Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• Step Ladder (VAS 5085)
• Engine Bung Set (VAS 6122)
• Scissor Type Assembly Platform (US) (VAS 6131 A)
• Drip Tray for VAS 6100 (VAS 6208)
• Hose Clip Pliers (VAS 6362)
• Support Set (VAS 6131/10)
• Supplementary Set (VAS 6131/11)
• Supplementary Set (VAS 6131/13)
• Tapered Mounting Pin (VAS 6131/10-2) (Qty: 3)
• Ball Joint Puller (T10187)
• Tensioning Strap (T10038)
- Check the Diagnostic Trouble Code (DTC) memories of all control modules before removing the engine. Refer to "Guided Functions" in the vehicle diagnostic tester.
• Secure all disconnected lines and connectors with suitable fixtures, for example, cable ties to the engine or to the body (depending on its "origin"). Seal off open connections with plugs.
• To rotate the driveshaft freely, move the selector lever to the "N" position.
• So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with the ignition key inserted.
- Disconnect the battery.
- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.
- Remove the seal from the plenum chamber bulkhead.
- Remove the windshield wiper arms.
- Remove the plenum chamber cover.
- Disconnect the engine harness connector from the Engine Control Module (ECM).
- Remove the nut - arrow - and ground connection inside the plenum chamber.
- Remove the screws and the connection and junction bolt 2 cover - A -.
- Disconnect all connectors to the engine.
- Remove the engine wiring harness from the plenum chamber and lay it on the engine.
- Disconnect the vacuum line - arrow -.
- Reposition the clamps and remove the fuel supply and return lines from the fuel filter.
- Remove the bolts - arrows - and remove the fuel filter upward.
- Disconnect the air suspension connector - A -, if equipped. Then remove the bolts/nuts - arrows - and the fuel filter bracket.
- Remove the bolt - arrow - and place the positive cable from the starter on the engine.
- Remove the charge air hose between the throttle valve control module and the charge air pipe.
- Loosen the clamps - 2 and 3 - and remove the charge air hoses from the right charge air pipe.
- Unclip the transmission vent line, if equipped.
- Open the clamps - arrows - and remove the intake hose.
- Remove the electrical connector - arrow - from the bracket and disconnect it.
- Remove the connector bracket from the cylinder head cover.
- Remove the connectors - 1, 2 and 4 - from the plenum chamber bulkhead and disconnect them.
- Remove the NOx sensor - 4 -, move it to the side and secure it.
• Ignore - 1 through 3 and 5 -.
- Recover the refrigerant in the Air Conditioning (A/C) system.
- Disconnect the connector - 2 - if applicable.
- Remove the bolts - 1 and 5 -.
- Remove the bolts - 3 and 4 - and then remove the refrigerant lines from the A/C compressor.
- Remove the noise insulation.
- Remove the front wheels.
- Remove the front wheel housing liners..
- Drain the coolant. Refer to => [ Coolant, Draining ] Coolant, Draining.
- Open the quick release coupling - arrow - below the coolant expansion tank and disconnect the coolant hose.
- Open the quick-release coupling - A - at the radiator upper connection and disconnect the coolant hose.
- Remove the coolant line - A - from the coolant expansion tank - arrows -. Then remove it from the plenum chamber bulkhead and lay it on the engine.
- Clamp off the power steering hose using a hose clamp up to 25 mm dia. (3094) , open the clamp - A - and remove the hose.
Vehicle, Lifting
- Remove the nut - A - and ground connection from the right longitudinal member.
- Remove the bolt - A - and the lines from the transmission fluid cooler. Catch any fluid coming out.
- Clamp off the power steering hose using a hose clamp up to 25 mm dia. (3094) , open the clamp - A - and remove the hose.
- Open the clamps - A - and remove the auxiliary heater coolant hoses.
- Remove the rear section of the exhaust system. Refer to => [ Muffler and Mounts Overview ] Service and Repair.
