Volkswagen Touareg (2003 year). Manual - part 7

Removing

– Remove engine 

⇒ page 3

 .

– Separate engine from gearbox.
– Remove drive plate 

⇒ page 22

 .

– Remove sump 

⇒ page 70

 .

– Remove sealing flange -arrow- from cylinder block.
– Remove existing gasket.

2.3.2

Installing

Note

♦

In the following work procedure the seal is illustrated without

sealing flange.

♦

If repair is required, sealing flange and seal must be renewed

completely. Use protective sleeve supplied when installing.

– Clean sealing surfaces on sealing flange and cylinder block.

They must be free of oil and grease.

– Remove oil residue from crankshaft journal using clean cloth.
– Fit new gasket -1- onto dowel sleeves on cylinder block.

Touareg 2003 ➤

2. Removing and installing sealing flange and drive plate    

25

-T10122/1- onto pulling sleeve -T10122/2- .

– Separate the two fitting sleeves.
– Then set pulling sleeve -T10122/2- with dry seal and sealing

flange onto crankshaft journal.

– Bolt sealing flange to cylinder block. Specified torque: 10 Nm
– Install sump 

⇒ page 70

 .

– Install drive plate 

⇒ page 22

 .

– Install engine 

⇒ page 3

 .

2.4

Renewing crankshaft oil seal, vibration

damper end

Special tools and workshop equipment required
♦ Thrust piece -T40007-

♦ Torque wrench (150…800 Nm) -V.A.G 1601-

Removing
– Remove noise insulation tray.
– Remove toothed belt 

⇒ page 34

 .

– Unscrew centre bolt -2- from crankshaft toothed belt pulley

-1- and remove crankshaft toothed belt pulley from crankshaft

journal.

– Then remove seal using extractor hook -T20143/1- .

Touareg 2003 ➤

26

washer front face -arrow- using a waterproof felt-tip marker.

Installing
– Remove oil residue from crankshaft journal and thrust washer

using a clean cloth.

– Press new seal in to stop using thrust piece -T40007- .
– Reverse thrust washer and fit it on crankshaft journal with

marked front face towards engine.

– Install crankshaft toothed belt pulley using a new centre bolt.

Specified torque: 200 Nm + 

1

/2 turn (180°) further.

– Install toothed belt. 

⇒ page 34

– Install poly V-belt 

⇒ page 18

 .

– Install noise insulation tray.

Touareg 2003 ➤

2. Removing and installing sealing flange and drive plate    

27

1

Cylinder head

Assembly overview 

⇒ page 29

 .

Removing and installing right cylinder head cover 

⇒ page 30

 .

Removing and installing left cylinder head cover 

⇒ page 32

 .

Removing, installing and tensioning toothed belt 

⇒ page 34

 .

Removing and installing left cylinder head 

⇒ page 40

 .

Removing and installing right cylinder head 

⇒ page 44

 .

Checking compression 

⇒ page 48

 .

Note

♦

To remove cylinder head, engine must first be removed

⇒ page 3

 .

♦

If an exchange cylinder head is installed, all the contact sur‐

faces between the support elements, roller rocker fingers and

the running surfaces of the cam shafts must be oiled before

the cylinder head cover is installed.

♦

The plastic protectors fitted to protect the open valves must be

removed only immediately before the cylinder head is fitted.

♦

When cylinder head or cylinder head gasket is renewed, the

complete coolant must be renewed.

♦

Removing and installing intake manifold 

⇒ page 132

 ; Re‐

moving and installing cylinder head cover.

♦

Checking compression 

⇒ page 48

 .

Touareg 2003 ➤

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