Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Scissor Lift Table (VAS 6131)
• Drip Tray (V.A.G 1306)
• Spring Type Clip Pliers (VAS 5024 A)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Tensioner Hooks (VW 552)
• Basic Set for Touareg (VAS 6131/6)
• Support F/VAS 6131 for V6 / V10 / V8 (VAS 6131/8)
• Container for Removed Parts (V.A.G 1698)
• Engine Bung Set (VAS 6122)
• Cable Tie
The engine with transmission is removed downward.
- Before removing the engine, check the Diagnostic Trouble Code (DTC) memories of all control modules. Refer to "Guided functions" in the vehicle diagnosis, testing and information system VAS 5051 or VAS 5052.
• To allow free rotation of the driveshaft, move the selector lever into the "N" position.
• Leave the key in the ignition lock to prevent the steering wheel lock from engaging.
• It is advisable to remove the front wheels before the disassembly. The vehicle can than be lowered on the hoist until the backing plates for 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 the engine.
• To prevent damage to the removed components, use a container for removed parts (V.A.G 1698) for storage.
• All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.
The procedure for disconnecting the battery must be observed exactly!
- Turn off the ignition and all electrical consumers.
- First, disconnect the battery under driver's seat.
- Disconnect the second battery inside the luggage compartment in the spare tire wheel well.
- Remove the right and left wiper arms.
- Pull engine compartment cover seal off the bulkhead.
- Remove the covers - A -, - B - (if equipped) and - C - from the engine compartment and - D - from the plenum chamber.
Vehicles with a Anti-Theft Engine Control Module (ECM):
• The threads of the shear bolts are equipped with locking compound. The inhibition effect of the locking compound can be lowered by heating the shear bolts and using the hot air gun from the wiring harness repair set (VAS 1978).
Cover wires, harness connectors and control modules in the close vicinity of the ECM to prevent damage from burning.
Perform the adjustments on the hot air gun - 4 - as shown:
- Turn the potentiometer for the temperature adjustment - 2 - to maximum heat output (600 °C (1112 °F)).
- Move the two stage switch for air quantity - 3 - to position 3.
By heating the shear bolts, parts of the protective housing are heated intensely. Wear protective gloves to prevent injuries.
- Guide the nozzle of the hot air gun onto the shear bolt - arrows -.
- Turn on the heat gun and heat the bolt head for approximately 20 to 25 seconds.
- Remove the shear bolt - arrows - using pliers.
The procedure for the second shear bolt is exactly the same.
- Remove the cover - 1 - from the ECM.
Continuation For all Vehicles:
- Disconnect the smaller connector - A - from the ECM and remove the Ground (GND) connection - arrow - for the wiring harness.
- Open the fuse box cover in the left plenum chamber and disconnect connectors - A, B and C -.
- Remove the wiring harness from the plenum chamber and place it on the engine.
- Remove the intake line on both sides between the air filter and intake connection.
• With connector couplings, follow the installation instructions closely. refer to => [ Hose Connections with Connector Couplings ] Service and Repair.
Vehicles with Engine Code BKW:
- Disconnect the vacuum lines - arrows - for the Exhaust Gas Recirculation (EGR) valve and brake booster as well as the harness connector - A - for the heated oxygen sensor (G39) for cylinder bank 1.
- Disconnect the vacuum line - arrow - for the EGR valve as well as the harness connector - A - for the heated oxygen sensor 2 (G108) for cylinder bank 2.
Vehicles with Engine Code BWF:
- Disconnect the vacuum lines - 1 - for the vacuum actuators for the bypass flap (mark the 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 the heated oxygen sensor (G39)
2 6-pin harness connector, brown: for the heated oxygen sensor 2 (G108)
3 2-pin harness connector, black: for the exhaust gas temperature sensor 1 (G235)
4 2-pin harness connector, brown: for the bank 2 exhaust gas temperature sensor 1 (G236)
Continuation for all Vehicles:
- Disconnect the harness connectors - arrows - for the glow plugs in cylinder bank 1 and cylinder bank 2.
- Secure the struts using the tensioner hooks (VW 552) as shown.
- Remove the bolts at the top of the struts.
- Remove the noise insulation.
- Extract the refrigerant from the Air Conditioning (A/C) system.
- Drain the coolant. Refer to => [ Draining and Filling ] Draining and Filling.
- Remove the bolt - arrow - from the transmission oil cooler below on the right. Catch any fluid which leaks out.
