ENGINE, SECURING ON ENGINE AND TRANSMISSION HOLDER
Special tools and workshop equipment required
- Lifting tackle 3033
- Universal mounting VAS 6095/1
- Bracket for V8 engine VAS 6095/1-6A
Note. To perform repair work and for mounting the V8 engine, the engine and transmission holder VAS 6095 must be modified with universal mounting VAS 6095/1.
Procedure
Scheme 296
- Engine and transmission assembly removed and separated on scissor lift table VAS 6131.
- Engine secured with joint support VAS 6131/13-7.
Note. Place a cloth under the separating point to catch draining hydraulic fluid.
Remove power steering pressure line banjo bolt -arrow-.
Remove engine mount bolts -arrows- on right and left side of engine.
Scheme 297
Note. Engine carrier remains in installation location.
Install the lifting tackle3033 to the engine lifting eyes and support using the shop crane VAS 6100 and workshop hoist lift arm VAS 6101 as shown in the illustration.
Scheme 298
Tension the engine slightly using the shop crane VAS 6100, do not lift.
Lower engine from scissor lift table VAS 6131 using shop crane VAS 6100.
After separating the engine from transmission, secure the torque converter to prevent it from "falling out".
Raise engine from scissor lift table using the workshop crane VAS 6100.
Remove engine mount bracket bolts -arrows- on right and left side of engine.
Scheme 299
Note. The left engine mount bracket is shown in the illustration.
Remove the left and right engine mounts and brackets.
Attach the bracket for V8 engine VAS 6095/1-6A using bolts -arrows- to the cylinder block (see sticker on bracket).
Scheme 300
Now, hand tighten all bolts on the engine hanging on the workshop crane VAS 6100 with the brackets on the engine and transmission holder VAS 6095.
Now tighten all bolts and then release engine from workshop crane VAS 6100.
Scheme 301
ENGINE, REMOVING
Special tools and workshop equipment required
- Basic set for Touareg VAS 6131/6
- Brace VAS 6131/8
- Step ladder VAS 5085
- Torque wrench (5 to 50 Nm) VAG 1331
- Lifting tackle VAS 3033
- Drip tray VAG 1306
- Engine and transmission holder VAS 6095
- Shop crane VAS 6100
- Scissor lift table VAS 6131
- Engine and transmission jack VAG 1383 A
- Parts trolley V.A.G 1698
The engine with transmission is removed downward.
Check Diagnostic Trouble Code (DTC) memories of all control modules, before removing engine.
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 and transmission assembly. The vehicle can be lowered on the hoist until the brake carriers 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 the container for removed parts trolley VAG 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 engine.
Procedure
Note. If the fuel system must be opened on the high pressure side immediately after removing the engine, first reduce fuel pressure.
| WARNING | The fuel injection system is divided into a high pressure side (maximum approximately 120 bar) and a low pressure side (approximately 6 bar). Before opening high pressure side - e.g. removing high pressure pumps, fuel rail, fuel injectors, fuel pipes or fuel pressure sensor -G247- - fuel pressure on high pressure side must be reduced to a residual pressure of approximately 6 bar. Refer to RELEASING PRESSURE ON HIGH PRESSURE SIDE . |
Remove the high pressure from fuel system.
| WARNING | Fuel supply line is still under pressure (approximately 6 bar)! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before separating hose connection, wrap a cloth around the connection. Then release pressure by carefully separating hose connection. |
Place a cloth around the connection to catch draining fuel.
Disconnect the fuel supply line -arrow-.
Scheme 302
Battery, Disconnecting
The procedure must be strictly followed!
Turn off the ignition and all electrical components.
First, disconnect battery under driver's seat. Refer to Removal and Installation .
Extract refrigerant from air conditioning system. Refer to Description and Operation .
Remove engine compartment cover seal from bulkhead.
Remove left and right wiper arms. Refer to Removal and Installation .
Remove plenum chamber cover. Refer to Removal and Installation .
