3.6L - Engine Assembly - Engine Code(s): Cgra: Other Volkswagen Touareg II

ENGINE MOUNT

Removing

Hold the engine in its installed position. Refer to ENGINE, HOLDING IN ITS INSTALLED POSITION .

Remove the engine mount bracket to engine mount nuts -arrow- on both the right and left sides.

Scheme 187

Lift the engine evenly by both spindles until the engine mount brackets come off the engine mount threaded pins.

Remove the engine mount to cylinder block bolts. Remove the engine mount.

Installing

Assembly is performed in reverse order.

1. Tightening specifications, refer to «ENGINE CARRIER, ENGINE MOUNT AND BRACKET OVERVIEW»(ref-498900-S09295167502012083100000) .

ENGINE, REMOVING

Special tools and workshop equipment required

1. Lifting Tackle 3033
2. Engine and Transmission Holder VAS 6095
3. Engine/Transmission Jack V.A.G 1383A
4. Drip Tray V.A.G 1306
5. Shop Crane VAS 6100
6. Scissor Lift Table VAS 6131
7. Hose Clip Pliers VAS 6340
8. Adapter for K-jetronic Test Device V.A.G 1318/20
9. Adapter V.A.G 1318/20-1
10. Container for Removed Parts V.A.G 1698
11. Basic Set for Touareg VAS 6131/6
12. Ball Joint Puller T10187
13. Hose Clamps up to 25 mm Dia 3094
14. Cable Tie

Note. Secure all disconnected lines and wires 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 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.

Procedure

The engine with transmission is removed downward.

On a vehicle with an air suspension, activate the vehicle lift mode. Refer to General Information .

Disconnect the battery. Refer to Removal and Installation .

Disconnect the hoses -1 and 2- and remove the connecting pipe -arrows-.

Scheme 188

Open the clamps and remove the upper part of the air filter housing.

Remove the windshield wiper arms. Refer to Removal and Installation .

Remove the plenum chamber cover. Refer to Removal and Installation .

Remove the anti-theft protection from the Engine Control Module (ECM). Refer to Engine Control Module -J623 .

Disconnect the engine wiring harness connector from the ECM.

Remove the nut -arrow- and disconnect the ground wire.

Scheme 189

Open the cover -A- for the E-box.

Scheme 190

Disconnect all connectors that go to the engine.

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

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

Scheme 191

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

Separate the fuel supply line -arrow-.

Scheme 192

Disconnect the vacuum lines -arrows-. Ignore the hose -1-.

Scheme 193

Open the cover over the B+ terminal in the -direction of the arrow-.

Scheme 194

Disconnect the B+ wires

1. To the generator
2. To the starter

Free up the electrical wires.

Recover the refrigerant from the Air Conditioning (A/C) system. Refer to Description and Operation .

Clamp off the power steering hose using the hose clamps up to 25 mm dia 3094. Disconnect the hose -A- from the power steering pump.

Scheme 195

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

Scheme 196

Remove the noise insulation. Refer to Description and Operation .

Remove the noise insulation bracket bolts -arrows- and bracket.

Scheme 197

Drain the coolant. Refer to COOLANT, DRAINING .

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

Scheme 198

Disconnect the upper coolant hose connection at the radiator.

Open the quick-release coupling -A- at the upper radiator connection and disconnect the coolant hose.

Scheme 199

Disconnect the coolant hose to the lower radiator connection.

Remove the front wheels.

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

Scheme 200

Remove the bolt -A- and the transmission fluid cooler line connection. Catch any fluid coming out.

Scheme 201

Clamp off the power steering hose using the hose clamps up to 25 mm dia 3094, open clamp -A- and remove the hose.

Scheme 202

Open the clamps -A- and disconnect the coolant hoses for the heater core.

Scheme 203

Remove the driveshaft from the transmission and tie it up. Refer to [For transmission(s) 0C8] Removal and Installation .

Disconnect the connectors -arrows- from the transmission.

