Engine, Removing

WARNING: This page is about a different car, the 2012 Volkswagen Touareg and 2011 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Used Oil Collection and Extraction Unit:SMN372500
Step Ladder:VAS5085
Engine Bung Set:VAS6122
Scissor Lift Table:VAS6131B with Scissor Lift Table - Audi Set:VAS6131/10 , Scissor Lift Table - A8 Set:VAS6131/11 , :VAS6131/13 and :VAS6131/10-2 quantity: 3
Shop Crane - Drip Tray:VAS6208
Hose Clip Pliers:VAS6362
Puller - Ball Joint:T10187

CAUTION:

This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure.

Mandatory Replacement Parts

Bolts - Engine to Transmission
O-rings- ATF Pipes
Bolts - Torque Converter

-- Check the DTC memories for all control modules before removing the engine using the Vehicle Diagnostic Tester in "Guided Functions".

NOTE:

Secure all disconnected lines and connection 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 "N".

So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.

-- Disconnect the battery. Refer to BATTERY .

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

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

-- Remove the windshield wiper arms. Refer to WINDSHIELD WIPER SYSTEM .

-- Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER .

-- Disconnect the engine cable connector from the engine control module.

-- Remove the ground connection -arrow- inside the plenum chamber.

Fig 1: Identifying Ground Wire

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-- Open the cover -A- on the central electric.

Fig 2: Identifying E-Box Cover

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-- Disconnect all connectors that go to the engine.

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

-- Disconnect the vacuum line -arrow-.

Fig 3: Identifying Vacuum Line -Arrow-

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-- Open the clamps and remove the fuel supply and return lines from the fuel filter.

Fig 4: Identifying Clamps -Arrows-, Fuel Supply Line And Return Lines

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-- Remove the bolts -arrows- and remove the fuel filter upward.

Fig 5: Fuel Filter -Arrows-

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-- Disconnect the air suspension connector, if equipped. Then remove the bolts -arrows- and the fuel filter bracket.

Fig 6: Connector For The Air Suspension

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-- Remove the bolt -arrow- and place the positive cable from the starter on the engine.

Fig 7: Identifying Bolt -Arrow- To Positive Cable

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-- Remove the hose that connects the throttle valve control module and the charge air pipe.

-- Open the clamps -2 and 3- and remove the connecting hoses from the right charge air pipe.

Fig 8: Air Guide Hoses, Remove/Install

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-- Unclip the transmission vent line -2-, if equipped.

-- Open the clamps -arrows- and remove the intake line.

Fig 9: Identifying Clamps -Arrows- And Intake Hose

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-- Remove the connector -arrow- from the bracket and disconnect it.

Fig 10: Connector

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-- Remove the bracket for the connector from the cylinder head cover.

-- Disconnect connectors -1, 2 and 4- from the plenum chamber bulkhead and disconnect them.

Fig 11: Component Location On Plenum Chamber Bulkhead

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-- Remove the NOx Sensor -G295- -4-, move it to the side and then tie it secure.

Fig 12: Identifying Installation Location Inside Exhaust System Tract

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NOTE:

Ignore -item 1 to 3, and 5-.

-- Evacuate the refrigerant in the A/C system. Refer to appropriate service information. .

-- Disconnect the connector -2- if applicable.

Fig 13: A/C Compressor Refrigerant Lines And Electrical Connector -2-, Remove/Install

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-- Remove the clamps -1 and 5-.

-- Remove the screws -3 and 4- and then remove the refrigerant lines from the A/C compressor.

-- Remove the noise insulation. Refer to NOISE INSULATION .

-- Remove the front wheels.

-- Remove the front wheel housing liners. Refer to WHEEL HOUSING LINER .

-- Drain the coolant. Refer to COOLANT, DRAINING .

-- Open quick-release coupling -A- below the coolant expansion tank and disconnect the coolant hose.

Fig 14: Identifying Coolant Hose Quick-Release Coupling

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-- Open quick-release coupling -A- at the radiator at the top and disconnect the coolant hose.

Fig 15: Identifying Coolant Hose Quick-Release Coupling

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-- Remove the coolant line -A- from the coolant reservoir -arrows-. Then remove it from the plenum chamber bulkhead and lay it on the engine.

Fig 16: Identifying Clamps -Arrows- And Coolant Line -A-

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-- Clamp the power steering hose with Hose Clamps - Up To 25mm:3094 , open clamp -A- and remove the hose.

Fig 17: Identifying Hose Clamp 3094 And Clamp -A- On Power Steering Hose

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Lift the Vehicle.

-- Disconnect ground connection -A- from the right longitudinal member.

Fig 18: Identifying Ground Connection

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-- Remove the bolt -A- and the connections on the transmission fluid cooler. Catch any fluid coming out.

Fig 19: Identifying Transmission Fluid Cooler Line Connection

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-- Clamp the power steering hose with Hose Clamps - Up To 25mm:3094 , open clamp -A- and remove the hose.

Fig 20: Identifying Power Steering Hose

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-- Open the clamps -A- and remove the auxiliary heater coolant hoses.

Fig 21: Identifying Heater Core Coolant Hoses

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-- Remove the exhaust system rear section. Refer to OVERVIEW - MUFFLER WITH MOUNTS .

-- Remove the driveshaft. Refer to REAR DRIVESHAFT, REMOVING AND INSTALLING [For transmission(s) 0C8] .

-- Disconnect the connector -A- from the transmission.

Fig 22: Identifying Transmission Connectors

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-- Remove the noise insulation retaining plate -A-.