Remove the rear engine cover in -direction of arrows- if applicable.
Scheme 303
Remove the front engine cover in -direction of arrows- if applicable.
Scheme 304
Remove small connector -A- from Engine Control Module (ECM) -J623- -1- and disconnect wiring harness ground connection -arrow-. ECM may have to be removed because of space restrictions. Refer to REMOVAL AND INSTALLATION .
Scheme 305
Note. Vehicles with anti theft ECM -J623-. Refer to ENGINE CONTROL MODULE WITH ANTI-THEFT IMMOBILIZER .
Open fuse box cover on left in plenum chamber and separate connectors -A-, -B- and -C-.
Scheme 306
Remove wiring harness from plenum chamber and set it on the engine.
Disconnect breather line -arrow- to solenoid valve in engine compartment.
Scheme 307
Remove nut -1- and disconnect starter wire, lay it aside on the engine.
Scheme 308
Extract the hydraulic oil from power steering reservoir using used oil collecting and extracting device VAG 1782.
Note. Place a cloth under separating point to catch draining hydraulic fluid.
Remove hose clamp -arrow- and hose from power steering fluid reservoir.
Scheme 309
Disconnect connector from left and right Mass Air Flow (MAF) sensors and remove intake hoses and left and right air filter housings. Refer to AIR FILTER ASSEMBLY OVERVIEW .
Disconnect connector -arrow- for the air suspension compressor from the right air filter housing. Refer to CONNECTING LINE TO AIR SUSPENSION COMPRESSOR, DISCONNECTING .
Scheme 310
Disconnect vacuum hose -arrow- from the suction jet pump.
Scheme 311
Separate connectors -1 through 4- for oxygen sensors and lay connectors aside on the engine.
Scheme 312
Note. Connector for cylinder bank 1 = Black, connector for cylinder bank 2 = Brown.
Remove air guide hose clamp -arrow- and hose from the Secondary Air Injection (AIR) combination valve connecting hose.
Scheme 313
Unclip transmission ventilation hose clip -arrow- from the brake system vacuum pump -V192-.
Scheme 314
In order to reach the coolant lines better, remove left front wheel housing liner, if necessary. Refer to Description and Operation .
Disconnect the electrical connector -1-.
Remove refrigerant lines -2- and -3- from Air Conditioning (A/C) compressor.
Scheme 315
Note. To prevent damage to the refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.
Seal open pipes and connections at A/C compressor with suitable sealing caps (to prevent dirt and moisture from entering).
Remove front -1- and rear -2- noise insulation. Refer to Description and Operation .
Scheme 316
Disconnect connectors -A- from the transmission and connectors -B- from the transfer case.
Scheme 317
Loosen double pipe clamps -1 and 2- between catalytic converter/front muffler and slide them forward.
Scheme 318
Support the exhaust system between the front muffler and rear muffler using the engine and transmission jack VAG 1383 A, remove mountings and lower the exhaust system.
Remove driveshaft. Refer to [For transmission(s) 09D] Removal and Installation .
Remove ground (GND) wire bolt -1- on longitudinal member at right front.
Scheme 319
Remove selector lever cable heat shield bolts -arrows- and shield.
Scheme 320
Pry selector lever cable ball head -2- from selector shaft lever using pry lever 80 - 200.
Remove selector lever cable from clamp -1- and remove cable from transmission. Refer to [For transmission(s) 09D] Removal and Installation .
Scheme 321
Note. Do not bend or kink selector lever cable.
Disconnect electrical connector -arrow- at steering gear.
Scheme 322
Remove steering gear heat shield bolts and shield -A- from steering gear.
| CAUTION | Separate universal joint from steering gear only when front wheels are in straight ahead position. Do not change steering wheel position and steering gear position any more, secure steering wheel with adhesive tape. |
Remove universal joint bolt -B-. Refer to Description and Operation .
Separate the universal joint from the steering gear.
Scheme 323
Place the used oil collecting and extracting device VAG 1782 under left cooler.