Scheme 204

Remove the bolts for exhaust system mounts -1 and 2-. Loosen the clamping sleeves -arrows- and push the exhaust system backward.

Scheme 205

Disconnect the selector lever from the ball head and remove the selector cable bolts -arrows- from the transmission. Disconnect the selector lever cable from the ball head -1- and remove the bolts -2- from the transmission. The lock washer -3- can remain installed.

Scheme 206

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

Scheme 207

Disconnect the connector -arrow- from the steering gear.

Scheme 208

Disconnect the connectors -arrow- from the left and right side front speed sensors.

Scheme 209

Disconnect the connector -arrow- from the brake pad wear indicator.

Scheme 210

Remove the wiring harness bolts -arrows-.

Scheme 211

Remove the brake caliper bolts -1-.

Note. Do not change the shape of the brake lines.

Secure the brake caliper in the wheel housing with wire.

Loosen the upper control arm nut a few turns and separate the ball joint from the wheel bearing housing using the ball joint puller T10187.

Scheme 212

Remove the nut completely and disconnect the control arm from the wheel bearing housing.

Remove the coupling rod bolt -arrow- from the stabilizer bar.

Scheme 213

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

Repeat the above 2 steps on the other side of the vehicle.

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

Scheme 214

Secure the subframe to the body using the locating pin T10300. Refer to Description and Operation .

Then proceed exactly the same with the other bolt -2-.

If the engine and transmission are to be separated after removing the engine/transmission assembly, remove the lower engine/transmission bolts -arrows-.

Scheme 215

Prepare the scissor lift table VAS 6131 with the basic set for Touareg VAS 6131/6 as follows

Scheme 216

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 poinst: A5; B5
4. VAS 6131/6-4 Attachment points: G5; H5
5. VAS 6131/6-5 Attachment point: B7
6. VAS 6131/6-5 Attachment point: G7
7. VAS 6131/6-6 Attachment point: B14
8. VAS 6131/6-6 Attachment point: G14

Note. Attach all supports to the scissor lift table just hand tight so that the position can be corrected later. The basic set for Touareg VAS 6131/6 consists of supportsVAS 6131/6-1 to 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).

Position the scissor lift table horizontally.

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

Position the scissor lift table VAS 6131 under the vehicle.

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

Scheme 217

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

Scheme 218

When all four supports are in the appropriate locations without pressure

Scheme 219

Guide the supports -5- into the corresponding locations in the subframe, if necessary check the support height of the knurled nut.

Tighten all of the supports on the scissor lift table to 20 Nm.

Using light pressure under the control arms, adjust the plates for supports 3 and 4.

Remove the right and left strut to lower control arm bolts -A-.

Remove the transfer case support bolts -1- and the subframe bolts -3 and 4-.

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

Tighten one engine mount bracket to engine mount nut -arrow- on the right or left side. This will prevent the engine carrier from slipping.

ENGINE AND TRANSMISSION, SEPARATING

Special tools and workshop equipment required

1. Bracket 30-211 A

Remove or disconnect all pipes, hoses, and wires as necessary from the transmission.. Refer to "Transmission" in [For transmission(s) 0C8] Removal and Installation .

Remove the starter.

Remove the 3 bolts -arrows- from the torque converter through the opening for the starter. Turn the crankshaft an additional 120° in engine rotation direction.

Scheme 220

Attach the mounts VAS 6131/6-7 to the scissor lift table as illustrated and support the transmission free of tension under the oil pan.

Scheme 221

Remove all the engine/transmission bolts.

Loosen the knobs -1- on the side of the scissor lift table VAS 6131 and pull the rear table plate with the transmission toward the rear -arrow-. Push the torque converter off the drive plate and through the opening for the starter.

Scheme 222

Secure the torque converter in the transmission against falling out using the bracket 30-211 A.

Scheme 223

Assembling

For the assembly, refer to [For transmission(s) 0C8] Transmission .

ENGINE, SECURING TO A ENGINE SUPPORT

Special tools and workshop equipment required

1. Engine and Transmission Holder VAS 6095 or
2. Engine Support 3269

Secure the engine to the engine and transmission holderVAS 6095 when working on the engine.

