Get Removing and installing engine -> 1.1 Removing engine Guide for Volkswagen Touareg SUV First Generation (2002-2010)

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

♦ Stepladder -VAS 5085-

♦ Torque wrench (5…50 Nm) -V.A.G 1331-

1.1

Removing engine

The engine is removed from below with the gearbox

– Read fault memories of all control units before removal: ⇒

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Diagnostic tester VAS 5051; Guided fault finding; Vehicle sys‐

tem test or VAS 5052; Vehicle self-diagnosis .

Note

♦ To enable the propshaft to rotate freely, move selector lever

to the „N“ position.

♦ Leave key in ignition to prevent steering wheel lock from en‐

gaging.

♦ It is advisable to remove the front wheels before beginning

engine removal. The vehicle can then be lowered on hoist until

the brake disc splash plates are just above the floor. This pro‐

vides the most ergonomic working position regarding acces‐

sibility of engine compartment components.

♦ Some components cannot be removed, or removed only with

difficulty, with the engine installed. Therefore, you should de‐

termine all defective components before removing engine and

renew them while engine is removed.

♦ To prevent damage to removed components, place them in

the container for removed parts -V.A.G 1698- .

♦ All cable ties which are opened or cut through when engine is

removed must be replaced in the same position when engine

is installed.

Disconnecting battery

The procedure must be strictly followed!

– Switch off ignition and all electrical consumers.

– First disconnect battery under driver seat ⇒ Electrical system;

Rep. gr. 27 ; Disconnecting and reconnecting batteries .

Procedure

– Remove left and right wiper arms: ⇒ Electrical system; Rep.

gr. 29 ; Removing and installing wiper system .

– Pull engine compartment seal off bulkhead.

– Remove covers -A-, -B- and -C- from engine compartment.

WARNING

Fuel supply lines are under pressure! Wear eye protection and

gloves to avoid injuries and skin contact. Before loosening

hose connections, wrap a cloth around the connection. Then

release pressure by carefully pulling hose off connection.

– Wrap a cloth around the joint to catch fuel which flows out.

1. Removing and installing engine

3

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

lk

– Disconnect fuel supply line -arrow-.

– Disconnect breather line -arrow- to solenoid valve in engine

compartment.

– Disconnect small connector -A- from engine control unit -1-

and disconnect earth connection -arrow- of wiring harness.

– Open fuse box cover in plenum chamber on left and separate

connectors -A-, -B- and -C-.

– Remove wiring harness from plenum chamber and lay it on

engine.

4

Rep. gr.10 - Removing and installing engine

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Disconnect starter wire -1- and and lay it on engine.

– Disconnect connector from air mass meter on left and remove

intake hose and air filter housing on left.

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– Separate connectors -1- to -4- for Lambda probes and lay

connectors on engine.

Note

Connector for cylinder bank 1 = black, connector for cylinder bank

2 = brown

– Remove intake hose on right leading to throttle valve module.

– Pull intake hose leading to secondary air pump motor -V101-

off upper part of air filter and remove upper part of air filter.

– Remove air filter element.

– Then pull connecting line -arrow- to air suspension compres‐

sor off right air filter housing downwards ⇒ page 135 .

– Unclip gearbox breather hose from air filter housing.

– Remove bracket for engine cover on right ⇒ page 134 .

– Pull lower part of air filter from air duct ⇒ Item 10 (page 134)

on right and remove it.

– Extract refrigerant from air conditioning system: ⇒ Heating, air

conditioning; Rep. gr. 87

– Remove insulation tray: ⇒ General body repairs, exterior;

Rep. gr. 50 ; Body - front; Assembly overview - noise insulation

– Loosen double clamp between catalytic converter and centre

silencer and slide clamp forward.

– Support exhaust system between rear silencer and centre si‐

lencer using engine and gearbox jack -V.A.G 1383 A- , un‐

screw mountings and lower exhaust system.

– Remove rear propshaft tube ⇒ Transfer box and final drive;

Rep. gr. 39 ; Removing and installing propshaft .

– Remove front wheels.

– Remove front wheel housing liners ⇒ General body repairs,

exterior; Rep. gr. 66 ; Exterior equipment; Removing and in‐

stalling wheel housing liner; Front wheel housing liner

– Disconnect hose connection to vacuum reservoir in front left

wheel housing.

1. Removing and installing engine

5

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Remove heat shield -A- from steering box and separate uni‐

versal joint -B-. ⇒ Running gear, axles, steering; Rep. gr. 48 ;

Repairing steering, power-assisted steering

– Separate connectors -A- on gearbox as well as transfer box

-B- and separate selector lever cable ⇒ Automatic gearbox;

Rep. gr. 37 ; Controls, housing .

– Separate brake lines at brake hoses in wheel housings and

collect brake fluid which runs out. ⇒ Brake system; Rep. gr.

46 ; Repairing front wheel brake

– Separate all connectors between body and front axle in wheel

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housings.

– Unbolt connecting lines of air suspension at suspension strut.

– Remove gearbox transverse support -A-.

WARNING

Steam may escape when expansion tank is opened. Wear eye

protection and protective clothing to avoid eye injuries and

scalding. Cover cap with cloth and open carefully.

– Open and close expansion tank cap to release pressure in

cooling system.

– Drain coolant ⇒ page 86 .

– Disconnect hose connection to heat exchanger working from

left wheel housing side and collect escaping coolant.

– Disconnect upper coolant hose from radiator and lower cool‐

ant hose from coolant pipe.

6

Rep. gr.10 - Removing and installing engine

Removing and installing engine -> 1.1 Removing engine for Your Volkswagen Touareg SUV First Generation (2002-2010)

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