Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Lifting Tackle (3033)
• Engine and Transmission Holder (VAS 6095)
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Drip Tray (V.A.G 1306)
• Shop Crane - Load Cap = 700-1200 KG (VAS 6100)
• Scissor Lift Table (VAS 6131)
• Hose Clip Pliers (VAS 6340)
• Adapter for K-jetronic Test Device (V.A.G 1318/20)
• Adapter (V.A.G 1318/20-1)
• Container for Removed Parts (V.A.G 1698)
• Basic Set for Touareg (VAS 6131/6)
• Ball Joint Puller (T10187)
• Hose Clamps up to 25 mm Dia (3094)
• Cable Tie
• Secure all disconnected lines and wires with suitable fixtures, for example, cable ties to the engine or to the body (depending on its "origin"). Seal off open connections with blind plugs.
• To rotate the driveshaft freely, move the selector lever into the "N" position.
• So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.
The engine with transmission is removed downward.
- On a vehicle with an air suspension, activate the vehicle lift mode.
- Disconnect the battery.
- Disconnect the hoses - 1 and 2 - and remove the connecting pipe - arrows -.
- Open the clamps and remove the upper part of the air filter housing.
- Remove the windshield wiper arms.
- Remove the plenum chamber cover.
- Remove the anti-theft protection from the Engine Control Module (ECM). Refer to => [ Engine Control Module J623 ] Service and Repair.
- Disconnect the engine wiring harness connector from the ECM.
- Remove the nut - arrow - and the ground wire.
- Open the cover - A - for the E-box.
- Disconnect all connectors that go to the engine.
- Remove the engine wiring harness from the plenum chamber and lay it on the engine.
- Disconnect all the connectors - 1 through 4 - for the Heated Oxygen Sensors (HO2S).
The fuel lines are under pressure.
Danger of personal injury to eyes and skin.
Wear protective goggles and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before disconnecting. Open the connection carefully and release the pressure.
- Wrap a cloth around the separating point to catch any fuel leaking out.
- Separate the fuel supply line - arrow -.
- Disconnect the vacuum lines - arrows -. Ignore the hose clamp - 1 -.
- Open the cover over the B+ terminal in the - direction of the arrow -.
- Disconnect the B+ wires:
1. To the generator
2. To the starter
- Free up the electrical wires.
- Recover the refrigerant from the Air Conditioning (A/C) system.
- Clamp off the power steering hose using the hose clamps up to 25 mm dia (3094). Disconnect the hose - A - from the power steering pump.
- Remove the refrigerant line bolts - 2 and 3 - and lines from the A/C compressor.
- Remove the noise insulation.
- Remove the noise insulation bracket bolts - arrows - and bracket.
- Drain the coolant. Refer to => [ Coolant, Draining ] Coolant, Draining.
- Open the quick-release coupling - arrow - below the coolant expansion tank and disconnect the coolant hose.
- Disconnect the upper coolant hose connection at the radiator.
- Open the quick-release coupling - A - at the upper radiator connection and disconnect the coolant hose.
- Disconnect the coolant hose to the lower radiator connection.
- Remove the front wheels.
- Remove the nut - A - and the ground cable from the right longitudinal member.
- Remove the bolt - A - and the transmission fluid cooler line connection. Catch any fluid coming out.
- Clamp off the power steering hose using the hose clamps up to 25 mm dia (3094) , open the clamp - A - and remove the hose.
- Open the clamps - A - and disconnect the coolant hoses for the heater core.
- Remove the driveshaft from the transmission and tie it up.
- Disconnect the connectors - arrows - from the transmission.
- Remove the bolts for exhaust system suspended mounts - 1 and 2 -. Loosen the clamping sleeves - arrows - and push the exhaust system backward.
- Disconnect the selector lever from the ball head and remove the selector cable bolts - arrows - from the transmission. Disconnect the selector lever cable from the ball head - 1 - and remove the bolts - 2 - from the transmission. The lock washer - 3 - can remain installed.
Risk of distorting the airbag spiral spring.
• Separate the universal joint from the steering gear only when the front wheels are in the straight ahead position.
• Secure the steering wheel with adhesive tape or other means to prevent the position of the steering wheel and steering gear from changing.
- Remove the universal joint bolt - A - and remove the steering column from the steering gear.
- Disconnect the connector - arrow - from the steering gear.
- Disconnect the connectors - arrow - from the left and right side front speed sensors.
- Disconnect the connector - arrow - from the brake pad wear indicator.
- Remove the wiring harness bolts - arrows -.
- Remove the brake caliper bolts - 1 -.
• Do not change the shape of the brake lines.
- Secure the brake calipers in the wheel housings with wire.
Risk of damaging the brake pistons.
• Do not operate the brake pedal when the brake caliper is removed.
- Loosen the upper control arm nut a few turns and separate the ball joint from the wheel bearing housing using the ball joint puller (T10187).
- Remove the nut completely and disconnect the control arm from the wheel bearing housing.
- Remove the coupling rod bolt - arrow - from the stabilizer bar.
- Remove the nut - A - from the strut to the lower control arm. Leave the bolt in the hole.
- Repeat the above 2 steps on the other side of the vehicle.
- Remove one of the rear subframe bolts - 2 - from the subframe.
- Secure the subframe to the body using the locating pin (T10300).
- Then proceed exactly the same with the other bolt - 2 -.
- If the engine and transmission are to be separated after removing the engine/transmission assembly, remove the lower engine/transmission bolts - arrows -.
Prepare the scissor lift table (VAS 6131) with the basic set for Touareg (VAS 6131/6) as follows:
1 VAS 6131/6-1
• Attachment points: A4; B3; B4
2 VAS 6131/6-2
• Attachment points: H4; G3; G4
3 VAS 6131/6-3
• Attachment points: A5; B5
4 VAS 6131/6-4
• Attachment points: G5; H5
5 VAS 6131/6-5
• Attachment point: B7
6 VAS 6131/6-5
• Attachment point: G7
7 VAS 6131/6-6
• Attachment point: B14
8 VAS 6131/6-6
• Attachment point: G14
• Attach all supports to the scissor lift table just hand tight so that the position can be corrected later.
• The basic set for Touareg (VAS 6131/6) consists of supports (VAS 6131/6-1) to (VAS 6131/6-7). They are referred to here simply as support 1 (for VAS 6131/6-1) through support 7 (for VAS 6131/6-7).
- Position the scissor lift table horizontally.
• Note the bubble level (sight glass) on the scissor lift table.
- Position the scissor lift table (VAS 6131) under the vehicle.
- The supports - 1 and 2 - must be guided into the corresponding locations - arrows - on the right and left.
- At the same time, guide the right and left transmission cross bar supports - 6 - into the corresponding locations - arrows -.
When all four supports are in the appropriate locations without pressure:
- Guide the supports - 5 - into the corresponding locations in the subframe, if necessary check the support height of the knurled nut.
- Tighten all of the supports on the scissor lift table to 20 Nm.
- Using light pressure under the control arms, adjust the plates for supports 3 and 4.
- Remove the right and left strut to lower control arm bolts - A -.
- Remove the transfer case carrier bolts - 1 - and the subframe bolts - 3 and 4 -.
Lower the engine very carefully. Ensure that all connections to the body are disconnected. Rework if necessary.
- Slowly lower the engine/transmission assembly always making sure there is enough clearance.
- Tighten one engine mount bracket to engine mount nut - arrow - on the right or left side. This will prevent the engine carrier from slipping.
