Volkswagen Touareg (2003 year). Manual - part 6

Removing and installing sealing

flange and drive plate

Note

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

ry out repairs.

Assembly overview 

⇒ page 21

 .

Removing and installing drive plate 

⇒ page 22

 .

Removing and installing sealing flange at drive plate end

⇒ page 24

Renewing crankshaft oil seal, vibration damper end

⇒ page 26

2.1

Assembly overview

1 - Gasket

❑ Renew.

2 - Sealing flange

❑ With seal.
❑ Remove sump in order

to remove and install

⇒ page 70

 .

❑ Must seat on dowel

sleeves.

❑ Before installing, re‐

move oil residue from

crankshaft journal using

a clean cloth.

❑ Do not additionally oil or

grease the oil seal seal‐

ing lip.

❑ Use support sleeve sup‐

plied when installing.

❑ Only remove supporting

sleeve after sealing

flange has been slid on‐

to crankshaft journal.

❑ If the sealing flange has

not been renewed use

fitting tool -T10122- for

installing 

⇒ page 26

 ,

Removing and installing

sealing flange at drive

plate end.

❑ Removing and installing

⇒ page 24

 .

3 - Shim

❑ 2 mm thick

4 - Drive plate

❑ Use locking pin -3242- to loosen and tighten 

⇒ page 22

 ; Removing and installing drive plate.

5 - Washer

❑ 3.4 mm thick

Touareg 2003 ➤

2. Removing and installing sealing flange and drive plate    

21

1

/4 turn (90°) further

❑ Renew.

7 - 10 Nm
8 - 15 Nm
9 - Cylinder block
10 - Oil sump

❑ Removing and installing 

⇒ page 70

11 - Securing bolt

❑ M7 = 15 Nm
❑ M8 = 22 Nm

12 - Timing chain

❑ Mark with arrow pointing in direction of rotation before removing (e.g. using paint).
❑ Do not mark with a centre punch mark, notch or anything similar!

13 - Chain sprocket

❑ For crankshaft.

14 - Thrust washer

❑ In case of signs of abnormal wear remove and reverse or renew.

15 - Gasket

❑ Renew.

16 - Sealing flange at belt pulley end

❑ Remove sump in order to remove and install 

⇒ page 70

 .

❑ Must seat on dowel sleeves.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.

17 - O-ring

❑ Renew.

18 - Spray nozzle valve, 35 Nm
19 - Seal

❑ Renew. 

⇒ page 26

 .

20 - Crankshaft toothed belt pulley

❑ Fitting possible in one position only.
❑ For removal lock crankshaft using locking pin -3242- 

⇒ page 22

 ; Removing and installing drive plate.

21 - 200 Nm + 

1

/2 turn (180°) further

❑ Renew.
❑ Do not oil.
❑ Turning further can be done in several stages.

22 - Vibration damper/belt pulley

❑ For poly V-belt.
❑ For removal lock crankshaft using locking pin -3242- 

⇒ page 22

 ; Removing and installing drive plate.

23 - 22 Nm
24 - 25 Nm
25 - Cover

2.2

Removing and installing drive plate

Special tools and workshop equipment required

Touareg 2003 ➤

22

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

Removing
– Remove engine 

⇒ page 3

 .

– Separate engine from gearbox.
– Set engine to TDC. For this, notches -A- and -B- must align.

Note

♦

The engine is cranked by turning crankshaft centre bolt.

♦

The engine must only be cranked in clockwise direction.

– Remove screw plug -arrow-.

Note

There is a TDC drilling in the crankshaft directly behind the plug

(it is possible to feel the hole).

Touareg 2003 ➤

2. Removing and installing sealing flange and drive plate    

23

note the following:

– Fit shim -1- of „2.0 mm thickness“ onto crankshaft journal.
– Then, install drive plate and washer -2- of „3.4 mm thickness“.
– Insert new securing bolts and tighten by hand.
– Tighten securing bolt to 30 Nm + 

1

/4 turn (The additional turn

may be performed in several steps.)

– Unscrew locking pin -3242- .
– Install sealing plug with a new seal. Specified torque: 35 Nm

2.3

Removing and installing sealing flange

at drive plate end

Removing 

⇒ page 25

 .

Installing 

⇒ page 25

 .

Special tools and workshop equipment required
♦ Fitting tool -T10122-

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

Touareg 2003 ➤

24