Engine, Removing

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Lifting Tackle 3033
Engine and Transmission Holder VAS 6095
Universal Mounting VAS 6095/1
Bracket for V6 TDI Engine VAS 6095/1-4
Engine-/Gearbox Jack V.A.G 1383 A
Drip Tray V.A.G 1306
Shop Crane VAS 6100
Scissor Lift Table VAS 6131
Hose Clamps Up to 25 mm Dia.3093
Tensioner Hooks VW 552
Torque Wrench (5-50 Nm) V.A.G 1331
Torque Wrench (40-200 Nm) V.A.G 1332
Spring Type Clip Pliers VAS 5024 A
Parts Trolley V.A.G 1698
Engine Bung Set VAS 6122
Basic Set for Touareg VAS 6131/6
Cable Tie

The engine, with transmission is removed downward.

-- Check the Diagnostic Trouble Code (DTC) memories for all control modules before removing the engine. Refer to "Guided Functions" in the vehicle diagnostic tester.

WARNING:

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route all lines and wires in their original locations.
Ensure sufficient clearance to all moving or hot components.

-- Check if a coded radio is installed. Obtain the anti-theft code if necessary.

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 from locking.

It is advisable to remove the front wheels before removing the engine/transmission assembly. The vehicle can be lowered on the hoist until the cover plates 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 parts trolley V.A.G 1698 for storage.

CAUTION:

The procedure for disconnecting the battery must be observed exactly!

-- Turn off the ignition and all electrical components.

-- First, disconnect the battery under driver's seat.

-- Disconnect the auxiliary battery in the luggage compartment spare wheel well. Refer to Removal and Installation .

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

-- Remove the engine cover. First pull the cover forward and then pull it upward -arrows-.

Fig 1: Identifying Removal Of Engine Cover From 4 Ball Studs -Arrows-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the engine compartment seal from the plenum chamber bulkhead.

-- Remove the plenum chamber cover.

-- Unclip the Engine Control Module (ECM) in the right of the plenum chamber from its retainers and remove the connector from the control module.

-- Disconnect the ground connector -1- from the ECM wiring harness.

Fig 2: Identifying Ground Connector -1-

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-- Open the fuse box cover in the left of the plenum chamber and disconnect the connectors -1, 2 and 3-.

Fig 3: Identifying Connectors -1, 2 And 3-

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-- Remove the engine wiring harness (smaller connector on the ECM) from the plenum chamber and lay it down on the engine.

-- Disconnect the vacuum hose from the vacuum reservoir.

-- Remove the fuel filter with the bracket and fuel cooler. Refer to FUEL FILTER AND COOLER OVERVIEW .

-- Remove the starter wire -arrow- and lay it down on the engine.

Fig 4: Identifying Starter Wire -Arrow-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the connecting hose between the throttle valve control module and the charge air pipe.

-- Disconnect the charge air pressure hoses -1- from the right charge air pipe.

Fig 5: Identifying Charge Air Pressure Hoses -1-

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-- Unclip the transmission ventilation line -2-.

-- Disconnect connector -arrow-.

Fig 6: Disconnecting Connector

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-- Remove the connector hose -5- between the Mass Airflow (MAF) sensor and turbocharger.

Fig 7: Identifying Connector Hose -5-

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-- Disconnect the following connectors at the plenum chamber bulkhead:

Connector 1 for the exhaust pressure sensor 1 -G450-
Connector 2 for the heated oxygen sensor -G39-
Connector 3 for the exhaust gas temperature sensor 1 -G235-
Connector 4 for the pre-particulate filter temperature sensor -G506-

-- Disconnect the vacuum line -arrow-.

Fig 8: Identifying Vacuum Line -Arrow-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Extract the refrigerant from the Air Conditioning (A/C) system. Refer to "A/C Service Station" in Description and Operation .

-- Disconnect the front refrigerant line from the A/C compressor.

-- Remove the noise insulation panel. Refer to "Underbody Impact Guard" in Description and Operation .

-- Remove the front wheels.

-- Remove the front wheel housing liners. Refer to Removal and Installation .

