Get Lubrication Guide for Volkswagen Touareg SUV First Generation (2002-2010)

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

17 – Lubrication

1

Removing and installing parts of lu‐

brication system

Dismantling and assembling oil filter housing ⇒ page 69

Removing and installing sump ⇒ page 70 .

Removing and installing oil pump ⇒ page 71 .

Removing and installing drive chain for oil pump ⇒ page 74

Checking oil pressure and oil pressure switch ⇒ page 75

Note

If large quantities of metal shavings or particles are found when

repairing the engine, the oil passages must be cleaned, and the

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oil cooler renewed in order to prevent further damage occurring

later ⇒ page 69 .

Removing and installing oil return valves ⇒ Item 6 (page 17) , and

⇒ Item 21 (page 17) .

1.1

Engine oil

Engine oil specifications:

Use „long-life engine oil“ conforming to VW standard „503 00“ or

„504 00“.

Note

♦ The engine is factory-filled with oil which is designed for long

service intervals.

♦ Engine oils conforming to VW standard 501 01 or 502 00 can

continue to be used. These oils must be changed every 12

months or 15,000 kilometres. The service interval display must

be programmed accordingly. Procedure: ⇒ Maintenance ;

Booklet 17.1

♦ Engine oil „ILSAC GF3 with viscosity class SAE5W-40“ may

be used to change or top up oil.

♦ Engine oil „ILSAC GF3 with viscosity class SAE5W-30“ may

be used only to top up oil.

1.2

Oil capacities:

With oil filter 7.5 l

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8-cylinder injection engine - Edition 11.2011

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Markings on oil dipstick

1 - Max. mark

2 - Min. mark

a - Area above hatched field up to max. mark: Do not top up with

engine oil!

b - Engine oil level within hatched zone: Engine oil can be topped-

up.

c - Area from min. mark up to hatched field: Must be topped up,

max. 0.5 l of engine oil!

1.3

Dismantling and assembling oil filter

housing

Assembly overview

Note

The oil filter housing can be removed or installed only with the

engine removed ⇒ page 2 .

1 - Dowel sleeve

2 - Gasket

❑ For oil passage

❑ Renew.

3 - 10 Nm

4 - Oil cooler seal

❑ For oil passage

5 - 20 Nm

❑ Renew.

6 - Oil cooler

7 - Oil filter element

❑ Observe change inter‐

vals ⇒ Maintenance ;

Booklet 17.1

8 - Oil filter lower part, 25 Nm

9 - Oil drain plug, 10 Nm

10 - Seal

11 - Oil cooler seal

❑ For coolant passage

12 - Oil filter housing

13 - 25 Nm

14 - Coolant drain plug, 10 Nm

15 - Coolant pipe

16 - 1.4 bar oil pressure switch

-F1- , 20 Nm

❑ Checking ⇒ page 75 .

1. Removing and installing parts of lubrication system

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1

17 - 50 Nm + / turn (90°) further

4

❑ Renew.

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18 - Engine mounting

1.4

Removing and installing oil sump

Note

The sump (upper and lower parts) can be removed or installed

only with the oil filter housing removed ⇒ page 69 .

1 - Oil pump

❑ Removing and installing

⇒ page 71

2 - Pipe connection

3 - 10 Nm

4 - Chain tensioner

❑ Secure with locking pin -

T40011- before remov‐

al.

5 - 10 Nm

6 - Chain sprocket

❑ Note installation posi‐

tion ⇒ page 71 .

7 - 34 Nm

8 - Drive chain

❑ For oil pump.

❑ Removing drive chain

⇒ page 74 .

9 - 30 Nm

10 - Sump, upper part

11 - Sump, lower part

12 - 10 Nm

13 - Oil level and oil tempera‐

ture sender -G266-

14 - 10 Nm

15 - Oil drain plug, 50 Nm

❑ For sump, lower part

16 - Seal

❑ Renew.

17 - 15 Nm

18 - Oil drain plug, 50 Nm

❑ For sump, upper part

19 - 22 Nm

20 - Seal

❑ Renew.

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Rep. gr.17 - Lubrication

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

21 - 10 Nm

22 - 25 Nm

23 - Oil suction pipe

❑ For sump, upper part

Installation position of oil pump chain drive sprocket

– Fit chain sprocket onto oil pump shaft. The flattened side

-arrow- faces oil pump shaft and the inscription on the chain

sprocket faces towards front.

1.4.1

Removing and installing oil pump

Special tools and workshop equipment required

♦ Engine and gearbox support -VAS 6095-

♦ Locking pin -T40011-

♦ Silicone sealant D176 501A1

♦ Eye protection

Prerequisites

•

Engine removed

Engine is secured on engine and gearbox support -VAS

6095- .

Removing

– Drain engine oil from lower part and upper part of sump.

Note

Observe environmental regulations for disposal.

– Remove engine mounting on right ⇒ Item 18 (page 70) .

– Now the oil filter housing can be removed

⇒ Item 12 (page 69) .

– Unscrew bracket for dipstick guide tube -1- from cylinder head

and pull out guide tube.

1. Removing and installing parts of lubrication system

71

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Unscrew bracket for coolant drain pipe -from- upper part of

sump. If necessary, slightly loosen banjo bolt -1-.

