Engine, Removing

WARNING: This page is about a different car, the 2014 Volkswagen Touareg and 2013 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Used Oil Collection and Extraction Unit: SMN372500
Step Ladder: VAS5085
Engine Bung Set: VAS6122
Scissor Lift Table: VAS6131B with Scissor Lift Table - Audi Set: VAS6131/10 , Scissor Lift Table - A8 Set : VAS6131/11 , Scissor Lift Table - Q7 Set: VAS6131/13 and Scissor Lift Table - Audi Set - Mounting Pin : VAS6131/10-2 quantity: 3
Shop Crane - Drip Tray: VAS6208
Hose Clip Pliers: VAS6362
Puller - Ball Joint: T10187
Hose Clamps - Up To 25mm: 3094
Pry Lever: 80-200

-- Check the Diagnostic Trouble Code (DTC) memories of all control modules before removing, see Vehicle Diagnostic Tester in "Guided Functions"

NOTE:

Secure all disconnected lines and connection with suitable fixtures, for example, cable ties to the engine or to the body (depending on its >>origin<<). Seal off open connections with blind plugs.

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

So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Remove the engine compartment seal from the plenum chamber bulkhead.

-- Remove the windshield wiper arm. Refer to WIPER ARMS, REMOVING AND INSTALLING .

-- Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER .

-- Disconnect the engine cable connector from the Engine Control Module (ECM). Refer to Engine Control Module -J623- WITH PROTECTIVE HOUSING, REMOVING AND INSTALLING .

-- Remove the Ground (GND) connection -arrow- inside the plenum chamber.

Fig 1: Identifying Ground Wire

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-- Open the cover -A- on the central electric.

Fig 2: Identifying E-Box Cover

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-- Disconnect all connectors that go to the engine.

-- If necessary, open the clips, remove the engine wiring harness from the plenum chamber and lay it on the engine.

-- Disconnect the vacuum line -arrow-.

Fig 3: Identifying Vacuum Line -Arrow-

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-- Open the clamps and remove all four fuel supply and return lines -arrows- from the fuel filter.

Fig 4: Identifying Clamps -Arrows-, Fuel Supply Line And Return Lines

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-- Remove the bolts -arrows- and remove the fuel filter upward.

Fig 5: Fuel Filter -Arrows-

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-- Disconnect the air suspension connector, if equipped. Then remove the bolts -arrows- and the fuel filter bracket.

Fig 6: Connector For The Air Suspension

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-- Remove the bolt -arrow- and place the positive cable from the starter on the engine.

Fig 7: Identifying Bolt -Arrow- To Positive Cable

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-- Remove the air guide hose by loosening the hose clamps -arrows-.

Fig 8: Charge Air Hose Clamps -Arrows- And Hose

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-- Remove the air duct pipes. Refer to AIR DUCT PIPE, REMOVING AND INSTALLING .

-- Disconnect the connector -3-.

Fig 9: Identifying Bolts -1 & 2- And Electrical Connector -3-

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-- Remove the bolts -1 and 2-, remove the Throttle Valve Control Module -J338- from the intake tube.

-- Open the clamps -2 and 3- and remove the connecting hoses from the right charge air pipe.

Fig 10: Air Guide Hoses, Remove/Install

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-- Unclip the transmission vent line -2-, if equipped.

-- Open the clamps -arrows- and remove the intake line.

Fig 11: Identifying Clamps -Arrows- And Intake Hose

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-- Remove the connector -arrow- from the bracket and disconnect it.

Fig 12: Connector

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-- Remove the connector -A- from the plenum chamber bulkhead and disconnect it.

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-- Extract the refrigerant from the Air Conditioning (A/C) system. Refer to EVACUATING AND CHARGING VALVE, REMOVING AND INSTALLING, LOW AND HIGH PRESSURE SIDE .

-- Disconnect the connector -2- if applicable. Remove wiring harness.

Fig 13: A/C Compressor Refrigerant Lines And Electrical Connector -2-, Remove/Install

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-- Remove the bolts -3 and 4- and then remove the refrigerant lines from the A/C compressor.

-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- Remove the front wheels.

-- Remove the front wheel housing liners. Refer to FRONT WHEEL HOUSING LINER .

-- Drain the coolant. Refer to Draining .

-- Open quick-release coupling -A- below the coolant expansion tank and disconnect the coolant hose.

-- Then loosen coolant hose on plenum chamber bulkhead bracket.

Fig 14: Identifying Coolant Hose Quick-Release Coupling

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-- Open the clamp -arrow- to remove the coolant hose.

-- Loosen coolant hose on plenum chamber bulkhead and put aside.

Fig 15: Disconnecting Coolant Hose At Clamp

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-- Clamp the power steering hose with Hose Clamps - Up To 25mm: 3094 , open clamp -A- and remove the hose.

Fig 16: Identifying Hose Clamp 3094 And Clamp -A- On Power Steering Hose

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Lift the Vehicle

-- Disconnect GND connection -A- from the right longitudinal member.

Fig 17: Identifying Ground Connection

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-- Remove the bolt -A- and the connections on the transmission fluid cooler. Catch any fluid coming out.

Fig 18: Identifying Transmission Fluid Cooler Line Connection

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-- Clamp the power steering hose with : 3094 , open clamp -A- and remove the hose.

Fig 19: Identifying Power Steering Hose

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-- Disconnect the connector -2- on the Engine Coolant Temperature Sensor on Radiator Outlet -G83-.

Fig 20: Engine Coolant Temperature (ECT) Sensor On Radiator Outlet -G83- -2-

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-- Open clamp -arrow- and remove lower left coolant hose from engine.

