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)

• Drip Tray for VAS 6100 (VAS 6208)

• Hose Clip Pliers (VAS 6362)

• Ball Joint Puller (T10187)

• Basic Set for Touareg (VAS 6131/6)

• Support F/VAS 6131 for V6/V10/V8 (VAS 6131/8)

• Step Ladder (VAS 5085)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

The engine and transmission are removed downward.

• 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 plugs.

• To rotate the driveshaft freely, move the selector lever into the "N" position.

• 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 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 the container for removed parts (V.A.G 1698) as 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.

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. Disable the high voltage system.

Procedure

- Disconnect the battery.

- Evacuate the refrigerant in the Air Conditioning (A/C) system.

- Remove the front wheels.

- Drain the coolant from the high temperature coolant system. Refer to => [ Draining and Filling, High Temperature Coolant Circuit ] Draining and Filling, High Temperature Coolant Circuit.

- Drain the coolant from the low temperature coolant system. Refer to => [ Draining and Filling, Low Temperature Coolant Circuit ] Draining and Filling, Low Temperature Coolant Circuit.

- Remove the clamps - arrows -, the hose - 1 - and the connecting pipe.






- Disconnect all the connectors - 1 through 4 - for the Heated Oxygen Sensors (HO2S).






- Remove the windshield wiper arms.

- Remove the plenum chamber cover.

- Remove the anti-theft protection from the Engine Control Module (ECM). Refer to => [ Engine Control Module J623 ] Service and Repair.

- Disconnect the engine harness connector from the ECM.

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






- Open the cover - A - for the connection/conjunction box 2.






- Disconnect all connectors that go to the engine.

- Remove the engine harness from the plenum chamber and lay it on the engine.

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






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






- Remove the coolant hoses - arrows -.






- Remove the bolt - arrow - and disconnect the A/C system refrigerant line. Close off any open lines with suitable plugs.






- Remove the bolts - 1 and 2 - and remove the electric drive power and control electronics cover panel - A -.






- Open both quick-release couplings - arrows - and remove the coolant lines.






- Unlock and disconnect the electrical A/C compressor high voltage cable - 1 -.






- Unlock and disconnect the pilot connector - 1 - from the electric drive power and control electronics. Unlock and disconnect the high voltage cables - 2, 3 and 4 - in sequence. Unclip the high voltage cables and lay them on the engine.






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






The fuel supply line is still under pressure (approximately 6 bar)! Wear eye protection and safety gloves in order to avoid injuries and skin contact. Wrap a cloth around the connection before removing the fuel hose. Remove the hose connection carefully to release the pressure.

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

- Disconnect the fuel supply line - arrow -.






- Disconnect the electrical connector - arrow - from the steering gear.






- Remove the bolts - arrows - and the heat shield - 1 - from the universal joint - 2 -.






• Separate the universal joint from the steering gear only when front wheels are in the straight ahead position.

• Do not change the steering wheel and steering gear positions any more, secure the steering wheel with adhesive tape.

- Remove the universal joint bolt - 1 - from the steering gear and separate it upward.






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

- Remove the bolt - arrow - and the ground cable from the engine.






- Remove the clamp - 1 -. Remove the circlip - arrow - and the clutch mechanism breather. Close off any open lines.






- Loosen the right front wheel housing liner and disconnect the connectors - arrows - from the auxiliary hydraulic pump control module. Free up the wiring harness.






- Remove the nut and the ground cable - A - from the right longitudinal member.






- Remove the bolt - A - and the connections from the transmission fluid cooler. Catch any fluid leaking out.






- Clamp off the power steering hose using the hose clamps up to 25 mm dia. (3094). Disconnect the power steering lines - arrows -. Use the used oil collecting and extracting device (V.A.G 1782) to catch any fluid leaking out.






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






- Loosen the upper control arm to wheel bearing housing nut a few turns, and separate the control arm from the wheel bearing housing the ball joint puller (T10187) - 1 -.






- Remove the nut completely and disconnect the control arm.

- Disconnect the connectors - arrow - from 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 - arrow -.






- Remove the shock absorber 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 caliper. Do not change the shape of the brake lines.

- Remove the brake caliper bolts - arrows -. Then remove the brake caliper and secure it inside the wheel housing using the tensioning strap (T10038).






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

- Disconnect the connectors - arrows - from the transmission.






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






- Support the exhaust system between the center and rear mufflers using the engine-/gearbox jack (V.A.G 1383 A). Remove the exhaust system suspended mounts and lower the exhaust system.

- Remove the rear driveshaft.

- Disconnect the selector lever cable - 1 - from the selector shaft ball stud and remove the lock washer - 3 -






• Ignore - item 2 -.

• Do not bend or kink the selector lever cable.

• Always replace the lock washer.

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

- Using the locating pins (T10300) , secure the subframe to the body.






- Then, proceed exactly the same with the other rear subframe bolt - 2 -.

- Remove the bolts - 1 - from the bottom of the engine. The engine support (VAS 6131/8-1) will be installed in this hole later.






- If the engine and the transmission are going to be separated after they have been removed, then remove the engine to transmission lower bolts - arrows -.

Prepare the scissor lift table (VAS 6131) for the next procedures:






1 VAS 6131/6-1

• Attachment points: A4, B3, B4

2 VAS 6131/6-2

• Attachment points: H4, G3, G4

3 VAS 6131/6-3

• Attachment points: A5, C5

• Use a plate with a short spindle.

4 VAS 6131/6-4

• Attachment points: F5, H5

• Use a plate with a short spindle.

5 VAS 6131/6-5

• Attachment point: B7

6 VAS 6131/8-1

• Attachment point: D7

7 VAS 6131/6-5

• Attachment point: G7

8 VAS 6131/6-6

• Attachment point: B14

9 VAS 6131/6-6

• Attachment point: G14

• Install all supports to the scissor lift table just hand tight so that the position can be corrected later.

• Use a plate with a short spindle for supports VAS 6131/6-3 and VAS 6131/6-4. The plates with a long spindles are needed to support the transmission.

- Move the scissor lift table under the engine. The supports - 1 - must be guided into the corresponding location - arrow - on the right and left sides.






- At the same time, guide the right and left supports for the transfer case support into the corresponding locations - arrow -.






When all 4 supports are in the appropriate locations, without pressure:

- Rotate the support plates under the control arms with a slight pretension.

- Guide the supports - 2 - into the corresponding locations in the subframe; if necessary, check the support height using the knurled nut.






- Tighten all the supports to the scissor lift table.

- Support the engine also with the engine support (VAS 6131/8-1). Install the hook into the open bolt hole on the engine from underneath. Use the spindle to adjust the height and then tighten the mounts on the scissor lift table.






- Remove the left and right shock absorber bolts - A - from the lower control arms.






- Remove the transmission support bolts - 1 - and remove the subframe bolts - 3 and 4 -.






Lower the engine very carefully. Ensure that all connections to the body are disconnected. Rework if necessary.

- Slowly lower the engine/transmission assembly always making sure there is enough clearance.

- Tighten the nuts - arrow - on the right and left sides. This will prevent the engine carrier from slipping.