– Now unscrew lower part and upper part of sump.

– Loosen sump with light blows of a rubber headed hammer or

light leverage with a lever, if necessary.

– Press chain tensioner together -in direction of arrow- and se‐

cure it with pin -T40011- -1-.

– Now unscrew chain sprocket -2- from oil pump.

– Unscrew the three oil pump securing bolts

⇒ Item 9 (page 70) and the oil suction pipe securing bolts

⇒ Item 22 (page 71) .

– Now oil pump can be removed.

– Remove sealant residue from cylinder block.

– Remove sealant residue on lower part and upper part of sump

using a rotating brush, e.g. an electric drill with a plastic brush

attachment (wear safety goggles).

– Clean sealing surfaces. They must be free of oil and grease.

Installing

– Reinstall oil pump.

– Bolt chain sprocket to oil pump ⇒ page 71 .

– Remove locking pin -T40011- from chain tensioner.

– Now install upper part of sump as follows:

Note

♦ Observe expiry date of sealing compound.

♦ The sump must be installed within 5 minutes of applying sili‐

cone sealing compound.

– Cut off tube nozzle at front marking (∅ of nozzle approx. 1

mm).

– Coat clean sealing surface on upper part of sump with silicone

sealant as shown in the illustration. The sealant bead must be

1.5 mm thick

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

Run bead along inner side of bolt holes -arrows-.

Note

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The sealant bead must not be thicker, otherwise excess sealing

compound will enter the oil sump and may block the oil suction

line strainer.

– Fit upper part of sump immediately and lightly tighten all sump

bolts „diagonally“.

– Then „diagonally“ tighten sump bolts -1- to 15 Nm and bolts

-2- to 22 Nm.

Now apply an approx. 1.5 mm bead of sealing compound

-arrow- onto the clean sealing flange of the lower part of the oil

sump as shown on illustration.

– Fit lower part of sump immediately and lightly tighten all sump

bolts „diagonally“.

– Then „diagonally“ tighten oil sump bolts to 10 Nm.

– Insert dipstick guide tube.

1. Removing and installing parts of lubrication system

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Touareg 2003 ➤

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– Bolt coolant drain pipe to sump upper part -arrow- to 10 Nm

and then bolt to cylinder block -1- to 30 Nm.

Note

Let sealing compound dry for approx. 30 minutes after installing

oil sump. Only then fill with engine oil.

Further assembly is basically the reverse of the dismantling se‐

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quence.

1.4.2

Removing and installing drive chain for

oil pump

♦ Engine removed

♦ Engine is secured on engine and gearbox support -VAS

6095- .

– Remove toothed belt ⇒ page 34 .

– Drain engine oil from lower part and upper part of sump.

Note

Observe environmental regulations for disposal.

– Remove lower part and upper part of sump.

– Remove front sealing flange ⇒ page 21 .

– Mark front face of thrust washer ⇒ Item 14 (page 22) using a

coloured felt-tip marker.

– Remove oil pump ⇒ page 71 .

– Remove thrust washer from crankshaft journal.

– Mark direction of rotation of drive chain using a coloured felt-

tip marker.

– Remove drive chain for oil pump.

The assembly is basically a reverse of the dismantling sequence.

When doing this note installation position of chain sprocket

⇒ page 71 .

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1.5

Checking oil pressure and oil pressure switch

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Special tools and workshop

equipment required

♦ Oil pressure tester -V.A.G

1342-

♦ Adapter -V.A.G 1342/14-

♦ Voltage tester -V.A.G

1527B-

♦ Auxiliary measuring set -

V.A.G 1594C-

Test prerequisites

•

Engine oil level OK.

Oil pressure warning lamp -K3- must light up for approx. 3

seconds when ignition is switched on

•

Engine oil temperature at least 80 °C (radiator fan must have

run once)

Checking oil pressure

– Check oil pressure at different revolutions: 2000 rpm: 3.0…5.5

bar, above 2000 rpm: maximal 7.0 bar.

If the specifications are not obtained

– Rectify mechanical damage, e.g. bearing damage.

At higher engine speeds, the oil pressure must not exceed 7.0

bar.

If the specification is exceeded:

– Renew oil pump, if necessary ⇒ page 71 .

1. Removing and installing parts of lubrication system

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

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Checking oil pressure switch

– Remove oil pressure switch -F1- and screw into tester.

– Screw oil pressure tester -V.A.G 1342- with adapter -

V.A.G 1342/14- into oil filter housing in place of oil pressure

switch. ⇒ Item 16 (page 69) .

Note

Observe installation position of adapter: the conical connecting

piece of adapter must be screwed into pressure hose of tester.

– Connect brown wire of tester to earth (-).

– Connect voltage tester -V.A.G 1527B- using test cables from

-V.A.G 1594 C- to battery positive (+) and oil pressure switch.

LED must not light up.

If the LED lights up:

– Renew oil pressure switch -F1- .

If LED does not light up:

– Start engine and run at idling speed. At 1.2…1.6 bar the LED

must light up, otherwise renew oil pressure switch -F1- .

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Rep. gr.17 - Lubrication

Lubrication for Your Volkswagen Touareg SUV First Generation (2002-2010)

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