Get Removing and installing engine -> 1.1.2 Notes on installing Guide for Volkswagen Touareg SUV First Generation (2002-2010)

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Attach lifting tackle -3033- as shown in illustration and lift en‐

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:

Rep. gr.10 - Removing and installing engine

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Reposition subframe with engine carrier onto prepared as‐

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

system; Rep. gr. 87 ; Repairing components of refrigerant cir‐

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.

1. Removing and installing engine

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Generate the readiness code in combination with a road test.

Observe applicable safety precautions during road test.

– Carry out road test.

– Then carry out vehicle system test again and rectify any faults

which may have occurred.

Specified torques

Threaded connection

Bolts, nuts

Specified torque

10 Nm

15 Nm

25 Nm

M10

M12

40 Nm

60 Nm

Deviations

Engine bracket to engine M10

75 Nm

mounting (nut)

Engine mounting to en‐

gine carrier (bolt)

M10

M12

60 Nm

Engine carrier to body

100 Nm + / turn (180°).

(bolt)

Drive shafts to gearbox

⇒ Running gear, axles, steer‐

ing - front and four-wheel

drive; Rep. gr. 40 ; Repairing

drive shaft

Gearbox carrier to body

Drive shafts to gearbox

⇒ Differential and final drive;

Rep. gr. 34 ; Installing gear‐

box carrier and console .

⇒ Running gear, axles, steer‐

ing; Rep. gr. 40 ; Front wheel

suspension

Rep. gr.10 - Removing and installing engine

Removing and installing engine -> 1.1.2 Notes on installing for Your Volkswagen Touareg SUV First Generation (2002-2010)

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