Remove hydraulic line hose clamp -1- and hose from the power steering cooler to the left of lock carrier.
Scheme 324
Note. Ignore -item 2-.
In wheel housings, separate all connectors between body and front axle.
Loosen brake line bracket and remove brake carrier from wheel bearing housing. Refer to Removal and Installation .
Secure brake caliper with wire in wheel housing without bending brake lines.
Remove right and left lower bolt/nut -2- on stabilizer bar. Bolt -1- remains fastened.
Scheme 325
Remove transmission transverse support -A-.
Scheme 326
| WARNING | Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover cap with a cloth and open carefully. |
Open and close the cap on the expansion tank, to relieve the cooling system pressure.
Drain cooling system. Refer to COOLING SYSTEM, DRAINING AND FILLING .
Remove both coolant hose clamps -arrows- and hoses from reservoir.
Scheme 327
From the area of the left wheel housing, remove the hose clamps -arrows- and hoses from the heater core. Allow remaining coolant to drain.
Scheme 328
Remove upper coolant hose with quick connect coupling on upper cooler and lower hose clamp -arrow- and hose on coolant pipe.
Scheme 329
Disconnect lines -arrow- from transmission oil cooler at lower right. Catch fluid which drains out.
Scheme 330
Now remove one of the rear bolts -3- for the subframe.
Using locating pins T10300, secure subframe to body. Refer to Description and Operation .
Scheme 331
Then proceed in exactly the same way with the other rear bolt -3-.
Preparing scissor lift table VAS 6131 for the continued work procedure.
Mount the front supports VAS 6131/6-1 for the left -1-, as well as VAS 6131/6-2 for the right -2- to the lift table. The arrows on the supports indicate forward. Fasten the bolts at the following positions: Left support -1- : A5, B4 and B5. Right support -2- : G4, H4 and H5
Scheme 332
Bolt both axle supports VAS 6131/6-3 and VAS 6131/6-4 -3- to lift table at following positions: Left axle support: A6 and C6. Right axle support: F6 and H6.
Turn the turntables on the axle supports downward.
Place supports VAS6131/6-5 -4- for subframe and VAS 6131/6-6 -5- for transmission bracket in the corresponding positions on the lift table.
Move the horizontally aligned lift table under the powertrain assembly. The supports -1- must be guided into the corresponding holes -arrow- on the right and left.
Scheme 333
Simultaneously, guide right and left supports for transmission bracket into corresponding holes -arrow-. When all four supports are in the appropriate holes without pressure
Scheme 334
Turn out both turntables of the axle supports with slight pre-loading under the control arms.
Guide support -2- into corresponding hole in subframe, if necessary check support height on knurled nut.
Turn out both turntables of the axle supports with slight pre-loading under the control arms.
Now remove the lower bolts -1- for the right and left struts.
Then remove upper right and left control arms from wheel bearing housings. Refer to Description and Operation .
Loosen the subframe bolts -1- and -2-, as well as transmission transverse support bolts -4-.
Slowly lower engine/transmission assembly, constantly observing clearance.
Now install a bolt with nut -arrow- on the right and left side in order to prevent the engine carrier from slipping and secure engine carrier with subframe.
Scheme 335
SEPARATING TRANSMISSION FROM ENGINE
If you would like to separate the transmission from engine after remove engine/transmission assembly
Free up electrical wires to oxygen sensors.
Scheme 336
Remove bolts -arrows- for the left main catalytic converter bracket.
Remove bolt -2- for the left primary catalytic converter bracket.
Scheme 337
Note. Ignore -item 1-.
Remove nuts -1 through 3-.
Scheme 338
Remove left front and main catalytic converters.
Remove bolts -arrows- for the right main catalytic converter bracket.
Scheme 339
Remove bolt -arrow- for the right primary catalytic converter bracket.
Scheme 340
Remove nuts -1 through 3-.
Scheme 341
Remove right primary and main catalytic converters.
