Engine, Removing

WARNING: This page is about a different car, the 2015 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
Shop Crane - Drip Tray: VAS6208
Hose Clip Pliers: VAS6362
Puller - Ball Joint: T10187
Scissor Lift Table - Touareg Set: VAS6131/6
Scissor Lift Table - Touareg Set - Support: VAS6131/8
Step Ladder: VAS5085
Torque Wrench 1331 5-50Nm: VAG1331

The Engine with Transmission Is Removed Downward.

NOTE:

Secure all disconnected lines and connections 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.

When the engine is installed some components cannot be removed or can only be removed with great difficulty. Therefore determine which components are faulty before removing so that they can replaced while they are removed.

To prevent damage to the removed components, use the Storage Rack: VAG1698A for storage.

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

WARNING:

Hybrid vehicles have a high voltage system! Danger of electrical shock! When performing the following work, it is also necessary to work on the high voltage system. De-energize the high voltage system now. Refer to DISABLING THE HIGH VOLTAGE SYSTEM .

Procedure:

-- Disconnect the battery. Refer to Battery, Disconnecting and Connecting .

-- Evacuate the refrigerant in the A/C system. Refer to REFRIGERANT CIRCUIT, EVACUATING .

-- Remove the front wheels.

-- Drain the coolant for the high temperature coolant system. Refer to COOLANT, DRAINING AND FILLING, HIGH TEMPERATURE CIRCUIT .

-- Drain the coolant for the low temperature cooling system. Refer to COOLANT, DRAINING AND FILLING, LOW TEMPERATURE CIRCUIT .

-- Remove the air guide pipe by removing the hose -1- and loosening the hose clamps -arrows-.

Fig 1: Air Guide Pipe, Hose And Clamps

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-- Disconnect all the connectors -1 through 4- from the heated oxygen sensors.

Fig 2: Identifying Oxygen Sensor Connectors

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-- Remove the windshield wiper arms. Refer to WIPER ARMS, REMOVING AND INSTALLING .

-- Remove the plenum chamber cover. Refer to Plenum Chamber Cover .

-- Remove the anti-theft protection from the engine control module. Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

-- Disconnect the engine wiring harness connector from the engine control module.

-- Remove the ground cable and disconnect the connectors -arrows-.

Fig 3: Locating Ground Cable Connector

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

Fig 4: 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.

-- Remove the coolant hose -1- and disconnect the breather lines -arrows-.

Fig 5: Identifying Vacuum Lines

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-- Remove the secondary air injection line -1- and the coolant hoses -arrows-.

Fig 6: Locating Secondary Air Injection (Air) Pipe & Coolant Hoses

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-- Remove the coolant hoses -arrows-.

Fig 7: Locating Coolant Hoses

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-- Disconnect the refrigerant line -arrow- for the A/C system. Seal the open lines with suitable plugs.

Fig 8: Disconnecting A/C System Refrigerant Line

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-- Remove the bolts -1 and 2- and remove the cover plate for the high voltage connection -A-.

Fig 9: Cover Panel -A- And Bolts -1 And 2-

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-- Open the retainers for both quick-release couplings -arrows- and remove the coolant lines in direction of -arrow-.

Fig 10: Locating Quick-Release Couplings

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-- Release and remove the Electrical A/C Compressor High Voltage Cable -P3- -1-.

Fig 11: High Voltage Cable -1

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-- Release the pilot contact -1- from the electric drive power and control electronics and remove it. Release and remove the high voltage cables -2, 3 and 4- in sequence. Unclip the high voltage cables and place them on the engine.

Fig 12: Identifying Pilot Connector -1- From Electric Drive Power And Control Electronics

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-- Remove the connector on the A/C compressor -arrow-. Remove the bolt -1- and remove the refrigerant line from the A/C compressor.

Fig 13: Locating A/C Compressor Connector

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Fig 14: Identifying Fuel Supply Line

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WARNING:

Fuel system is under pressure.

Risk of injury from fuel spraying out.

Wear protective eyewear.
Wear safety gloves.
Reduce the pressure: Lay clean cloths around the connection point and carefully open the connection point.

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

-- Remove the fuel supply line -arrow-.

Fig 15: Identifying Steering Gear Connector

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-- Disconnect the connector from the steering gear.

-- Remove the heat shield -1- for the universal joint -2-.

Fig 16: Identifying Heat Shield -1- And Universal Joint -2-, Removal

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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 the universal joint -1- from the steering gear and push it upward.

Fig 17: Identifying Hoses From Coolant Pipes -2-

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-- Remove the hoses from the coolant pipes -2-.

-- Remove the ground cable from the drive motor -arrow-.

