbs., and M12 43 ft.lbs., exhaust pipe to manifold, 22 ft.lbs., exhaust pipe support, 22 ft.lbs., power steering pump, 14 ft.lbs., starter, 14 ft.lbs., subframe to body, 51 ft.lbs., and drive belt pulley, 14 ft.lbs.