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Service

Workshop Manual
Touareg 2003 ➤
8-cylinder injection engine
Engine ID AXQ BHX

Edition 11.2011

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Service Department. Technical Information


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Repair Group
00 - Technical data

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10 - Removing and installing engine
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13 - Crankshaft group
15 - Cylinder head, valve gear

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17 - Lubrication
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19 - Cooling

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20 - Fuel supply system

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24 - Mixture preparation - injection

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26 - Exhaust system
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28 - Ignition system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.


No reproduction without prior agreement from publisher.

Copyright © 2011 Volkswagen AG, Wolfsburg K0058961520


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Assembly overview - part I, toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Assembly overview - part II, cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4 Checking alignment of poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Removing and installing sealing flange and drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3 Removing and installing sealing flange at drive plate end . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.4 Renewing crankshaft oil seal, vibration damper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28


1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2 Removing and installing right cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3 Removing and installing left cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.4 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.5 Removing and installing left cylinder shead AG. Volkswagen
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1.7 Checking compression . h. o.ris. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .nt.ee. . . . . . . . . . . . . . . . 48
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2 Repairing valve gear s.s.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.c . . . . . . . . . . . . . 50
2.1 Camshafts, checking axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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2.2 Renewing camshaft oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54


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2.3 Renewing Hall sender seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55


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2.4 Removing and installing camshafts and variable camshaft timing adjusters . . . . . . . . . . . . 56
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2.5 Removing and installing roller rocker finger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62


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2.6 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62


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2.7 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65


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2.8 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68


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1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68


1.2 Oil capacities: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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1.3 Dismantling and assembling oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69


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1.4 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70


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1.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75


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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77


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1.1 Assembly overview - radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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1.2 Assembly overview - radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.3 Removing and installing fan support with fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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1.4 Assembly overview - parts of cooling system, engine side, front . . . . . . . . . . . . . . . . . . . . 81
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Contents i
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

1.5 Assembly overview - parts of cooling system, engine side, rear . . . . . . . . . . . . . . . . . . . . 81


1.6 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.7 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.8 Checking water pump V36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.9 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.10 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.11 Removing and installing coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.12 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93


1 Parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.1 Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.2 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.3 Renewing fuel filter . . . . . . . . . . . . . . . . . . g. e.n.A.G.. V
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1.4 Schematic diagram of fuel lines and ycomponentsV olks in fuel tank . . .s.no. t .gu. . . . . . . . . . . . . . . . 98
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1.5 Safety precautions when working ris on fuel supply system . . . . . . . . . . . . n. te.e. . . . . . . . . . . .
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1.6 Rules for cleanliness . . . . .a.uth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o. r .a . . . . . . . . . . 99
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1.7 Emptying fuel tank . . . . . .s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

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1.8 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pumps . . . . 102

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1.9 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 104

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1.10 Checking fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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1.11 Checking delivery rate of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

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1.12 Checking non-return valve of right pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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1.13 Checking non-return valve of left pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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2 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

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3.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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4 Activated charcoal filter system (vehicles for USA and Canada) . . . . . . . . . . . . . . . . . . . . 122
4.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

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4.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131


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1 Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131


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1.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132


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1.2 Assembly overview - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133


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1.3 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.4 Assembly overview - vacuum hose assembly on intake manifold . . . . . . . . . . . . . . . . . . . . 136
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1.5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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1.6 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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1.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137


2 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.1 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.2 Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.2 Reading and erasing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147


1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.1 Assembly overview - exhaust manifold with starter catalytic converters and attachments
........................................................................ 148
1.2 Removing and installing Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.3 Assembly overview - silencers with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

ii Contents
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

2.1 Assembly overview - removing and installing parts of secondary air system . . . . . . . . . . . . 155

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157


1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.1 Assembly overview - parts of ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.3 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.4 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

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1 Technical data
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Engine data ⇒ page 1

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The engine number („engine code“ and „serial number“) is stam‐
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Additionally there is a sticker on the toothed belt guard with „en‐
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The engine code is also included on the vehicle data sticker.