Fig 18: Locating Ground Cable Bolt

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-- Remove the clamp -1-. Remove the circlip -arrow- and remove the clutch mechanism breather. Seal the open lines.

Fig 19: Locating Clutch Mechanism Breather

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-- Loosen the right front wheel housing liner and remove the connectors -arrows- from the Auxiliary Hydraulic Pump Control Module -J922-. Free up the wiring harness.

Fig 20: Identifying Auxiliary Hydraulic Pump Control Module

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

Fig 21: 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 22: Identifying Transmission Fluid Cooler Line Connection

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-- Clamp the power steering hose with the Hose Clamps - Up To 25mm: 3094 . Disconnect the power steering lines -arrows-. Catch any escaping fluid using the Used Oil Collection and Extraction Unit: SMN372500 .

Fig 23: Identifying Power Steering Hoses

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-- Disconnect the coolant hoses -arrows- and remove the upper coolant hose -1- from the brackets.

Fig 24: Coolant Hoses -Arrows

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

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

Fig 26: Identifying Speed Sensor Connector

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

Fig 27: Identifying Brake Pad Wear Indicator Connector

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-- Remove the cable holder bolts -arrows-.

Fig 28: Identifying Wheel Bearing Housing Brackets

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

Fig 29: Identifying Coupling Rod To Stabilizer Bar Bolts/Nuts -Arrow- And Shock Absorber Nuts -A-

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-- Remove the nut -A- from the control arm. Leave the bolt 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 30: Locating Multi-Point Bolt

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

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

Fig 31: Identifying Transmission Connectors

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-- Loosen the clamping sleeves -1 and 2- between the front muffler and the center muffler.

Fig 32: Identifying Double Pipe Clamps Between Catalytic Converter/Front Muffler

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-- Support the exhaust system between the center muffler and the rear muffler using the Engine and Gearbox Jack: VAS6931 . Remove the exhaust system mounts and lower the exhaust system.

-- Remove the rear driveshaft. Refer to REAR DRIVESHAFT, REMOVING AND INSTALLING .

NOTE:

Ignore -2-.

Do not bend or kink the selector lever cable.

Always replace the lock washer.

-- Remove the selector lever cable from the ball head -1- and then remove the lock washer -3-.

Fig 33: Identifying Selector Lever Cable, Removal/Installation

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

-- Secure the subframe on the body using the Assembly Carrier Locating Pins: T10300 . Refer to OVERVIEW - SUBFRAME .

Fig 34: Identifying Bolts -4- And Engine Carrier Bolts -3-

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

-- Remove the bolt -1- at the bottom of the engine. The Scissor Lift Table - Engine Support: VAS6131/8-1 will be inserted into this hole later.

Fig 35: Identifying Transmission Bolts

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-- If the engine and the transmission with the drive motor are to be separated after removing, remove the bolts -arrows-.

Prepare the Scissor Lift Table: VAS6131B for the Following Procedure:

Fig 36: Identifying VAS 6131

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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; C5
- Use a turntable with a short spindle
VAS6131/6-4
- Attachment point: F5; H5
- Use a turntable with a short spindle
VAS6131/6-5
- Attachment point: B7
Scissor Lift Table - Engine Support VAS6131/8-1
- Attachment point: D7
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.

Use the turntable with the short spindle for the axle supports VAS6131/6-3 and VAS6131/6-4. The turntables with the long spindle are needed to support the transmission.

-- Position the horizontal scissor lift table under the engine. The supports -1- must be guided into the corresponding mount -arrow- at right and left.

Fig 37: Identifying Supports And Mounts

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-- At the same time, guide the right and left support for the transmission bracket into the corresponding hole -arrow-.

Fig 38: Identifying Right And Left Supports For Transmission Console Guided Into Corresponding Holes

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When all four supports are in the locating holes without contact pressure:

-- With light pre-tension, turn the turntables for the axle supports under the control arms.

-- Guide the supports -2- into the corresponding mounts in the subframe. Use the knurled nut to adjust the height of the support, if necessary.

Fig 39: Identifying Supports And Mounts

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-- Tighten all mounts on the scissor lift table.

-- Also support the engine with the Scissor Lift Table - Engine Support: VAS6131/8-1 . To do so, guide the hook from below into the open bolt hole on the engine. Adjust the height using the spindle and tighten the mounts on the scissor lift table.

Fig 40: Identifying VAS 6131/8-1

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

Fig 41: Identifying Coupling Rod To Stabilizer Bar Bolts/Nuts -Arrow- And Shock Absorber Nuts -A-

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-- Remove the bolts for the transmission transverse support -1- and for the subframe -2, 3 and 4-.

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.

-- 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 43: Identifying Engine Mount Nuts

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