-- Clamp off the power steering fluid hose using hose clamps up to 25 mm dia.3093 and disconnect it -arrow-. Catch fluid which runs out.

Fig 9: Identifying Power Steering Fluid Hose

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the clamp on the refrigerant line, remove the bolt -2- and disconnect the refrigerant line.

-- Drain the coolant. Refer to DRAINING AND FILLING .

-- Disconnect the coolant hoses from the expansion tank.

-- Unclip the coolant hoses from the retainers on the plenum chamber bulkhead.

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

Fig 10: Identifying Line From Transmission Oil Cooler

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the double clamp between the particulate filter and rear muffler and slide it forward.

-- Support the exhaust system using engine-/gearbox jack V.A.G 1383 A, remove the mounts and lower the exhaust system.

-- Disconnect the pressure lines from the particulate filter.

-- Remove the heat shield on the steering gear and loosen the universal joint. Refer to Description and Operation .

-- Disconnect the connectors on the transmission and transfer case and loosen the selector cable. Refer to [For transmission(s) 09D] Removal and Installation .

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

-- Remove the transmission crossmember -A-.

Fig 11: Identifying Transmission Transverse Support

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the coolant hose upward from the radiator.

-- Disconnect the coolant hose on the upper coolant hose junction piece.

-- Remove the Ground (GND) wire bolt -1- on the longitudinal member.

Fig 12: Identifying Ground (GND) Cable On Longmember

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the auxiliary heater coolant hoses -1- and collect the coolant. Position them so they do not break off when removing the engine.

Fig 13: Identifying Auxiliary Heater Coolant Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the brake lines in the wheel housing at brake hose and catch fluid which runs out. Refer to Description and Operation .

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

-- Secure the struts using a tensioner hook VW 552 as illustrated.

Fig 14: Engaging Upper Control Arm To Body Using Tensioner Hooks VW 552

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the strut upper bolts. Refer to Removal and Installation .

NOTE:

To separate the engine from the transmission after removing the engine, remove the lower bolts connecting them together.

Preparing the scissor lift table VAS 6131 :

NOTE:

The vehicle specific basic set for Touareg VAS 6131/6 consists of the supports VAS 6131/6-1 through 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).

-- Install support 1 on the left and support 2 on the right on the scissor lift table VAS 6131 with the arrows pointing in the direction of travel and tighten the bolts in the following locations:

Fig 15: Identifying Left/Right Support

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Support 1: A5, B4 and B5

Support 2: G4, H4 and H5

-- Secure support 3 and support 4 on the lift table in the following locations:

Support 3: A6 and C6

Support 4: F6 and H6

-- Lower the support plates on supports 3 and 4.

NOTE:

Next, secure the subframe in order to be able to find the exact installation position when reinstalling. If it is not possible to secure it, the vehicle subframe must be measured after in has been reinstalled.

-- Secure the subframe. Refer to Description and Operation .

-- Place support 5 for the subframe and support 6 for the transmission crossmember in the correct locations on the scissor lift table.

-- Position the horizontal scissor lift table under the engine. Guide supports 1 and 2 into the corresponding mount -arrow- on the left and right.

Fig 16: Identifying Supports And Mounts

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-- At the same time, guide support 6 for the transmission crossmember into the corresponding holes -arrows- on the right and left.

Fig 17: Identifying Support For Transmission Cross Bar And Holes

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

When all four supports are in the correct mounts without being pressed into place:

-- Position both support plates on the axle supports under the control arm and support it lightly so the retainer can be removed with the tensioner hook VW 552.

-- Now guide support 5 into the correct mounts in the subframe -arrow- and correct the height of the supports with the knurled nut if necessary.

Fig 18: Identifying Support In Mount In Subframe

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the subframe bolts -1, 2 and 3- and the transmission crossmember -4-.

Fig 19: Identifying Subframe Bolts And Transmission Transverse Support

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Guide the engine and transmission carefully when lowering to prevent damage to the vehicle body.

If the subframe was not secured on the body, perform an alignment after installing.

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