Volkswagen Touareg (2003 year). Manual - part 3

verse support -4-.

– Unscrew the third bolt of each suspension strut using steplad‐

der -VAS 5085- .

– Now slowly lower engine/gearbox assembly, constantly ob‐

serving the clearance.

Procedure
– Support gearbox on assembly platform using -VAS 6131/7-6- .
– Unscrew one of the lower gearbox securing bolts.
– Insert angled guide pin of -VAS 6131/8- into threaded hole

from engine side.

– Bolt supports stress free to assembly platform.
– Now remove all gearbox securing bolts.

Note

Separating engine and gearbox: ⇒  Operating instructions for

scissor-type assembly platform VAS 6131 .

1.1.1

Securing engine on engine and gearbox

support -VAS 6095-

Special tools and workshop equipment required
♦ Shackle -10 - 222 A /12-

Secure engine to engine and gearbox support -VAS 6095- to car‐

ry out repairs.

Note

To prevent damage to engine when lifting down, additionally use

shackles -10 - 222 A /12- .

Vehicles with automatic gearbox
– Secure torque converter against „falling out“ after separating

engine from gearbox.

Continuation for all vehicles
– Bolt shackles -10 - 222 A /12- to each lifting eye of engine.

Touareg 2003 ➤

1. Removing and installing engine    

9

gine from scissor-type assembly platform using workshop

crane -VAS 6100- .

– Lift engine using workshop crane -VAS 6100- until the centre

of the flywheel is at the same height as the assembly plate of

the engine and gearbox support -VAS 6095- . Then bolt sup‐

port to cylinder block as shown in the illustration using univer‐

sal fastening elements.

1.1.2

Notes on installing

Note

When fitting engine and gearbox to body, it is essential to position

engine carrier against body with the aid of scissor-type assembly

platform -VAS 6131- . »Pulling up« engine carrier with securing

bolts will damage threads.

Procedure
Install in reverse order. In the process, note the following:
When the engine has been separated from the gearbox:
– Check whether dowel sleeves for centring engine/gearbox are

in cylinder block and install if necessary ⇒  5-speed automatic

gearbox 09D, four-wheel drive; Rep. gr.  37 ; Removing and

installing gearbox .

If subframe with engine carrier has been removed from assembly

platform:

Touareg 2003 ➤

10

sembly platform.

– Set engine on subframe.
If gearbox is not yet bolted on:
– Support engine from below using support -VAS 6131/8- .
– Before installing assembly, install exhaust manifold with cat‐

alytic converters to engine.

Caution

When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐

tions:

♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐

vated charcoal filter system, coolant, refrigerant, brake

fluid and vacuum) and electrical wiring in their original po‐

sitions.

♦ To avoid damage to lines, ensure sufficient clearance to

all moving or hot components.

Vehicles with automatic gearbox
– When installing engine, first raise scissor-type assembly plat‐

form only sufficiently to clip selector lever cable in position.

– Reconnect all electrical connections, lines, hoses and con‐

nectors which were separated during removal.

– Top up ATF level ⇒  5-speed automatic gearbox 09D, four-

wheel drive; Rep. gr.  37 ; Checking ATF level and topping-

up .

– Reconnect air conditioning lines: ⇒  Heating, air conditioning

cuit .

– Recharge air conditioning system with refrigerant: ⇒  Heating,

air conditioning system; Rep. gr.  87 ; Repairing components

of refrigerant circuit .

– Replenish oil in power-assisted steering: ⇒  Running gear,

axles, steering, front and four-wheel drive; Rep. gr.  48 ;

Checking power-assisted steering system oil level .

– Replenish coolant 

⇒ page 86

 .

– Replenish engine oil if necessary.
– Connect battery.

Note

Perform wheel alignment after the installation of subframe ⇒ 

Running gear, axles, steering, front and four-wheel drive; Rep.

gr.  44 ; Wheel alignment .

– Connect Vehicle diagnosis, testing and information system -

VAS 5052- .

– Carry out vehicle system test ⇒ Vehicle diagnostic tester „Gui‐

ded fault finding“.

– Finish the vehicle system test so that any fault entries stored

during assembly can be deleted automatically.

Touareg 2003 ➤

1. Removing and installing engine    

11

which may have occurred.

Specified torques

Threaded connection

 

Specified torque

Bolts, nuts

M6

10 Nm

 

M7

15 Nm

 

M8

25 Nm

 

M10

40 Nm

 

M12

60 Nm

Deviations

 

 

Engine bracket to engine

mounting (nut)

M10

75 Nm

Engine mounting to en‐

gine carrier (bolt)

M10

60 Nm

Engine carrier to body

(bolt)

M12

100 Nm + 

1

/2 turn (180°).

Drive shafts to gearbox

⇒  Running gear, axles, steer‐

ing - front and four-wheel

drive shaft

Gearbox carrier to body

⇒  Differential and final drive;

Rep. gr.  34 ; Installing gear‐

box carrier and console .

Drive shafts to gearbox

⇒  Running gear, axles, steer‐

suspension

Touareg 2003 ➤

12