Volkswagen Touareg 2004-06

Engine

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Removal & Installation




NOTE
The engine is lowered from the vehicle together with the front driveline, transmission and transfer case. All tie wraps that are loosened or removed in order to remove the engine must be replaced or reinstalled to the same place when the engine is reinstalled. Tag all hoses and wiring during removal to use as reference during reassembly.

3.2L Engine


Click image to see an enlarged view

Fig. Engine cover identification-3.2L engines

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the battery.
  4.  
  5. Remove the left and right wiper arms.
  6.  
  7. Remove the engine covers (A, B and C) and plenum cover (D).
  8.  
  9. Relieve the fuel system pressure.
  10.  
  11. Disconnect the fuel supply line.
  12.  
  13. Disconnect the breather line to the EVAP purge valve.
  14.  
  15. Unplug the small connector from the Engine Control Module (ECM) and the wiring harness ground connection.
  16.  
  17. Unplug the wiring harness connectors from the left plenum fuse box. Remove the harness from the plenum chamber and place it on the engine.
  18.  
  19. Disconnect the harness from the starter and alternator, place it on the engine.

    Click image to see an enlarged view

    Fig. Unplug connector (A) from the ECM (1), and the ground connection (arrow)-3.2L and 4.2L engines



    Click image to see an enlarged view

    Fig. Unplug connectors (A), (B) and (C) from the fuse box-3.2L and 4.2L engines



    Click image to see an enlarged view

    Fig. Disconnect the starter (A) and alternator (B) harness-3.2L engines

  20.  
  21. Disconnect the vacuum hose from the intake manifold.
  22.  
  23. Pull the pressure hose from the secondary air injection pump.
  24.  
  25. Unplug the oxygen sensor wiring harness and place it on the engine.
  26.  
  27. If equipped, unplug the connecting line to the air suspension compressor at the air filter.
  28.  
  29. Remove the top part of the air filter upwards and out.
  30.  
  31. Remove the transmission breather line from the air filter housing.
  32.  
  33. Discharge and recover the air conditioning system refrigerant.
  34.  
  35. Remove the sound insulation tray.
  36.  
  37. Drain the cooling system. Pull the upper hose from the radiator and the lower hose off the coolant pipe.
  38.  
  39. Disconnect the lines from the transmission cooler and power steering cooler; catch any fluid that runs out.
  40.  
  41. Loosen the double clamp between the catalytic converter and the center muffler and push the clamp forward.
  42.  
  43. Support the rear muffler, remove the rear mountings and lower the exhaust system.
  44.  
  45. Remove the heat shield from the steering shaft and loosen the universal joint.
  46.  
  47. Unplug all connections on the transmission and transfer case.
  48.  
  49. Matchmark the rear driveshaft and transfer case output flange. Counterhold the nuts with an open end wrench, and remove the bolts securing the driveshaft to the flange. Secure the driveshaft to prevent it from flexing.

    Click image to see an enlarged view

    Fig. Unplug all connections on the transmission (A) and transfer case (B)-3.2L and 4.2L engines



    Click image to see an enlarged view

    Fig. Matchmark the driveshaft and transfer case flanges-3.2L and 4.2L engines



    Click image to see an enlarged view

    Fig. Remove the fasteners securing the driveshaft to the transfer case flange-3.2L and 4.2L engines

  50.  
  51. Remove the front wheels and wheel house liners.
  52.  
  53. Disconnect and plug the brake lines from the brake hoses. Catch any fluid that runs out.
  54.  
  55. Label and separate connectors between the body and front axle. If equipped, disconnect the lines for the air suspension at the strut.
  56.  
  57. Remove the transmission transverse support
  58.  
  59. Use tool VW 552 or similar spring compressor to secure the struts, then remove the upper bolts securing the struts to each side of the vehicle.
    NOTE
    Use of tool VAS6131 or a similar scissor lift table providing support of the subframe and engine/driveline assembly is recommended. This allows for proper alignment of the subframe and engine/driveline assembly during removal and installation.



    Click image to see an enlarged view

    Fig. Remove the transmission transverse support-3.2L and 4.2L engines



    Click image to see an enlarged view

    Fig. Secure the strut as shown-3.2L engines

  60.  
  61. Prepare tool VAS6131 or similar scissor lift as follows:
    1. Attach pulley end engine supports VAS6131/6-1 and VAS6131/6-2, or similar. Secure the bolts at the following positions:

      Left subframe support: A5, B4 and B5
       
      Right subframe support: G4, H4 and H5
       

    2.  
    3. Attach axle supports VAS6131/6-3 and VAS6131/6-4, or similar. Secure the bolts at the following positions:

      Left suspension support: A6 and C6
       
      Right suspension support: F6 and H6
       

    4.  
    5. Rotate the turntables of the axle supports downward.
    6.  
    7. Place axle supports VAS6131/6-5 (or similar) for the subframe and VAS6131/6-6 (or similar) for the transmission mount at the appropriate positions on the scissor lift table.
    8.  

