3.2L - Engine Assembly - Engine Code(s): Baa & Bmx: Other Volkswagen Touareg I

ENGINE, REMOVING

Special tools and workshop equipment required

1. Lifting Tackle 3033
2. Tensioner Hooks VW 552
3. Engine and Transmission Holder VAS 6095
4. Drip Tray V.A.G 1306
5. Torque Wrench (5-50 Nm) V.A.G 1331
6. Torque Wrench (40-200 Nm) V.A.G 1332
7. Engine-/Gearbox Jack V.A.G 1383 A
8. Spring Type Clip Pliers VAS 5024 A
9. Step Ladder VAS 5085
10. Suction Pump VAS 5226
11. Shop Crane - Load Cap = 700-1200 KG VAS 6100
12. Scissor Lift table VAS 6131
13. Adapter for K-jetronic Test Device V.A.G 1318/20
14. Container for Removed Parts V.A.G 1698
15. Left Subframe Support VAS 6131/6-1
16. Right Subframe Support VAS 6131/6-2
17. Left Suspension Support VAS 6131/6-3
18. Right Suspension Support VAS 6131/6-4
19. Supports VAS 6131/6-5 (Qty. 2)
20. Supports VAS 6131/6-6 (Qty. 2)
21. Transmission Support VAS 6131/6-7
22. V6 Engine Support VAS 6131/7
23. Cable Tie

Procedure

The engine with transmission is removed downward.

Note. 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 lock from engaging. It is advisable to remove the front wheels before removing the engine/transmission assembly. The vehicle can be lowered on the hoist until the brake disc splash shields are just above the floor. This enables the most ergonomic work position possible regarding accessibility of components in the engine compartment. To prevent damage to the removed components, use the container for removed parts V.A.G 1698 for storage. When the engine is 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.

Check the Diagnostic Trouble Code (DTC) memories of all control modules, before removing the engine. Refer to the vehicle diagnostic tester.

Battery, Disconnecting

The procedure must be strictly followed!

Turn off the ignition and all electrical components.

First, disconnect the battery under the driver seat. Refer to Removal and Installation

Removing

Remove the left and right windshield wiper arms. Refer to "Windshield Wiper System" in Removal and Installation .

Remove the engine compartment cover seal from the bulkhead.

Remove the covers -A, B and C- in the engine compartment and cover -D- for plenum chamber.

Scheme 173

Install the adapter V.A.G 1318/20-1 to the adapter for K-jetronic test device V.A.G 1318/20.

Scheme 174

Turn the T-piece counterclockwise in the -direction of the arrow- until it is completely open.

Remove the protective cap from the breather valve.

Install the adapter for K-jetronic test device V.A.G 1318/20 and the adapter V.A.G 1318/20-1 with the suction pump VAS 5226 to the breather valve -1-.

Scheme 175

Turn the T-piece clockwise into the breather valve until the stop.

When the fuel pressure has been released, the fuel system may be opened.

In addition, wrap a cloth around the connection to catch any fuel which leaks out.

Scheme 176

Disconnect the fuel supply line -arrow-.

All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.

Disconnect the breather line -arrow- from the EVAP canister purge regulator valve 1 -N80- in the engine compartment.

Scheme 177

Disconnect the small connector -A- from the Engine Control Module (ECM) and disconnect the ground connection -arrow- for the wiring harness.

Scheme 178

Open the fuse box cover in the left plenum chamber and disconnect connectors -A, B and C-.

Scheme 179

Remove the wiring harness from the plenum chamber and place it on engine.

Remove the starter wire -A- and generator wire -B- and place them on engine.

Scheme 180

Remove the vacuum hose -1- from the intake manifold.

Scheme 181

With Engine Code BAA

Remove the vacuum hose -4- from the intake manifold.

Continuation for all Vehicles

Remove the pressure hose from the Secondary Air Injection (AIR) pump -arrow-.

Scheme 182

Disconnect connectors -1 through 4- for the Oxygen Sensors (O2S) and place the connectors on engine.

Scheme 183

1. Cylinders 1 through 3 = black
2. Cylinders 4 through 6 = brown

Disconnect the line -arrow- for the air suspension compressor from the air filter housing as follows

Scheme 184

Carefully pry off the green circlip -1- using a screwdriver. Then, press the clamping ring -2- in the direction of the -arrow-.

Pull only the line -B- from the connection -A- on the air filter housing.

Scheme 185

Remove the upper air filter housing. Refer to AIR FILTER ASSEMBLY OVERVIEW .

Unclip the transmission breather line from the air filter housing.

Evacuate the refrigerant from the Air Conditioning (A/C) system. Refer to "A/C Service Station" in Description and Operation .

Disconnect the A/C lines from the A/C compressor.

Remove the noise insulation. Refer to "Underbody Impact Guard" in Description and Operation .

Scheme 186

Remove the refrigerant line bolts -2 and 3- and lines from the A/C compressor.

Drain the coolant. Refer to DRAINING AND FILLING .

Remove the upper coolant hose from the radiator, and the lower coolant hose from the coolant pipe.

Disconnect all the coolant hoses from the expansion tank.

Note. Observe disposal regulations!

Remove the bolt -arrow- and disconnect the line from the transmission oil cooler at the lower right. Catch any fluid which leaks out.

