Engine, Removing: Notes

WARNING: This page is about a different car, the 2007 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Basic set for Touareg VAS 6131/6
Brace VAS 6131/8
Step ladder VAS 5085
Torque wrench (5 to 50 Nm) VAG 1331
Lifting tackle VAS 3033
Drip tray VAG 1306
Engine and transmission holder VAS 6095
Shop crane VAS 6100
Scissor lift table VAS 6131
Engine and transmission jack VAG 1383 A
Parts trolley V.A.G 1698

The engine with transmission is removed downward.

-- Check Diagnostic Trouble Code (DTC) memories of all control modules, before removing engine.

NOTE:

To allow free rotation of the driveshaft, move the selector lever to the "N" position.

Leave the key in the ignition lock to prevent the steering wheel lock from engaging.

It is advisable to remove the front wheels before removing the engine and transmission assembly. The vehicle can be lowered on the hoist until the brake carriers for the brake discs are just above the floor. This enables the most ergonomic work position possible regarding accessibility of components in the engine compartment.

When the engine is installed in the engine compartment some components cannot be removed or can only be removed with great difficulty. Therefore determine which components are faulty before removing engine.

To prevent damage to the removed components, use the container for removed parts trolley VAG 1698 as storage.

All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing engine.

Procedure

NOTE:

If the fuel system must be opened on the high pressure side immediately after removing the engine, first reduce fuel pressure.

WARNING:

The fuel injection system is divided into a high pressure side (maximum approximately 120 bar) and a low pressure side (approximately 6 bar).

Before opening high pressure side - e.g. removing high pressure pumps, fuel rail, fuel injectors, fuel pipes or fuel pressure sensor -G247- - fuel pressure on high pressure side must be reduced to a residual pressure of approximately 6 bar. Refer to RELEASING PRESSURE ON HIGH PRESSURE SIDE .

-- Remove the high pressure from fuel system.

WARNING:

Fuel supply line is still under pressure (approximately 6 bar)! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before separating hose connection, wrap a cloth around the connection. Then release pressure by carefully separating hose connection.

-- Place a cloth around the connection to catch draining fuel.

-- Disconnect the fuel supply line -arrow-.

Fig 1: Identifying Fuel Supply Line

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Battery, Disconnecting

The procedure must be strictly followed!

-- Turn off the ignition and all electrical components.

-- First, disconnect battery under driver's seat. Refer to Removal and Installation .

-- Extract refrigerant from air conditioning system. Refer to Description and Operation .

-- Remove engine compartment cover seal from bulkhead.

-- Remove left and right wiper arms. Refer to Removal and Installation .

-- Remove plenum chamber cover. Refer to Removal and Installation .

-- Remove the rear engine cover in -direction of arrows- if applicable.

Fig 2: Identifying Rear Engine Cover

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-- Remove the front engine cover in -direction of arrows- if applicable.

Fig 3: Identifying Front Engine Cover, Electrical Connector, And Left Air Guide Hose

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-- Remove small connector -A- from Engine Control Module (ECM) -J623- -1- and disconnect wiring harness ground connection -arrow-. ECM may have to be removed because of space restrictions. Refer to REMOVAL AND INSTALLATION .

Fig 4: Identifying Small Connector, Engine Control Module (ECM) J623, And Wiring Harness Ground Connection

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NOTE:

Vehicles with anti theft ECM -J623-. Refer to ENGINE CONTROL MODULE WITH ANTI-THEFT IMMOBILIZER .

-- Open fuse box cover on left in plenum chamber and separate connectors -A-, -B- and -C-.

Fig 5: Identifying Connectors In Fuse Box

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-- Remove wiring harness from plenum chamber and set it on the engine.

-- Disconnect breather line -arrow- to solenoid valve in engine compartment.

Fig 6: Identifying Nut -1- And Starter Wire

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-- Remove nut -1- and disconnect starter wire, lay it aside on the engine.

Fig 7: Identifying Alligator Of Remote Control To B+ Connection

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-- Extract the hydraulic oil from power steering reservoir using used oil collecting and extracting device VAG 1782.

