Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Lifting Tackle (3033)
• Engine and Transmission Holder (VAS 6095)
• Universal Mounting (VAS 6095/1)
• Bracket for V6 TDI Engine (VAS 6095/1-4)
• Engine/Transmission Jack (V.A.G 1383 A)
• Drip Tray (V.A.G 1306)
• Shop Crane (VAS 6100)
• Scissor Lift Table (VAS 6131)
• Hose Clamps Up to 25 mm Dia. (3093)
• Tensioner Hooks (VW 552)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Spring Type Clip Pliers (VAS 5024A)
• Parts Trolley (V.A.G 1698)
• Engine Bung Set (VAS 6122)
• Basic Set for Touareg (VAS 6131/6)
• Cable Tie
The engine with transmission is removed downward.
- Check the Diagnostic Trouble Code (DTC) memories for all control modules before removing the engine. Refer to "Guided Functions" in the vehicle diagnostic tester.
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route all lines and wires in their original locations.
• Ensure sufficient clearance to all moving or hot components.
- Check if a coded radio is installed. Obtain the anti-theft code if necessary.
• To allow free rotation of the driveshaft, move the selector lever to the "N" position.
• Leave the key in the ignition lock to prevent the steering wheel from locking.
• It is advisable to remove the front wheels before removing the engine/transmission assembly. The vehicle can be lowered on the hoist until the cover 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 engine.
• To prevent damage to the removed components, use (V.A.G 1698) for storage.
CAUTION!
The procedure for disconnecting the battery must be observed exactly!
- Turn off the ignition and all electrical components.
- First, disconnect the battery under driver's seat.
- Disconnect the auxiliary battery in the luggage compartment spare wheel well.
- All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.
- Remove the engine cover. First pull the cover forward and then pull it upward- arrows -.
- Remove the engine compartment seal from the plenum chamber bulkhead.
- Remove the plenum chamber cover.
- Unclip the Engine Control Module (ECM) in the right of the plenum chamber from its retainers and remove the connector from the control module.
- Disconnect the ground connector - 1 - from the ECM wiring harness.
- Open the fuse box cover in the left of the plenum chamber and disconnect the connectors - 1, 2 and 3 -.
- Remove the engine wiring harness (smaller connector on the ECM) from the plenum chamber and lay it down on the engine.
- Disconnect the vacuum hose from the vacuum reservoir.
- Remove the fuel filter with the bracket and fuel cooler. Refer to => [ Fuel Filter and Cooler Overview ] Description and Operation.
- Remove the starter wire - arrow - and lay it down on the engine.
- Remove the connecting hose between the throttle valve control module and the charge air pipe.
- Disconnect the charge air pressure hoses - 1 - from the right charge air pipe.
- Unclip the transmission ventilation line - 2 -.
- Disconnect connector - arrow -.
- Remove the connector hose - 5 - between the Mass Airflow (MAF) sensor and turbocharger.
- Disconnect the following connectors at the plenum chamber bulkhead:
• Connector 1 for the exhaust pressure sensor 1 (G450)
• Connector 2 for the Heated Oxygen Sensor (HO2S) (G39)
• Connector 3 for the Exhaust Gas Temperature (EGT) sensor 1 (G235)
• Connector 4 for the pre-particulate filter temperature sensor (G506)
- Disconnect the vacuum line - arrow -.
- Extract the refrigerant from the Air Conditioning (A/C) system.
- Disconnect the front refrigerant line from the A/C compressor.
- Remove the noise insulation panel.
- Remove the front wheels.
- Remove the front wheel housing liners..
- Clamp off the power steering fluid hose using (3093) and disconnect it - arrow -. Catch fluid which runs out.
- Loosen the clamp on the refrigerant line, remove the bolt - 2 - and disconnect the refrigerant line.
- Drain the coolant. Refer to => [ Draining and Filling ] Draining and Filling.
- Disconnect the coolant hoses from the expansion tank.
- Unclip the coolant hoses from the retainers on the plenum chamber bulkhead.
- Disconnect lines - arrow - from transmission oil cooler at lower right. Catch fluid which runs out.
- Loosen the double clamp between the particulate filter and rear muffler and slide it forward.
- Support the exhaust system using (V.A.G 1383 A), remove the mounts and lower the exhaust system.
- Disconnect the pressure lines from the particulate filter.
- Remove the heat shield on the steering gear and loosen the universal joint.
- Disconnect the connectors on the transmission and transfer case and loosen the selector cable.
- Remove the driveshaft.
- Remove the transmission crossmember - A -.
- Remove the coolant hose upward from the radiator.
- Disconnect the coolant hose on the upper coolant hose junction piece.
- Remove the Ground (GND) wire bolt - 1 - on the longitudinal member.
- Disconnect the auxiliary heater coolant hoses - 1 - and collect the coolant. Position them so they do not break off when removing the engine.
- Disconnect the brake lines in the wheel housing at brake hose and catch fluid which runs out.
- In the wheel housings, separate all connectors between the body and front subframe.
- Secure the struts using (VW 552) as illustrated.
- Remove the strut upper bolts.
• To separate the engine from the transmission after removing the engine, remove the lower bolts connecting them together.
Preparing the (VAS 6131) for the continued work procedure:
• The vehicle specific basic set for Touareg VAS 6131/6 consists of the 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).
- Install support 1 on the left and support 2 on the right on the (VAS 6131) with the arrows pointing in the direction of travel and tighten the bolts in the following locations:
Support 1: A5, B4 and B5
Support 2: G4, H4 and H5
- Secure support 3 and support 4 on the lift table in the following locations:
Support 3: A6 and C6
Support 4: F6 and H6
- Lower the support plates on supports 3 and 4.
- Secure the subframe.
- Place support 5 for the subframe and support 6 for the transmission crossmember in the correct locations on the scissor lift table.
- Position the horizontal scissor lift table under the engine. Guide supports 1 and 2 into the corresponding mount - arrow - on the left and right.
- At the same time, guide support 6 for the transmission crossmember into the corresponding holes - arrows - on the right and left.
When all four supports are in the correct mounts without being pressed into place:
- Position both support plates on the axle supports under the control arm and support it lightly so the retainer can be removed with the (VW 552).
- Now guide support 5 into the correct mounts in the subframe - arrow - and correct the height of the supports with the knurled nut if necessary.
- Loosen the subframe bolts - 1, 2 and 3 - and the transmission crossmember - 4 -.
• Guide the engine and transmission carefully when lowering to prevent damage to the vehicle body.
• If the subframe was not secured on the body, perform an alignment after installing.
- Slowly lower the engine/transmission assembly, constantly observing clearance.