Secure the engine to the engine support3269 when working on the chain drive.

Procedure

Separate the engine and transmission from each other, refer to ENGINE AND TRANSMISSION, SEPARATING .

After separating the engine from the transmission, secure the torque converter to prevent it from falling out.

Install the lifting tackle3033 as follows and lift the engine from the scissor lift table6131 using the shop craneVAS 6100.

Scheme 224

1. Vibration damper side: Position 3.

1. Flywheel side: Position 11

Note. Threaded spindles are set in length according to necessity.

Secure the Engine to the Engine and Transmission HolderVAS 6095

Scheme 225

Bolt the engine to the engine and transmission holderVAS 6095 as shown.

Secure the Engine to the Engine Support3269

Scheme 226

Remove the right engine mount bracket.

Bolt the engine to the engine support3269 as shown.

ENGINE, INSTALLING

Note. When moving the engine/transmission assembly into the body, it is always necessary to bring the engine carrier into contact with the body using the scissor lift tableVAS 6131. >>Pulling up<< the engine carrier with the bolts damages the thread inserts!

Procedure

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

When assembling the engine and transmission, refer to "Transmission" in [For transmission(s) 0C8] Removal and Installation .

Move the drivetrain under the vehicle using the scissor lift tableVAS 6131. Pay attention to the locating pinsT10300.

Install the subframe to the vehicle. Refer to Removal and Installation .

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

Install the plenum chamber cover. Refer to Removal and Installation .

Install the windshield wiper arms. Refer to Removal and Installation .

Fill the power steering system with fluid.

Fill the coolant. Refer to COOLANT, FILLING .

Fill the engine oil, if necessary.

Connect the battery. Refer to Removal and Installation .

Adjust the selector lever cable. Refer to [For transmission(s) 0C8] Diagnosis and Testing .

Fill the automatic transmission with fluid. Refer to [For transmission(s) 0C8] General Information .

Connect the vehicle diagnostic tester.

Perform a vehicle system test using "Guided Fault Finding" in the vehicle diagnostic tester.

End the vehicle system test in such a way that possibly existing Diagnostic Trouble Code (DTC's) are automatically erased.

Create the readiness code with a road test.

Always observe all safety precautions when performing the road test.

Perform another vehicle system test and correct any faults.

Note. If, during the road test, it is discovered that the steering wheel is not exactly straight when driving in a straight line, then perform a wheel alignment. Refer to Description and Operation .

Tightening Specifications

ENGINE, HOLDING IN ITS INSTALLED POSITION

Special tools and workshop equipment required

1. Engine Support Bridge 10-222 A
2. Adapter 10-222 A/29
3. Bracket with Spindle and Hook 10-222 A/10
4. Adapter 10-222 A/28
5. Engine Support Basic Set T40091 (Quantity: 2)
6. Support T40093/5
7. Movable Joint T40093/4 (Quantity: 2)

Slide the moveable joint T40091/3 and the bracket with spindle and hook 10-222 A/10 onto the square pipe of the engine support bridge10-222 A.

Install the adapters 10-222 A/29 onto the square pipe.

Install the engine support bridge 10-222 A as illustrated.

Scheme 227

Slide the moveable joint T40093/4 and the adapter 10-222 A/28 onto the square pipe square pipe T40091/1 from the engine support basic setT40091.

Scheme 228

Place the adapter 10-222 A/28 on the longitudinal member and slide the square pipe T40091/1 into the moveable joint T40091/3.

Repeat the procedure on the other side of the vehicle.

Slide the rail with holes T40091/2 through the moveable joint T40093/4 on one side.

Slide the mount T40093/5 onto the rail with holes T40091/2 and then the rail with holes into the moveable joint on the other side.

Scheme 229

Install the locking pin and secure it.

Tighten all the threaded connectors hand tight.

Attach the hooks on the spindle to the lifting eyes on the engine and hold the engine in its installed position.