Fig 21: Identifying Coolant Hose -Arrow- To Left Coolant Pipe

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-- Open the clamps -A- and remove the auxiliary heater coolant hoses.

Fig 22: Identifying Heater Core Coolant Hoses

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-- Remove the exhaust system rear section. Refer to OVERVIEW - MUFFLER .

-- Remove the driveshaft. Refer to DRIVESHAFT .

-- Disconnect the connector -A- from the transmission.

Fig 23: Identifying Transmission Connectors

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-- Remove the noise insulation retaining plate -A-.

Fig 24: Identifying Transmission Transverse Support

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-- Remove the bolts -arrow- from the particulate filter.

Fig 25: Identifying Particulate Filter Suspended Mount Bolts -Arrow-

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-- If equipped remove the Exhaust Gas Temperature Sensor 3 -G495- -arrow-.

Fig 26: Locating Exhaust Gas Temperature Sensor 3 -G495- -Arrow-

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-- If equipped, remove the connecting hoses -arrow- from the particle filter that runs from the pressure lines to the Differential Pressure Sensor -G505-.

Fig 27: Disconnect Differential Pressure Sensor Hoses -Arrows

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-- If equipped, remove the reducing agent line on the Reducing Agent Injector -N474- and free it up.

-- Disconnect the gearshift mechanism at the ball head and remove it from the transmission.

Fig 28: Locating Selector Lever Cable Bolts

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CAUTION:

Risk of distorting airbag spiral spring.

Separate universal joint from steering gear only when front wheels are in straight ahead position.
Secure steering wheel with adhesive tape to prevent position of steering wheel and steering gear from changing.

-- If equipped, remove bolts -arrows-.

-- Remove heat shield -1- on steering gear -2-.

Fig 29: Identifying Heat Shield -1- And Universal Joint -2-, Removal

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-- Remove the bolt -A- and remove the universal joint from the steering gear.

Fig 30: Identifying Bolt -A- To Universal Joint Bolt

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-- Disconnect the connector from the steering gear.

Fig 31: Identifying Steering Gear Connector

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-- Disconnect the connectors -arrow- at the left and right on the front speed sensors.

Fig 32: Identifying Speed Sensor Connector

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-- Disconnect the connector -arrow- from the wear display.

Fig 33: Identifying Brake Pad Wear Indicator Connector

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-- Remove wiring harness bolts -arrows-.

Fig 34: Identifying Wheel Bearing Housing Brackets

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CAUTION:

Be careful not to stretch the lines when removing and installing the brake caliper. Do not change the bent shape of the brake lines.

-- Remove the bolts -A- from the brake caliper. Then remove the brake caliper and secure it inside the wheel housing using the Tensioning Strap: T10038 .

Fig 35: Locating Multi-Point Bolt

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-- Loosen upper control arm nut a few turns and pull joint off with Puller - Ball Joint: T10187 -1-.

Fig 36: Identifying Removal Of Ball Joint With Puller T10187 -1-

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-- Remove the nut completely and disconnect the control arm.

-- Remove the bolt -arrow- at the bottom of the coupling rod.

Fig 37: Identifying Coupling Rod To Stabilizer Bar Bolts/Nuts -Arrow- And Shock Absorber Nuts -A-

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-- Remove the nut -A- from the lower control arm. Leave the bolt in the hole.

-- 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.

Fig 38: Identifying Lower Bolts -Arrows- From Transmission

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Prepare the Scissor Lift Table: VAS6131B with the Scissor Lift Table - Touareg Set: VAS6131/6 as follows:

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VAS6131/6-1
- Fastening point: A2; B1; B2
VAS6131/6-2
- Fastening point: H2; G1; G2
VAS6131/6-3
- Fastening point: A3; C3
- Use a plate with a short spindle
VAS6131/6-4
- Fastening point: F3; H3
- Use a plate with a short spindle
VAS6131/6-5
- Fastening point: A7
VAS6131/6-5
- Fastening point: H7
VAS6131/6-6
- Fastening point: B12
VAS6131/6-6
- Fastening point: G12

NOTE:

The Scissor Lift Table - Touareg Set: VAS6131/6 consists of the Scissor Lift Table - Touareg Set - Support: VAS6131/6-1 through Scissor Lift Table - Touareg Set - Support: VAS6131/6-7 . They are referred to here simply as support 1 (for VAS6131/6-1) through support 7 (for VAS6131/6-7).

-- First manually secure the mounting elements to the scissor lift table.

-- Position the scissor lift table horizontally.

Note the bubble level (sight glass) on the scissor lift table.

-- Position the Scissor Lift Table: VAS6131B under the vehicle.

-- The supports -1 and 2- must be guided into the corresponding mount -arrows- at right and left.

Fig 39: Identifying Supports And Mounts

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-- At the same time, guide right and left transmission cross bar supports -6- into the corresponding holes -arrows-.

Fig 40: Identifying Support For Transmission Cross Bar And Holes

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When all four supports are in the appropriate receptacle holes without pressure:

-- Guide the supports -5- to the corresponding mounts of the subframe. Use the knurled nut to adjust the height of the support, if necessary.

Fig 41: Identifying Support In Mount In Subframe

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-- Using light pressure under the control arms, screw the rotary plate of supports 3 and 4.

-- Secure subframe installation position. Refer to OVERVIEW - SUBFRAME .

-- Mark the location of the engine carrier to the longitudinal members using a felt-tip pen.

-- Remove the bolts -1-.

-- Remove the bolts -2 to 4- in a diagonal sequence in steps.

Fig 42: Identifying Bolts -4- And Engine Carrier Bolts -3-

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CAUTION:

Lower the engine very carefully. Make sure all connections to the body are disconnected. Rework if necessary.

-- Carefully lower the engine/transmission.