Scheme 187

Disconnect the line from the power steering fluid cooler below on the left. Catch any fluid which leaks out.

Scheme 188

Remove the nut -A- and ground connection -A- from the longitudinal member.

Loosen the double clamp between the catalytic converter and center muffler and push the clamp forward.

Support the rear muffler using the engine-/gearbox jack V.A.G 1383 A, remove the rear mounts and lower the exhaust system.

Remove the suspended mount for the catalytic converter from the body.

Remove the heat shield from the steering gear and loosen the universal joint. Refer to Description and Operation .

Disconnect connectors -A- on the transmission as well as on the differential -B- and release the gear selector cable. Refer to [For transmission(s) 09D] Removal and Installation .

Scheme 189

Remove the rear driveshaft. Refer to [For transmission(s) 09D] Removal and Installation .

Remove the front wheels.

Remove the front wheel housing liners. Refer to Description and Operation .

Note. Observe disposal regulations!

Disconnect the brake lines from the brake hoses (in the wheel housing) and catch any leaking fluid.

In the wheel housings, Disconnect all connectors between the body and front suspension.

Disconnect the air suspension connecting lines from the strut.

Remove the noise insulation angle bracket nuts and bracket -A-.

Scheme 190

Secure the struts using the tensioner hooks VW 552 as shown.

Scheme 191

On each side of the vehicle, remove the strut upper bolts. Refer to Removal and Installation .

Preparing the Scissor Lift table VAS 6131

Install the left subframe support VAS 6131/6-1 -1- and right subframe support VAS 6131/6-2 -2- -arrows show the direction of travel- to the scissor lift table VAS 6131 at the following positions and tighten the bolts

Scheme 192

1. Left support -1- : A5, B4 and B5
2. Right support -2- : G4, H4 and H5

Install both suspension supports VAS 6131/6-3 and VAS 6131/6-4 -3- to the scissor lift table VAS 6131 at the following positions

1. Left support: A6 and C6
2. Right support: F6 and H6

Rotate the pads on the supports downward.

Install the support VAS 6131/6-5 -4- for the subframe and -5- support VAS 6131/6-6 for the transmission mount in the appropriate positions on the scissor lift table VAS 6131.

Position the horizontally adjusted scissor lift table VAS 6131 under the engine/transmission assembly. The supports -1- must be guided into the corresponding mounts -arrow- on the right and left.

Scheme 193

Simultaneously, guide the right and left supports for the transmission mounts into the corresponding holes -arrow-.

Scheme 194

When all four supports are in the appropriate holes without pressure

Using light pressure beneath the control arm, turn both pads on the axle supports until the securing device can be removed using the tensioner hook VW 552.

Guide the supports -2- into their respective holes in the subframe, correcting the support height as necessary with the knurled nuts.

Loosen the subframe bolts -1, 2 and 3- as well as the transmission carrier -4- bolts.

Scheme 195

Note. After loosening the subframe, it will be necessary to perform a wheel alignment on the vehicle.

Slowly lower the engine/transmission assembly, constantly observing clearance.

ENGINE, INSTALLING

Note. When installing the engine/transmission assembly, it is always necessary to bring the engine carrier into contact with the body using the scissor lift table VAS 6131. >>Pulling up<< the engine carrier using the bolts damages the thread inserts! If a new engine is being installed, then the three holes on the front side -arrows- must be closed up with bolts.

Installing

Installation is performed in reverse order. When doing this note the following

Make sure the alignment bushings for the engine to transmission are installed in the cylinder block. Install if necessary.

If the subframe with suspension has been removed from the scissor lift table VAS 6131

Position the suspension with subframe again on the prepared scissor lift table VAS 6131.

Set the engine on assembly carrier.

If the transmission is not yet bolted on

Support the engine using the V6 engine support VAS 6131/7.

Before installing the assembly, install the exhaust manifolds with catalytic converters onto the engine. Refer to EXHAUST MANIFOLD WITH PRIMARY CATALYTIC CONVERTER AND ATTACHMENTS OVERVIEW .

When installing the engine, raise the V6 engine support VAS 6131/7 only so far that the gear selector cable can be attached.

Reconnect all lines, hoses and connections that were disconnected for the removal procedure.

Connect the Air Conditioning (A/C) lines.

Charge the A/C system. Refer to "A/C Service Station" in Description and Operation .

Fill the power steering fluid. Refer to General Information .

Top off the engine oil. Refer to ENGINE OIL, DRAINING OR EXTRACTING, CHANGING OIL FILTER AND FILLING OIL

Electrical connections and routing. Refer to the appropriate SYSTEM WIRING DIAGRAMS information.

Fill the cooling system. Refer to DRAINING AND FILLING .

Fill the transmission fluid. Refer to [For transmission(s) 09D] General Information .

Note. After installing the assembly, perform a vehicle alignment. Refer to General Information .

Perform a vehicle system test, refer to "Guided Fault Finding" in the vehicle diagnostic tester.

End the vehicle system test, this will automatically erase Diagnostic Trouble Code (DTC) entries which occurred during the assembly.

Perform a road test.

Generate a readiness code in conjunction with a road test.

Note. Observe the safety precautions that apply to road tests. Refer to SAFETY PRECAUTIONS .

Then perform a vehicle system test again and repair any occurring malfunctions if necessary.

Tightening Specifications