Engine Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Scissor lift table (VAS 6131)
• Drip tray (VAG 1306)
• Frame support (T10191)
• Spring-type clip pliers (VAS 5024 A)
• Torque wrench (40 to 200 Nm) (VAG 1332)
• Tensioner hooks (VW 552)
• Standard set for Touareg (VAS 6131/6)
• Support for V10, V8 and V6 assembly, Touareg (VAS 6131/8)
• Container for removed components (V.A.G 1698)
• Engine bung set (VAS 6122)
• Cable tie
The engine with transmission is removed downward.
- Before removing engine, check Diagnostic Trouble Code (DTC) memories of all control modules. Refer to or VAS 5052 "Guided functions ".
• To allow free rotation of the driveshaft, move the selector lever in the "N" position.
• Leave vehicle key in the ignition lock to prevent steering wheel lock from locking.
• It is advisable to remove the front wheels before the disassembly. The vehicle can be lowered on the hoist until the cover plates of 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 a parts trolley (VAG 1698) for storage.
• All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
CAUTION!
The procedure for disconnecting the battery must be observed exactly!
- Turn off the ignition and all electrical consumers.
- First, disconnect batter under driver's seat.
- Then, disconnect the auxiliary battery, in spare wheel well of luggage compartment..
- Remove left and right windshield wiper arms.
- Pull engine compartment cover seal off bulkhead.
- Remove covers - A -, - B - (if equipped) and - C - in engine compartment and - D - for plenum chamber.
- Disconnect the smaller connector - A - from Engine Control Modules (ECM) and remove ground (GND) connection - arrow - for wiring harness.
- Open fuse box cover on left in plenum chamber and separate connectors - A -, - B - and - C -.
- Remove wiring harness from plenum chamber and place it on engine.
- Remove intake line on both sides between air filter and intake connection.
• With connector couplings, follow the installation instructions closely. Refer to --> [ Hose Connections with Connector Couplings ] Hose Connections with Connector Couplings.
With Engine Code BKW
- Disconnect vacuum lines - arrows - for Exhaust Gas Recirculation (EGR) valve and brake booster as well as harness connector - A - for Heated Oxygen Sensor (HO2S) (G39) of cylinder bank 1.
- Disconnect vacuum line - arrow - for EGR valve as well as harness connector - A - for HO2S 2 (G108) of cylinder bank 2.
With Engine Code BWF
- Disconnect the vacuum lines - 1 - for the vacuum actuators of the bypass flap (mark lines before separating) and the brake booster - 2 -.
- Disconnect the following connections and free up the wiring harness to the components:
1 6 pin harness connector, black: For HOS (G39)
2 6 pin harness connector, brown: For HOS 2 (G108)
3 2 pin harness connector, black: for Exhaust Gas Temperature (EGT) sensor 1 (G235)
4 2 pin harness connector, brown: for bank 2 EGT sensor 1 (G236)
Continuation for All
- Disconnect harness connectors - arrows - for glow plugs in cylinder bank 1 and cylinder bank 2.
- Secure suspension struts using tensioner hooks (VW 552.) as shown.
- Remove strut upper bolts.
- Remove noise insulation..
- Recover refrigerant from Air Conditioning (A/C) system.
- Drain the cooling system. Refer to --> [ Cooling System, Draining and Filling ] [1][2][3]Cooling System, Draining and Filling.
- Disconnect line - arrow - from transmission oil cooler below on right. Catch fluid which drains out.
- Disconnect line - A - from cooler for servo oil at lower left. Catch fluid which drains out.
- Remove charge air connecting pipe - B - for cylinder bank 1 and cylinder bank 2.
- Loosen clamp - arrow - from connecting pipe to air filter for cylinder bank 1 and cylinder bank 2 and remove it.
- Disconnect coolant hoses - arrows - and lay then so that they cannot be pinched when removing and installing engine.
- Disconnect starter wire - A - and generator wire - B - and place them on the engine.
- Unclip transmission ventilation line - arrows -.
