Engine, Removing

WARNING: This page is about a different car, the 2017 Volkswagen Touareg, 2016 Volkswagen Touareg, and 2015 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Lifting Tackle :3033
Engine And Transmission Holder :VAS6095
Engine and Gearbox Jack :VAS6931
Drip Tray for VAG1202A :VAG1306
Shop Crane :VAS6100
Scissor Lift Table :VAS6131
Hose Clip Pliers :VAS6340
Fuel Injection Gauge Kit - Fuel Bleeder 20 :VAG1318/20
Adapter :VAG1318/20-1
Storage Rack :VAG1698
Left Support :VAS6131/6-1
Right Support :VAS6131/6-2
Left Axle Support :VAS6131/6-3
Right Axle Support :VAS6131/6-4
Support :VAS6131/6-5 (quantity: 2)
Support :VAS6131/6-6 (quantity: 2)
V6 Engine Support :VAS6131/7
Lubricant (Vehicles with Manual Transmission) :G 000 1000
Cable Tie

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.

Work Procedure

The Engine with Transmission Is Removed Downward

-- On a vehicle with air suspension, activate vehicle lift mode. Refer to Self-Leveling Suspension .

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Disconnect hoses -1 and 2- and remove the air guide pipe -arrows-.

Fig 1: Identifying Connecting Pipe -Arrows- And Electrical Connector -1-

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-- Open the clamps and remove the upper part of the air filter.

-- Remove the windshield wiper arms. Refer to Windshield Wiper System .

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

-- Remove the protective housing from the Engine Control Module (ECM). Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

-- Disconnect the engine wiring harness connector from the ECM.

-- Disconnect the Ground (GND) wire -arrows-.

Fig 2: Identifying Ground Wire

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

Fig 3: 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 all the connectors -1 through 4- from the heated oxygen sensors.

Fig 4: Identifying Oxygen Sensor Connectors

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WARNING:

Fuel lines are under pressure.

Danger of personal injury to eyes and skin.

Wear protective eyewear and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before loosening hose connections. Open the connection carefully and release the pressure.

-- Wrap a cloth around the separating point to catch any fuel from leaking out.

-- Remove the fuel supply line -arrow-.

Fig 5: Identifying Fuel Supply Line

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-- Disconnect the vacuum lines -arrows-. Ignore hose -1-.

Fig 6: Identifying Vacuum Lines

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-- Open the cover over the B+ distributor in direction of -arrow-.

Fig 7: Identifying B+ Wires

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-- Disconnect the B+ wire:

To the generator
To the starter

-- Free up the electric wires.

-- Extract the refrigerant from the Air Conditioning (A/C) system. Refer to the appropriate service information .

-- Clamp the power steering hose with the :3094 . Disconnect hose -A- from the power steering pump.

Fig 8: Identifying Hose Clamp 3094 And Clamp -A- On Power Steering Hose

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-- Remove refrigerant lines -2 and 3- from A/C compressor.

Fig 9: Identifying A/C Compressor Lines

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

-- Remove the noise insulation bracket -arrows-.

Fig 10: Identifying Bracket For Noise Insulation

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

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

Fig 11: Identifying Coolant Hose Quick-Release Coupling

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-- Disconnect the upper coolant hose connection at the radiator.

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

Fig 12: Identifying Coolant Hose Quick-Release Coupling

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-- Disconnect the coolant hose to the lower radiator connection.

-- Remove the front wheels.

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

Fig 13: 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 14: Identifying Transmission Fluid Cooler Line Connection

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-- Clamp the power steering hose with :3094 , open clamp -A- and remove the hose.

Fig 15: Identifying Power Steering Hose

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-- Open clamps -A- and disconnect the refrigerant hoses for the heater core for the heater.

Fig 16: Identifying Heater Core Coolant Hoses

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-- Press the driveshaft from the transmission and tie it upward OVERVIEW - DRIVESHAFT .

-- Disconnect the connector -arrows- from the transmission.

Fig 17: Identifying Transmission Connectors

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-- Unscrew mount -1 and 2-. Loosen the clamping sleeves -arrows- and push backward.

Fig 18: Identifying Clamps -Arrows- And Bolts -1 To 2-

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-- Disconnect the selector lever cable from the ball head -1- and remove the transmission bolts -2-. The lock washer -3- can remain installed.

Fig 19: Identifying Selector Lever Cable, Removal/Installation

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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 20: Identifying Bolt -A- To Universal Joint Bolt

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-- Disconnect the connector from the steering gear.

Fig 21: Identifying Steering Gear Connector

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

Fig 22: Identifying Speed Sensor Connector

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

Fig 23: Identifying Brake Pad Wear Indicator Connector

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-- Remove wiring harness bolts -arrows-.

Fig 24: Identifying Wire Harness Bolts

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-- Remove brake caliper bolts -1-.

NOTE:

Do not change the shape of the brake lines.

-- Engage brake caliper in wheel housing with wire.

CAUTION:

Risk of damaging brake pistons.

Do not operate brake pedal when the brake caliper is removed.

-- Loosen the upper control arm nut a few turns and pull the joint off using the :T10187 .

Fig 25: Identifying Removal Of Ball Joint With Puller T10187 -1-

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

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

Fig 26: 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.

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

-- Remove one of the rear bolts -2- from the subframe.

Fig 27: Identifying Bolts -4- And Engine Carrier Bolts -3-

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-- Secure the subframe on the body using the : T10300 . Refer to OVERVIEW - SUBFRAME .

-- Then proceed in exactly the same with the bolt -2-.

-- If engine and transmission are to be separated after removing engine/transmission assembly, remove lower bolts -arrows- from engine to transmission connection.

Fig 28: Identifying Lower Engine/Transmission Bolts

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Prepare the :VAS6131B with :VAS6131/6 as Follows:

Fig 29: Preparing Scissor Lift Table

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VAS6131/6-1
- Attachment point: A4; B3; B4
VAS6131/6-2
- Attachment point: H4; G3; G4
VAS6131/6-3
- Attachment point: A5; B5
VAS6131/6-4
- Attachment point: G5; H5
VAS6131/6-5
- Attachment point: B7
VAS6131/6-5
- Attachment point: G7
VAS6131/6-6
- Fastening point: B14
VAS6131/6-6
- Attachment point: G14

NOTE:

Attach all support to the scissor lift table just hand-tight so that the position can be corrected later.

The :VAS6131/6 consists of the :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).

-- Position the scissor lift table horizontally.

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

-- Position the :VAS6131B under the vehicle.

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

Fig 30: 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 31: Identifying Support For Transmission Cross Bar And Holes

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

Fig 32: Identifying Support In Mount In Subframe

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

-- Tighten all of the supports on the :VAS6131B to 20 Nm.

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

-- Remove the right and left bolts -A- from the suspension strut.

Fig 33: Identifying Coupling Rod To Stabilizer Bar Bolts/Nuts -Arrow- And Shock Absorber Nuts -A-

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-- Remove the bolts from the transmission transverse support -1- and from the subframe -3 and 4-.

Fig 34: 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.

-- Slowly lower the engine/transmission assembly always making sure there is enough clearance.

-- Tighten one bolt and nut -arrow- on the right and left sides of the subframe mount. This will prevent the engine support from slipping.

Fig 35: Identifying Engine Mount Nuts

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