NOTE:

Place a cloth under separating point to catch draining hydraulic fluid.

-- Remove hose clamp -arrow- and hose from power steering fluid reservoir.

Fig 8: Identifying Hose For Power Steering Fluid Reservoir

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-- Disconnect connector from left and right Mass Air Flow (MAF) sensors and remove intake hoses and left and right air filter housings. Refer to AIR FILTER ASSEMBLY OVERVIEW .

-- Disconnect connector -arrow- for the air suspension compressor from the right air filter housing. Refer to CONNECTING LINE TO AIR SUSPENSION COMPRESSOR, DISCONNECTING .

Fig 9: Identifying Connecting Wire To Air Suspension Compressor

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-- Disconnect vacuum hose -arrow- from the suction jet pump.

Fig 10: Identifying Vacuum Hose To Suction Jet Pump

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-- Separate connectors -1 through 4- for oxygen sensors and lay connectors aside on the engine.

Fig 11: Identifying Connectors For Oxygen Sensors

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NOTE:

Connector for cylinder bank 1 = Black, connector for cylinder bank 2 = Brown.

-- Remove air guide hose clamp -arrow- and hose from the Secondary Air Injection (AIR) combination valve connecting hose.

Fig 12: Identifying Air Guide Hose

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-- Unclip transmission ventilation hose clip -arrow- from the brake system vacuum pump -V192-.

Fig 13: Identifying Transmission Ventilation Hose

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-- In order to reach the coolant lines better, remove left front wheel housing liner, if necessary. Refer to Description and Operation .

-- Disconnect the electrical connector -1-.

-- Remove refrigerant lines -2- and -3- from Air Conditioning (A/C) compressor.

Fig 14: Identifying Refrigerant Lines From A/C Compressor

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NOTE:

To prevent damage to the refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

-- Seal open pipes and connections at A/C compressor with suitable sealing caps (to prevent dirt and moisture from entering).

-- Remove front -1- and rear -2- noise insulation. Refer to Description and Operation .

Fig 15: Identifying Front/Rear Noise Insulation

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-- Disconnect connectors -A- from the transmission and connectors -B- from the transfer case.

Fig 16: Identifying Connectors At Transmission And Transfer Case

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-- Loosen double pipe clamps -1 and 2- between catalytic converter/front muffler and slide them forward.

Fig 17: Identifying Double Pipe Clamps Between Catalytic Converter/Front Muffler

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-- Support the exhaust system between the front muffler and rear muffler using the engine and transmission jack VAG 1383 A, remove mountings and lower the exhaust system.

-- Remove driveshaft. Refer to [For transmission(s) 09D] Removal and Installation .

-- Remove ground (GND) wire bolt -1- on longitudinal member at right front.

Fig 18: Identifying Ground (GND) Cable On Longmember

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-- Remove selector lever cable heat shield bolts -arrows- and shield.

Fig 19: Identifying Selector Lever Cable Heat Shield/Ball Head

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-- Pry selector lever cable ball head -2- from selector shaft lever using pry lever 80 - 200.

-- Remove selector lever cable from clamp -1- and remove cable from transmission. Refer to [For transmission(s) 09D] Removal and Installation .

Fig 20: Identifying Locking Washer & Selector Lever Cable

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NOTE:

Do not bend or kink selector lever cable.

-- Disconnect electrical connector -arrow- at steering gear.

Fig 21: Identifying Electrical Connector And Heat Shield

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-- Remove steering gear heat shield bolts and shield -A- from steering gear.

CAUTION:

Separate universal joint from steering gear only when front wheels are in straight ahead position.
Do not change steering wheel position and steering gear position any more, secure steering wheel with adhesive tape.

-- Remove universal joint bolt -B-. Refer to Description and Operation .

-- Separate the universal joint from the steering gear.

Fig 22: Identifying Universal Joint Bolt

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-- Place the used oil collecting and extracting device VAG 1782 under left cooler.

-- Remove hydraulic line hose clamp -1- and hose from the power steering cooler to the left of lock carrier.