- Disconnect connector from Intake Air Temperature (IAT) sensor (G42) - A - and from Mass Air Flow (MAF) sensor (G70) - B - for cylinder bank 1.
- Disconnect connector from MAF sensor 2 (G246) - A - and from IAT sensor 2 (G299) - B - for cylinder bank 2.
- Remove wire connection - arrow - of compressor for air suspension on air filter housing, refer to --> [ Wire Connection to Compressor for Air Suspension ] Service and Repair
- Remove both top sections of air filter upward.
- Open clamp and pull off servo-line - A -. Catch any fluid which drains out. Remove the A/C lines - B - from the A/C compressor.
With Engine Code BKW
- Disconnect fuel lines - arrows - from fuel filter.
- Separate connection of catalytic converter/center muffler and remove exhaust system. Refer to --> [ Muffler and Mountings Assembly Overview ] Service and Repair.
With Engine Code BWF
- Disconnect fuel lines - arrows - from fuel filter.
- Separate connection of particle filter/exhaust pipe and remove exhaust system. Refer to --> [ Muffler and Mountings Assembly Overview ] Service and Repair.
Continuation for All
- Remove heat shield on steering box and loosen universal joint. Refer to --> Suspension, Wheels, Steering 48 Description and Operation.
- Separate connectors on transmission as well as transfer case and loosen selector lever cable.
- Remove the driveshaft.
- Remove transmission carrier - A -.
- Disconnect brake lines at points indicated - arrow -. Catch draining brake fluid.
- In wheel housings, separate all connectors between body and front axle.
Preparing Scissor lift table (VAS 6131) for the continued work procedure:
• The basic set for Touareg (VAS 6131/6) consists of supports supports (VAS 6131/6-1) to (VAS 6131/6-7). To describe the following work sequence more clearly, they are called support 1 (for VAS 6131/6-1) to support 7 (for VAS 6131/6-7).
- Install support - 1 - on left and support - 2 - on right (arrows point in direction of travel) on the scissor lift platform (VAS 6131) and secure the bolts at the following positions:
• Left support - 1 -: A5, B4 and B5
• Right support - 2 -: G4, H4 and H5
- Tighten support 3 and support 4 on scissor lift table in the following positions:
• Left support - 3 -: A6 and C6
• Right support - 4 -: F6 and H6
- Turn down the turntables of supports - 3 - and - 4 -.
- Place supports - 5 - for subframe and - 6 - for transmission console in the corresponding positions on lift table.
Engine and transmission are separated after removal:
- Remove insulation mat under lower section of oil pan.
- Loosen clamp for starter cable.
- Loosen and remove transmission bolts - A -.
- Remove the six bolts for torque converter through hole in upper section of oil pan - arrow -. To do so, rotate engine at vibration damper using counter holder (T10172) and the associated pin (T10172/2).
- Install support - 7 - for transmission support in the corresponding positions on scissor lift platform and turn down its turntables completely.
- Before raising up the scissor lift platform, always engage the support for V10, V8 and V6 assembly (VAS 6131/8), which was completely turned down earlier, into hole of transmission flange - arrow - as shown.
- Position horizontally adjusted scissor lift table under engine/transmission assembly. The supports - 1 - and - 2 - must be guided into the corresponding mount - arrows - at right and left.
- At the same time, guide support - 6 - for transmission cross bar into corresponding holes - arrows - at right and left.
When all four supports are in the appropriate receptacle holes without pressure:
- If installed, check the support height of support for V10, V8 and V6 assembly (VAS 6131/8) at knurled nut and secure support in position D7 on scissor lift platform.
- Using light pressure beneath control arm, turn both turning knobs of supports 3 and 4 until the securing device can be removed using the tensioner hooks (VW 552).
- Guide support - 5 - into corresponding mount in subframe, if necessary check support height on knurled nut.
- Secure subframe to body.
- Loosen subframe bolts - 2 - and - 3 -, as well as transmission transverse support - 4 -.
If the subframe was not located:
- Loosen the subframe bolts - 1 -.
• If the subframe was not located, it is necessary to perform a vehicle alignment.
- Slowly lower the assembly, constantly observing clearances.