Fig 23: Identifying Transmission Transverse Support

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-- Remove the bolts -arrow- from the particulate filter.

Fig 24: Identifying Particulate Filter Suspended Mount Bolts -Arrow-

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-- Remove Exhaust Gas Temperature Sensor 4 -G648- -arrow- and tie it to the body.

Fig 25: Identifying Exhaust Gas Temperature Sensor 4 -Arrow-

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-- Remove NOx Sensor 2 -G687- -3- and tie it to the body.

Fig 26: Disconnect Connector -5-

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-- Remove the Reducing Agent Injector -N474- -5-. Refer to Reducing Agent Injector -N474-, REMOVING AND INSTALLING .

-- Remove the nuts -1- and the bolts -2- and -4- and then remove the reducing agent catalytic converter.

All Engine Codes

Fig 27: Disconnect Differential Pressure Sensor Hoses -Arrows

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-- Remove the connecting hoses -arrows- for the Differential Pressure Sensor -G505- from the pressure lines on the particulate filter.

-- Disconnect the gearshift mechanism at the ball head and remove it from the transmission.

Fig 28: Locating Selector Lever Cable Bolts

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CAUTION:

Risk of distorting airbag spiral spring.

Separate universal joint from steering gear only when front wheels are in straight ahead position.
Secure steering wheel with adhesive tape to prevent position of steering wheel and steering gear from changing.

-- Remove the bolt -A- and remove the universal joint from the steering gear.

Fig 29: Identifying Bolt -A- To Universal Joint Bolt

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-- Disconnect the connector from the steering gear.

Fig 30: Identifying Steering Gear Connector

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-- Loosen upper control arm nut a few turns and pull joint off with Puller - Ball Joint:T10187 -1-.

Fig 31: Identifying Removal Of Ball Joint With Puller T10187 -1-

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-- Remove the nut completely and disconnect the control arm.

-- Disconnect the connectors -arrow- at the left and right on the front speed sensors.

Fig 32: Identifying Speed Sensor Connector

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-- Disconnect the connector -arrow- from the wear display.

Fig 33: Identifying Brake Pad Wear Indicator Connector

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-- Remove wiring harness bolts -arrows-.

Fig 34: Identifying Wheel Bearing Housing Brackets

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-- Remove the bolt -arrow- at the bottom of the coupling rod.

Fig 35: Identifying Coupling Rod To Stabilizer Bar Bolts/Nuts -Arrow- And Shock Absorber Nuts -A-

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-- Remove the nut -A- from the lower control arm. Leave the screw in the hole.

CAUTION:

Be careful not to stretch the lines when removing and installing the brake caliper. Do not change the bend shape of the brake lines.

-- Remove the bolts -arrows- from the brake caliper. Then remove the brake caliper and secure it in the wheel housing using the Tensioning Strap:T10038 .

Fig 36: Identifying Wire Harness Bolts

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-- Repeat the procedure on the other side of the vehicle.

-- If the engine and the transmission are going to be separated after being removed, then remove the lower bolts -arrows- from the transmission.

Fig 37: Identifying Lower Bolts -Arrows- From Transmission

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Prepare the Scissor Lift Table:VAS6131B with the Scissor Lift Table - Touareg Set:VAS6131/6 as follows:

Fig 38: Identifying Scissor Type Assembly Platform (US) VAS6131A With Basic Set For Touareg VAS6131/6

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VAS6131/6-1
- Fastening point: A2; B1; B2
VAS6131/6-2
- Fastening point: H2; G1; G2
VAS6131/6-3
- Fastening point: A3; B3
- Use a plate with a short spindle
VAS6131/6-4
- Fastening point: G3; H3
- Use a plate with a short spindle
VAS6131/6-5
- Fastening point: A7
VAS6131/6-5
- Fastening point: H7
VAS6131/6-6
- Fastening point: B14
VAS6131/6-6
- Attachment point: G14

NOTE:

The Scissor Lift Table - Touareg Set:VAS6131/6 consists of the Support:VAS6131/6-1 through :VAS6131/6-7 . They are referred to here simply as support 1 (for VAS6131/6-1) through support 7 (for VAS6131/6-7).

-- First manually secure the mounting elements to the scissor lift table.

-- Position the scissor lift table horizontally.

Note the bubble level (sight glass) on the scissor lift table.

-- Position the Scissor Lift Table:VAS6131B under the vehicle.

-- The supports -1 and 2- must be guided into the corresponding mount -arrows- at right and left.

Fig 39: Identifying Supports And Mounts

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-- At the same time, guide right and left transmission cross bar supports -6- into the corresponding holes -arrows-.

Fig 40: Identifying Support For Transmission Cross Bar And Holes

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When all four supports are in the appropriate receptacle holes without pressure:

-- Guide the supports -5- to the corresponding mounts of the subframe. Use the knurled nut to adjust the height of the support, if necessary.

Fig 41: Identifying Support In Mount In Subframe

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-- Using light pressure under the control arms, screw the rotary plate of supports 3 and 4.

-- Secure subframe installation position. Refer to SUBFRAME .

-- Mark the location of the engine carrier to the longitudinal members using a felt-tip pen.

-- Remove the bolts -1-.

-- Remove the bolts -2 to 4- in a diagonal sequence in steps.

Fig 42: Identifying Bolts -4- And Engine Carrier Bolts -3-

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CAUTION:

Lower the engine very carefully. Make sure all connections to the body are disconnected. Rework if necessary.

-- Carefully lower the engine/transmission.