Fig 23: Identifying Hydraulic Line Hose

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NOTE:

Ignore -item 2-.

-- In wheel housings, separate all connectors between body and front axle.

-- Loosen brake line bracket and remove brake carrier from wheel bearing housing. Refer to Removal and Installation .

-- Secure brake caliper with wire in wheel housing without bending brake lines.

-- Remove right and left lower bolt/nut -2- on stabilizer bar. Bolt -1- remains fastened.

Fig 24: Identifying Right/Left Lower Bolt On Stabilizer Bar

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-- Remove transmission transverse support -A-.

Fig 25: Identifying Transmission Transverse Support

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WARNING:

Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover cap with a cloth and open carefully.

-- Open and close the cap on the expansion tank, to relieve the cooling system pressure.

-- Drain cooling system. Refer to COOLING SYSTEM, DRAINING AND FILLING .

-- Remove both coolant hose clamps -arrows- and hoses from reservoir.

Fig 26: Identifying Coolant Hoses

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-- From the area of the left wheel housing, remove the hose clamps -arrows- and hoses from the heater core. Allow remaining coolant to drain.

Fig 27: Identifying Hose Connections To Heater Core

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-- Remove upper coolant hose with quick connect coupling on upper cooler and lower hose clamp -arrow- and hose on coolant pipe.

Fig 28: Identifying Quick Coupling On Upper Cooler And Lower Hose On Coolant Pipe

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-- Disconnect lines -arrow- from transmission oil cooler at lower right. Catch fluid which drains out.

Fig 29: Identifying Lines From Transmission Oil Cooler And Rear Mounting Bolts

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-- Now remove one of the rear bolts -3- for the subframe.

-- Using locating pins T10300, secure subframe to body. Refer to Description and Operation .

Fig 30: Identifying Subframe Bolts And Transmission Transverse Support

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-- Then proceed in exactly the same way with the other rear bolt -3-.

Preparing scissor lift table VAS 6131 for the continued work procedure.

-- Mount the front supports VAS 6131/6-1 for the left -1-, as well as VAS 6131/6-2 for the right -2- to the lift table. The arrows on the supports indicate forward. Fasten the bolts at the following positions: Left support -1- : A5, B4 and B5. Right support -2- : G4, H4 and H5

Fig 31: Identifying Scissor Lift Table VAS 6131

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-- Bolt both axle supports VAS 6131/6-3 and VAS 6131/6-4 -3- to lift table at following positions: Left axle support: A6 and C6. Right axle support: F6 and H6.

-- Turn the turntables on the axle supports downward.

-- Place supports VAS6131/6-5 -4- for subframe and VAS 6131/6-6 -5- for transmission bracket in the corresponding positions on the lift table.

-- Move the horizontally aligned lift table under the powertrain assembly. The supports -1- must be guided into the corresponding holes -arrow- on the right and left.

Fig 32: Identifying Supports And Mounts

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-- Simultaneously, guide right and left supports for transmission bracket into corresponding holes -arrow-. When all four supports are in the appropriate holes without pressure:

Fig 33: Identifying Right And Left Supports For Transmission Console Guided Into Corresponding Holes

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-- Turn out both turntables of the axle supports with slight pre-loading under the control arms.

-- Guide support -2- into corresponding hole in subframe, if necessary check support height on knurled nut.

Fig 34: Identifying Supports And Mounts

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-- Turn out both turntables of the axle supports with slight pre-loading under the control arms.

-- Now remove the lower bolts -1- for the right and left struts.

Fig 35: Identifying Right/Left Lower Bolt On Stabilizer Bar

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-- Then remove upper right and left control arms from wheel bearing housings. Refer to Description and Operation .

-- Loosen the subframe bolts -1- and -2-, as well as transmission transverse support bolts -4-.

Fig 36: Identifying Subframe Bolts And Transmission Transverse Support

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-- Slowly lower engine/transmission assembly, constantly observing clearance.

-- Now install a bolt with nut -arrow- on the right and left side in order to prevent the engine carrier from slipping and secure engine carrier with subframe.

Fig 37: Identifying Bolt

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