- Remove the rear driveshaft.
- Disconnect the connectors - arrows - from the transmission.
- Remove the noise insulation angle bracket nuts and bracket - A -.
- Remove the particulate filter mount bolts - arrow -.
- Remove the exhaust gas temperature sensor 4 - arrow - and secure it to the body.
- Remove the NOx sensor 2 (- 3 -) and secure it to the body.
- Remove the reducing agent injector - 5 -. Refer to => [ Reducing Agent (AdBlue(R)) Injector N474 ] Service and Repair.
- Remove the nuts - 1 - and the bolts - 2 and 4 - and then remove the rear exhaust pipe with catalytic converter.
- Remove the hoses - arrows - for the differential pressure sensor from the pressure lines on the particulate filter.
- Disconnect the selector lever cable from the selector shaft ball stud and remove the bolts - arrows -.
Risk of distorting the airbag spiral spring.
• Separate the universal joint from the steering gear only when the front wheels are in the straight ahead position.
• Secure the steering wheel with adhesive tape to prevent the position of the steering wheel and steering gear from changing.
- Remove the bolt - A - and separate the universal joint from the steering gear.
- Disconnect the connector - arrow - from the steering gear.
- Loosen the upper control arm to wheel bearing housing nuts a few turns and separate the ball joints using the ball joint puller (T10187) - 1 -.
- Remove the nuts completely and separate the control arms from the wheel bearing housings.
- Disconnect the connectors - arrow - for the left and right front wheel speed sensors.
- Disconnect the connector - arrow - from the brake pad wear indicator.
- Remove the wiring harness bolts - arrows -.
- Remove the coupling rod to stabilizer bar bolt/nut - arrow -.
- Remove the shock absorber/strut nut - A - from the lower control arm. Leave the bolt in the hole.
Be careful not to stretch the lines when removing and installing the brake calipers. Do not change the shape of the brake lines.
- Remove the bolts - 1 - from the brake caliper. Then remove the brake caliper and secure it inside the wheel housing using a tensioning strap (T10038).
- 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.
Prepare the scissor lift table (VAS 6131) using the basic set for Touareg (VAS 6131/6) as follows:
1 VAS 6131/6-1
• Attachment points: A2, B1, and B2
2 VAS 6131/6-2
• Attachment points: H2, G1, and G2
3 VAS 6131/6-3
• Attachment points: A3 and B3
• Use a plate with a short spindle.
4 VAS 6131/6-4
• Attachment points: G3 and H3
• Use a plate with a short spindle.
5 VAS 6131/6-5
• Attachment point: A7
6 VAS 6131/6-5
• Attachment point: H7
7 VAS 6131/6-6
• Attachment point: B14
8 VAS 6131/6-6
• Attachment point: G14
• The basic set for Touareg (VAS 6131/6) consists of 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).
- Next secure the supports elements to scissor lift table by hand.
- Position the scissor lift table horizontally.
• Note the bubble level (sight glass) on the scissor lift table.
- Position the scissor lift table (VAS 6131) under the vehicle.
- The supports - 1 and 2 - must be guided into the corresponding mounts - arrows - on the right and left.
- At the same time, guide the right and left transmission cross bar supports - 6 - into the corresponding holes - arrows -.
When all four supports are in the appropriate locations without pressure:
- Guide the supports - 5 - into the corresponding locations in the subframe, if necessary adjust the support height using the knurled thumb wheels.
- Using light pressure under the control arms, turn the rotary plate of supports 3 and 4.
- Secure the subframe.
- Mark the location of the engine carrier to the longitudinal members using a felt tip marker.
- Remove the bolts - 1 -.
- Remove the bolts - 2 through 4 - in a diagonal sequence and in steps.
Lower the engine very carefully. Ensure that all connections to the body are disconnected. Rework if necessary.
- Carefully lower the engine and transmission.