Removing the engine

NOTE: The engine is removed with the gearbox down. Before dismantling, interrogate the fault memory of all control units.

NOTE: To ensure unobstructed rotation of the driveshaft, set the selector lever to the position «N».

NOTE: Leave the key in the ignition to prevent the steering wheel from locking.

NOTE: It is recommended to remove the front wheels before beginning disassembly. Due to this, the car can be lowered on the lift, leaving a few centimeters between the casings of the brake discs and the floor. Thus, during operation, optimal reach of all components in the engine compartment will be ensured. Some components in this vehicle cannot be or are difficult to remove without removing the engine. Therefore, before removing the engine, it is necessary to identify all defective parts and replace them after removing the engine.

NOTE: To avoid damaging the removed parts, use the VAG 1698 removed parts container.

NOTE: After installing the engine, you must reinstall any cable ties that are removed or sheared when removing it.

ATTENTION: When carrying out work, it is imperative to comply with the requirement to disconnect the battery.

Switch off the ignition and all electrical consumers.

First, disconnect the battery under the driver's seat.

Then disconnect the second battery, which is located in the trunk, in the spare wheel well.

Remove the right and left wiper arms.

Remove the hood seal from the front wall.

Remove covers A, B (in the presence of) and C in the engine compartment and D plenum box (pic. 2.136).




Disconnect the small plug A from the engine control unit and disconnect the ground terminal of the wiring harness (pic. 2.137).



Open the cover of the fuse box, on the left in the plenum chamber and disconnect the plug connections A, B and C (pic. 2.138).



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


Remove the suction pipe between the air filter and the intake manifold on both sides.

NOTE: For in-line connectors, follow the instructions in the installation manual.

Vehicles with engine codes AYH, BKW

Disconnect the vacuum lines - arrows - from the exhaust gas recirculation valve and the brake booster, as well as the plug connection A of the lambda probe G39 of the first bank of cylinders (pic. 2.139).



Disconnect the vacuum line (see fig. 2.140) valve for the exhaust gas recirculation system, as well as plug connection A for lambda probe 2 G108 in bank 2.

Vehicles with BLE and BWF engines

Disconnect the vacuum lines 1 vacuum servo bypass cover (mark tubes before disconnecting) and brake booster 2 (pic. 2.141).




Disconnect the following plug connections and disconnect the cable from the following components (pic. 2.142):

• 1-6 - pin connector (black) for lambda probe G39;
• 2-6 - pin connector (brown) for lambda probe 2 G108;
• 3-2 - pin connector (black) for air temperature sender before turbocharger G507;
• 4-2 - pin connector (brown) for air temperature sender 2 before turbocharger G499.

Continuation of assembly operations for all vehicles

Disconnect plug connections (pic. 2.143) glow plugs of cylinders of the first and second row.



Fix the shock absorber struts as shown in Figure 2.144, using a spring clamp VW 552.




Unscrew the upper mounts, shock absorber struts.

Remove soundproofing.

Pump out the coolant.

Drain the coolant.

Disconnect the handset (pic. 2.145) from the transmission oil cooler at the bottom right. Place a container under the leaking oil.



Then, disconnect pipe A from the hydraulic oil cooler at the bottom left. Place a container under the leaking oil.

Remove the charge air connecting pipe in the first and second row of cylinders (pic. 2.146).



Loosen and remove clamp (pic. 2.147) connecting tube of the air filter of the first and second row of cylinders.



Remove the engine cooling hoses (pic. 2.148) and lay in such a way that when installing and removing the engine they are not pinched.



Disconnect starter A and alternator B cables and place them on the engine (pic. 2.149).



Unclip the gearbox ventilation system pipeline (pic. 2.150).



Disconnect the connector from the G42-A intake air temperature sender and the G70-B mass air flow sender for the first bank of cylinders (pic. 2.151).



Disconnect the connector from the mass air flow sensor A - G246-A and from the intake air temperature sensor B - G299-B of the second row of cylinders (pic. 2.152).



Disconnect the handset (pic. 2.153) air suspension compressor on the air filter housing.



Remove both upper parts of the air filter upwards.