  62.  
  63. Position the scissor lift table under the engine/transmission assembly. The supports must be guided into the corresponding engine and transmission mounts.

    Click image to see an enlarged view

    Fig. The carrier supports must be positioned on the scissor table as shown-3.2L and 4.2L engines



    Click image to see an enlarged view

    Fig. Guide the supports into the corresponding mounts-3.2L and 4.2L engines

  64.  
  65. Make sure all four supports are in the appropriate receptacle holes without pressure being applied to them. Using light pressure beneath the control arms, screw both turntables of the axle supports until the securing device can be removed using tool VW 552 or similar spring tensioner tool.
  66.  
  67. Guide the subframe supports into their respective receptacles, correcting the support height as necessary with the knurled nuts.
  68.  
  69. Loosen subframe bolts (1, 2 and 3), as well as transmission transverse support (4).
    NOTE
    Anytime the subframe is loosened, it will be necessary to perform a wheel alignment on the vehicle.



    Click image to see an enlarged view

    Fig. Loosen subframe bolts (1, 2 and 3), as well as transmission transverse support (4)-3.2L and 4.2L engines

  70.  
  71. Slowly lower the engine/transmission assembly, constantly observing clearance and checking for items that may not have been disconnected.
  72.  

To install:


NOTE
When installing the drivetrain assembly back into the vehicle, make sure to bring the mounts to rest against the body using the scissor lift table. Do not let the bolts draw up the drivetrain assembly as the threaded inserts in the body could become damaged.

  1. Installation is the reverse of removal.
    1. Observe the following tightening torques:

      Engine bracket to mount: 55 ft. lbs. (75 Nm)
       
      Engine mount to carrier: 44 ft. lbs. (60 Nm)
       
      Engine carrier to chassis (use new bolts): 74 ft. lbs. (100 Nm), plus a 1 / 2 turn
       
      Transmission crossmember (use new bolts): 37 ft. lbs. (50 Nm), plus a 1 / 4 turn
       
      Driveshaft to transfer case flange (use new bolts/nuts): 55 ft. lbs. (75 Nm)
       

    2.  
    3. All other fasteners:

      M6: 7 ft. lbs. (10 Nm)
       
      M7: 11 ft. lbs. (15 Nm)
       
      M8: 18 ft. lbs. (25 Nm)
       
      M10: 30 ft. lbs. (40 Nm)
       
      M12: 44 ft. lbs. (60 Nm)
       

    4.  

  2.  
  3. Make sure all lines, hoses and wiring harnesses are properly routed. Refill or top off all fluids and recharge the A/C system. Perform a wheel alignment.
  4.  

4.2L Engine


Click image to see an enlarged view

Fig. Engine cover identification-4.2L engines

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the battery.
  4.  
  5. Remove the left and right wiper arms.
  6.  
  7. Remove the engine covers (A and B) and plenum covers (C).
  8.  
  9. Relieve the fuel system pressure.
  10.  
  11. Disconnect the fuel supply line.
  12.  
  13. Disconnect the breather line to the EVAP purge valve.
  14.  
  15. Unplug the small connector from the Engine Control Module (ECM) and the wiring harness ground connection.
  16.  
  17. Unplug the wiring harness connectors from the left plenum fuse box. Remove the harness from the plenum chamber and place it on the engine.
  18.  
  19. Disconnect the harness from the starter, place it on the engine.