- Disconnect the line - A - from the power steering cooler at the lower left. Catch any fluid which leaks out.
- Remove the charge air pipe - B - for cylinder bank 1 and cylinder bank 2.
- Loosen the clamp - arrow - for the pipe to the air filter for cylinder bank 1 and cylinder bank 2 and remove it.
- Disconnect the coolant hoses - arrows - and lay them so that they cannot be pinched when removing and installing the engine.
- Remove the nuts and the starter wire - A - and generator wire - B - and place them on the engine.
- Unclip the transmission ventilation line - arrows -.
- Disconnect the connectors from the intake air temperature sensor (G42) - A - and the mass air flow sensor (G70) - B - for cylinder bank 1.
- Disconnect the connectors from the mass air flow sensor 2 (G246) - A - and the intake air temperature sensor 2 (G299) - B - for cylinder bank 2.
- Disconnect the connection - arrow - for the air suspension compressor from the air filter housing. Refer to => [ Line Connection for Air Suspension ] Description and Operation.
- Remove both upper air filter housings upward.
- Open the clamp and pull off the power steering cooler line - A -. Catch any fluid which leaks out. Remove the A/C lines - B - from the A/C compressor.
Vehicles with Engine Code BKW:
- Disconnect the fuel lines - arrows - from the fuel filter.
- Separate the connection for the catalytic converter/center muffler and remove the exhaust system. Refer to => [ Muffler and Mounts ] Muffler and Mounts.
Vehicles with Engine Code BWF:
- Disconnect the fuel lines - arrows - from the fuel filter.
- Separate the connection for the particle filter/exhaust pipe and remove the exhaust system. Refer to => [ Muffler and Mounts ] Muffler and Mounts.
Continuation for all Vehicles:
- Remove the heat shield from the steering gear and loosen the universal joint bolt.
- Disconnect the connectors from the transmission and the transfer case. Then loosen the selector lever cable.
- Remove the rear driveshaft.
- Remove the transmission support - A -.
- Disconnect brake lines at the points indicated - arrow -. Catch the leaking brake fluid.
- In the wheel housings, disconnect all connectors between the body and front subframe.
Preparing the scissor lift table (VAS 6131) for the continued work procedure:
• The basic set for Touareg (VAS 6131/6) consists of supports (VAS 6131/6-1) to (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).
- Install the support - 1 - on the left and the support - 2 - on the right (arrows point in direction of travel) of the scissor lift table (VAS 6131) and secure the supports at the following positions:
• Left support - 1 -: A5, B4 and B5
• Right support - 2 -: G4, H4 and H5
- Tighten support 3 and support 4 to the 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 the subframe and - 6 - for the transmission in the corresponding positions on the lift table.
Engine and transmission are separated after removal:
- Remove the insulation mat under the lower oil pan.
- Loosen the clamp for the starter cable.
- Loosen and remove the transmission bolts - A -.
- Remove the six bolts for the torque converter through the hole in the upper oil pan - arrow -. To do so, rotate the engine at the vibration damper using the counterhold tool Touareg V10 (T10172) and the associated adapter for T10172 counter hold tool (T10172/2).
- Install the support - 7 - for the transmission in the corresponding positions on the scissor lift table and turn down its turntables completely.
- Before raising up the scissor lift table, always engage the support F/VAS 6131 for V6 / V10 / V8 (VAS 6131/8) , which was completely turned down earlier, into the hole in the transmission flange - arrow - as shown.
- Position the horizontally adjusted scissor lift table under the engine/transmission assembly. The supports - 1 and 2 - must be guided into the corresponding locations - arrows - on the right and left.
- At the same time, guide support - 6 - for the transmission into the corresponding locations - arrows - on the right and left.
When all four supports are in the appropriate locations without pressure:
- If installed, check the support height of the support F/VAS 6131 for V6 / V10 / V8 (VAS 6131/8) at the knurled nut and secure the support in position D7 on the scissor lift table.
- Using light pressure beneath the control arm, turn both knobs for supports 3 and 4 until the securing device can be removed using the tensioner hooks (VW 552).
- Guide the support - 5 - into the corresponding location in the subframe, if necessary check the support height on the knurled nut.
- Secure the subframe.
- Loosen the subframe bolts - 2 and 3 - , as well as transmission carrier bolts - 4 -.
If the subframe was not located:
- Loosen the subframe bolts - 1 -.
• It will be necessary to perform a wheel alignment if the subframe was not secured
- Slowly lower the assembly, constantly observing clearances.