Volkswagen Touareg (2003 year). Manual - part 5

Assembly overview - part II, cylinder block

1 - 10 Nm
2 - Cover

❑ With connection for

crankcase breather

3 - Connecting hose

❑ For crankcase ventila‐

tion.

4 - Clip
5 - Baffle plate

❑ With seal.
❑ Renew.

6 - Oil return supply valve

❑ For cylinder head, right

7 - O-ring

❑ Renew.

8 - 20 Nm

❑ The specified torque in‐

fluences the function of

the knock sensor.

9 - Knock sensor 1 (G61)
10 - Knock sensor 2 (G66)
11 - Plug, 35 Nm
12 - Seal

❑ Renew.

13 - Engine bracket

❑ Engine bracket and

specified torques

⇒ page 18

14 - 40 Nm + 

1

/4 turn (90°) fur‐

ther

❑ Renew.

15 - Banjo bolt, 30 Nm
16 - 10 Nm
17 - Coolant drain pipe
18 - Cylinder block
19 - Thermostat

❑ Removing and installing 

⇒ page 89

20 - Thermostat housing
21 - Oil return supply valve

❑ For cylinder head, left

Touareg 2003 ➤

1. Dismantling and assembling engine    

17

1.3

Removing and installing poly V-belt

Special tools and workshop equipment required
♦ Locking pin -T10060 A-

Removing poly V-belt
– Remove noise insulation tray.
– Mark direction of rotation of poly V-belt.
– Turn spanner clockwise until tensioning element can be

locked using locking pin -T10060 A- .

– Remove poly V-belt.
Installing poly V-belt

Note

♦

Before installing poly V-belt, ensure that all ancillary assem‐

blies (alternator, air conditioner compressor, vane pump) are

secured tightly.

♦

Check that idler roller turns easily.

♦

When installing poly V-belt, check direction of belt rotation and

proper seating of belt in pulleys.

Touareg 2003 ➤

18

1.4

Checking alignment of poly V-belt

Note

Alignment of poly V-belt must always be checked to prevent dam‐

age if power-assisted steering vane pump, air conditioning sys‐

tem compressor or the respective brackets for power-assisted

steering or air conditioning system compressor have been re‐

newed.

Special tools and workshop equipment required
♦ Aligning gauge -3201-

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

Procedure
– Remove power-assisted steering vane pump pulley.
– Remove poly V-belt 

⇒ page 18

 .

Touareg 2003 ➤

1. Dismantling and assembling engine    

19

compressor belt pulley.

Note

The air conditioning system compressor pulley must align with the

power-assisted steering vane pump pulley.

If belt pulleys do not align

– Compensate misalignment of pulleys using shims with thick‐

nesses of 0.6, 0.8, 1.0, 1.2, and 1.4 mm.

– Check alignment of belt pulleys again with aligning gauge

-3201-

– Install idler roller. Specified torque: 25 Nm
– Install poly V-belt 

⇒ page 18

 .

– Tighten power-assisted steering belt pulley securing bolts to

22 Nm.

Touareg 2003 ➤

20