    Click image to see an enlarged view

    Fig. Disconnect the starter (1) harness-4.2L engines

  20.  
  21. Unplug the left Mass Air Flow (MAF) sensor connector. Remove the intake hose and left air filter housing.
  22.  
  23. Unplug the oxygen sensor wiring harness and place it on the engine.
  24.  
  25. Remove the right intake hose leading to the throttle body.
  26.  
  27. Pull the intake hose from the secondary air injection pump on the air filter cover. Remove the cover and air filter.
  28.  
  29. If equipped, unplug the connecting line to the air suspension compressor at the air filter.
  30.  
  31. Remove the transmission breather line from the air filter housing.
  32.  
  33. Remove the bracket for the right engine cover.
  34.  
  35. Pull the lower part of the air filter housing from the air duct and remove it from the vehicle.
  36.  
  37. Discharge and recover the air conditioning system refrigerant.
  38.  
  39. Remove the sound insulation tray.
  40.  
  41. Loosen the double clamp between the catalytic converter and the center muffler and push the clamp forward.
  42.  
  43. Support the rear muffler, remove the rear mountings and lower the exhaust system.
  44.  
  45. Matchmark the rear driveshaft and transfer case output flange. Counterhold the nuts with an open end wrench, and remove the bolts securing the driveshaft to the flange. Secure the driveshaft to prevent it from flexing.
  46.  
  47. Remove the front wheels and wheel house liners. Unplug the hose from the vacuum reservoir in the left wheel housing.
  48.  
  49. Remove the heat shield from the steering shaft and loosen the universal joint.
  50.  
  51. Unplug all connections on the transmission and transfer case.
  52.  
  53. Disconnect and plug the brake lines from the brake hoses. Catch any fluid that runs out.
  54.  
  55. Label and separate connectors between the body and front axle. If equipped, disconnect the lines for the air suspension at the strut.
  56.  
  57. Remove the transmission transverse support
  58.  
  59. Drain the cooling system. Pull the upper hose from the radiator and the lower hose off the coolant pipe. Disconnect the hoses from the heater core in the left wheel housing.
  60.  
  61. Disconnect the lines from the transmission cooler and power steering cooler; catch any fluid that runs out.
  62.  
  63. Disconnect the ground harness (1) from the longmember. Pull the coolant hose (3) and unfasten the coolant pump and bracket (2).

    Click image to see an enlarged view

    Fig. Ground harness (1), coolant pump and bracket (2), and coolant hose (3)-4.2L engines

  64.  
  65. From inside the plenum area, remove the 2 least accessible bolts from the suspension strut on each side of the vehicle.
    NOTE
    Use of tool VAS6131 or a similar scissor lift table providing support of the subframe and engine/driveline assembly is recommended. This allows for proper alignment of the subframe and engine/driveline assembly during removal and installation.

  66.  
  67. Prepare tool VAS6131 or similar scissor lift as follows:
    1. Attach pulley end engine supports VAS6131/6-1 and VAS6131/6-2, or similar. Secure the bolts at the following positions:

      Left subframe support: A5, B4 and B5
       
      Right subframe support: G4, H4 and H5
       

    2.  
    3. Attach axle supports VAS6131/6-3 and VAS6131/6-4, or similar. Secure the bolts at the following positions:

      Left suspension support: A6 and C6
       
      Right suspension support: F6 and H6
       

    4.  
    5. Rotate the turntables of the axle supports downward.
    6.  
    7. Place axle supports VAS6131/6-5 (or similar) for the subframe and VAS6131/6-6 (or similar) for the transmission mount at the appropriate positions on the scissor lift table.
    8.  

  68.  
  69. Position the scissor lift table under the engine/transmission assembly. The supports must be guided into the corresponding engine and transmission mounts.
  70.  
  71. Make sure all four supports are in the appropriate receptacle holes without pressure being applied to them. Extend both turntables of the axle supports to slightly preload the control arms.
  72.  
  73. Guide the subframe supports into their respective receptacles, correcting the support height as necessary with the knurled nuts.
  74.  
  75. Loosen subframe bolts (1, 2 and 3), as well as transmission transverse support (4).
    NOTE
    Anytime the subframe is loosened, it will be necessary to perform a wheel alignment on the vehicle.

  76.  
  77. Remove the third bolt securing each strut.
  78.  
  79. Slowly lower the engine/transmission assembly, constantly observing clearance and checking for items that may not have been disconnected.
  80.  

To install:


NOTE
When installing the drivetrain assembly back into the vehicle, make sure to bring the mounts to rest against the body using the scissor lift table. Do not let the bolts draw up the drivetrain assembly as the threaded inserts in the body could become damaged.

  1. Installation is the reverse of removal.
    1. Observe the following tightening torques:

      Engine bracket to mount: 55 ft. lbs. (75 Nm)
       
      Engine mount to carrier: 44 ft. lbs. (60 Nm)
       
      Engine carrier to chassis (use new bolts): 74 ft. lbs. (100 Nm), plus a 1 / 2 turn
       
      Transmission crossmember (use new bolts): 37 ft. lbs. (50 Nm), plus a 1 / 4 turn
       
      Driveshaft to transfer case flange (use new bolts/nuts): 55 ft. lbs. (75 Nm)
       

    2.  
    3. All other fasteners:

      M6: 7 ft. lbs. (10 Nm)
       
      M7: 11 ft. lbs. (15 Nm)
       
      M8: 18 ft. lbs. (25 Nm)
       
      M10: 30 ft. lbs. (40 Nm)
       
      M12: 44 ft. lbs. (60 Nm)
       

    4.  

  2.  
  3. Make sure all lines, hoses and wiring harnesses are properly routed. Refill or top off all fluids and recharge the A/C system. Perform a wheel alignment.
  4.  

 
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