Remove Automatic Transmission Fluid (ATF) line bolt -1- from transmission.
Remove 3 lower transmission bolts -2 through 4-.
Support the transmission without tension with VAS 6131/7-6 on the lift table.
Scheme 342
Remove the engine speed (RPM) sensor -G28- -1-.
From the engine side, insert the angled guide pin from VAS 6131/5-4 into the threaded hole.
Scheme 343
Fasten the supports, positioned free of stress, to the table.
Now remove all transmission bolts. Refer to [For transmission(s) 09D] Removal and Installation .
Remove the right and left engine mount bracket to engine mount nuts -arrow-.
Scheme 344
Note. To separate engine and transmission, refer to operating instructions for scissor lift table VAS 6131.
ENGINE, INSTALLING
Note. When installing engine/transmission assembly to the body, it is always necessary to bring the engine carrier into contact on the body using the scissor lift table VAS 6131. By pulling up the engine carrier via the mounting bolts, the threaded inserts will be damaged!
Procedure
Installation is performed in reverse order. When doing this note the following
If engine was separated from transmission
Check whether alignment pins for centralizing the engine/transmission are installed in cylinder block, install if necessary. Refer to [For transmission(s) 09D] Removal and Installation .
If the subframe with drive axle assemblies has been removed from the scissor lift table
Position the drive axles with subframe again on the prepared scissor lift table.
Set engine on assembly carrier.
If transmission is not yet bolted on
Support the engine from below using the support VAS 6131/5-4.
Before installing the assembly, install the exhaust manifolds with catalytic converters onto the engine.
| CAUTION | When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues: Route lines of all types (e.g. for fuel, hydraulic, Evaporative Emission (EVAP) system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed. To prevent damages to the lines, make sure there is sufficient clearance to all moving or hot components. |
When installing the engine, use the scissor lift table to lift until the selector cable can be attached.
Then engine/transmission assembly with scissor lift table VAS 6131 under vehicle, considering locating pin T10300 still installed.
Reconnect all lines, hoses and electrical connections that were disconnected for the removal procedure.
Install plenum chamber cover. Refer to Removal and Installation .
Install left and right wiper arms. Refer tot Removal and Installation .
Top off Automatic Transmission Fluid (ATF) level. Refer to [For transmission(s) 09D] Diagnosis and Testing .
Connect Air Conditioning (A/C) lines. Refer to Description and Operation .
Charge A/C system with refrigerant again. Refer to Description and Operation .
Fill power steering system. Refer to General Information .
Fill cooling system. Refer to COOLING SYSTEM, DRAINING AND FILLING .
Fill engine oil.
Connect battery.
Adjust selector lever cable. Refer to [For transmission(s) 09D] Diagnosis and Testing .
Connect vehicle diagnosis and service system VAS 5052.
Perform vehicle system test.
End vehicle system test, this will automatically erase Diagnostic Trouble Code (DTC) entries which occurred during the assembly.
Generate readiness code in connection with road test.
Observe safety precautions that apply to road tests.
Perform test drive.
Then perform vehicle system test anew and repair any occurring malfunctions if necessary.
Note. If it is determined during a road test that the steering wheel is not straight when driving straight ahead, perform an axle alignment. Refer to Specifications .
Tightening Specifications
| Bolted connections | Tightening Specifications | |
|---|---|---|
| Bolts and Nuts | M6 | 10 Nm |
| M7 | 15 Nm | |
| M8 | 25 Nm | |
| M10 | 40 Nm | |
| M12 | 60 Nm | |
| Deviation from | ||
| Engine bracket to cylinder block | M10 | 60 Nm |
| Engine bracket to engine mount (nut) | M10 | 75 Nm |
| Engine mount to engine carrier (bolt) | M10 | 60 Nm |
| Engine carrier to chassis (bolt) | M12 | 100 Nm + 1 / 2 turn (180°) |
| Drive axles to transmission | Specifications . | |
| Transmission carrier to body | [For transmission(s) 09D] Specifications . | |