Open the clamp and remove the hydraulic system pipe A. Place a container under the flowing oil. Unscrew the tubes of the air conditioning circuit B from the air conditioning compressor (pic. 2.154).

Vehicles with engine codes AYH, BKW

Remove fuel lines (see fig. 2.155) from the fuel filter.



Disconnect the catalytic converter and the additional muffler, remove the exhaust system.

Vehicles with BLE and BWF engines

Remove fuel lines (see fig. 2.156) from the fuel filter.



Separate the particle filter and exhaust pipe, remove the exhaust system.

Continuation of assembly operations for all vehicles.

Remove the heat-insulating screen of the steering mechanism and cardan joint.

Disconnect the plug connections on the gearbox and transfer case, unscrew the cable drive of the selector lever.

Remove the rear driveshaft.

Remove the transaxle A (pic. 2.157).



Disconnect the brake lines at the location shown (pic. 2.158).



Place a container under the leaking brake fluid.

Disconnect all plug connections between the body and the front axle in the wheel arches.

Prepare the mounting table VAS 6131 for further operations.

NOTE: The basic kit for the Touareg IMS 6131/6 consists of supports IMS 6131/61 up to IMS 6131/6-7. For the most visual display of the workflow, it is mentioned here: support 1 (for IMS 6131/6-1) -support 7 (for IMS 6131/6-7).

Install support 1 on the left and support 2 on the right (arrows point in the direction of travel) on the assembly table VAS 6131 and fasten the screws in the following positions:

• left support 1 - A5, B4 and B5;
• right support 2 - G4, H4 and H5.

Fasten supports 3 and 4 on the mounting table in the following positions:

• left support 3 - A6 and C6;
• right support 4 - F6 and H6.

Unscrew plates of supports 3 and 4 down.

Install supports 5 for the subframe and 6 for the gearbox console in their respective positions on the lifting table.

The engine and transmission after removal must be disconnected from each other.

Remove the noise isolation under the oil sump.

Remove the starter cable clamps.

Loosen and remove gearbox bolts A.

Through a hole in the oil pan (pic. 2.160) unscrew the six bolts of the gearbox. To do this, turn the engine at the damper using the counter support T10172 and the supplied bolt T10172/2.



Place the supports 7 for the gearbox support in the appropriate positions on the mounting table and unscrew the support plates all the way down.

Just before lifting the mounting table, hang the stop for V-shaped 10, 8 and 6-cylinder engines of the Touareg VAS 6131/8 car turned out in advance to the highest position in the gearbox flange hole as shown in Figure 2.161.



Position a horizontally leveled mount table under the power unit. Supports 1 and 2 must be inserted from the left and right into the corresponding sockets (pic. 2.162).



At the same time, insert supports 6 for the gearbox cross member on the left and right into the corresponding holes.

When all four supports are fixed in the receiving holes without pressure, if necessary, adjust the height of the stop for V-shaped 10-, 8-, and 6-cylinder engines of the Touareg VAS 6131/8 using knurled nuts and fix the support in position D7 on the mounting table.

Unscrew both support plates 3 and 4 against the levers so that the spring clamp VW 552 suspended for insurance can be removed.

Insert supports 5 into the corresponding sockets on the subframe, if necessary, adjust the height of the supports using the knurled nut.

Fix the subframe to the body (pic. 2.163).



Loosen the subframe bolts 2 and 3, as well as the gearbox cross members 4.

If the subframe has not been fixed, loosen the subframe bolts 1 (pic. 2.164).

NOTE: If the subframe is not fixed, the axles must be measured.

NOTE: Now slowly lower the implement down while constantly checking for a smooth ride.

Installation instructions

WARNING: When carrying out all assembly work, in particular in the engine compartment, due to the dense layout, pay attention to the following: lines of all kinds (e.g. fuel, hydraulic, additive, cooling system, air conditioning circuit, brake lines, vacuum hoses), as well as electrical wires must be laid as they were originally laid. Ensure sufficient clearance to all moving and hot components to avoid damage of any kind to lines.

Installation is carried out in the reverse order. When doing this, the following must be taken into account: check the presence of dowel sleeves in the cylinder block for centering the engine/gearbox, insert the dowels if necessary.

Reconnect all pipes, hoses and electrical plugs that were disconnected during removal.