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1.1 Engine data
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Issued 11.2011; Version 6.0
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Engine code AXQ BHX


Manufactured 03.03 ► 03.03 ►
Cylinder arrangement V-engine V-engine
Cylinder angle 90° 90°
Capacity l 4.2 4.2
Output kW at rpm 228/6200 228/6200
Torque Nm at rpm 410/3200 410/3200
Bore ∅ mm 84.5 84.5
Stroke mm 93.0 93.0
Compression ratio 11.0 11.0
Valves per cylinder 5 5
Injection, ignition Motronic ME 7.1 Motronic ME 7.1
Firing order 1-5-4-8-6-3-7-2 1-5-4-8-6-3-7-2
Knock control 2 knock sensors 2 knock sensors
Lambda control 4 probes 4 probes
Leak diagnosis system Only vehicles for USA and yes
Canada
Catalytic converter yes yes
Exhaust gas recirculation no no
Turbocharging/supercharging no no
Secondary air system yes yes
Electronic power control yes yes
Variable intake manifold yes yes
Camshaft timing control yes yes
RON min. 98 unleaded1) 98 unleaded1)

1) In exceptional circumstances min. 95 RON, however with reduced perform‐


ance.

1. Technical data 1
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

10 – Removing and installing engine


1 Removing and installing engine
Removing engine ⇒ page 3 .
Securing engine on engine and gearbox support -VAS 6095-
⇒ page 9 .
Notes on installing ⇒ page 10 .

Special tools and workshop


equipment required
♦ Lifting tackle -VAS 3033-
♦ Drip tray -V.A.G 1306-
♦ Engine and gearbox sup‐
port -VAS 6095-
♦ Workshop hoist -VAS
6100- n AG. Volkswagen AG do
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♦ Scissor-type assembly d byV ua
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platform -VAS 6131- ir se tee
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♦ Engine and gearbox jack - ss
V.A.G 1383 A-

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es, in part or in w

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Not illustrated:
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♦ Left support -VAS 6131/6-1-


♦ Right support -VAS 6131/6-2-
♦ Left running gear support -VAS 6131/6-3-
♦ Right running gear support -VAS 6131/6-4-
♦ Support (Qty. 2) -VAS 6131/6-5-
♦ Support (Qty. 2) -VAS 6131/6-6-
♦ Support -VAS 6131/8-

2 Rep. gr.10 - Removing and installing engine


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

♦ Stepladder -VAS 5085-


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

1.1 Removing engine


The engine is removed from below with the gearbox
– Read fault memories of all control Aunits
G. Volkbefore removal:
swagen A ⇒
Diagnostic tester VAS 5051; agen
Guided
G do
fault finding; Vehicle
es n sys‐
olksw o
tem test or VAS 5052;
ed
bVehicle
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Note ss

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♦ To enable the propshaft to rotate freely, move selector lever


itte

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to the „N“ position.

ab
ility
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♦ Leave key in ignition to prevent steering wheel lock from en‐

wit
is n

gaging.

h re
ole,

spec
♦ It is advisable to remove the front wheels before beginning
urposes, in part or in wh

engine removal. The vehicle can then be lowered on hoist until

t to the co
the brake disc splash plates are just above the floor. This pro‐
vides the most ergonomic working position regarding acces‐
sibility of engine compartment components.

rrectne
♦ Some components cannot be removed, or removed only with

s
difficulty, with the engine installed. Therefore, you should de‐

s o
termine all defective components before removing engine and
cial p

f in
renew them while engine is removed.

form
mer

♦ To prevent damage to removed components, place them in


atio
m

the container for removed parts -V.A.G 1698- .


o

n
c

i
or

n thi
e

♦ All cable ties which are opened or cut through when engine is
t

sd
va

removed must be replaced in the same position when engine


i

o
pr

cum
r

is installed.
fo

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Disconnecting battery
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The procedure must be strictly followed!
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– Switch off ignition and all electrical consumers.
– First disconnect battery under driver seat ⇒ Electrical system;
Rep. gr. 27 ; Disconnecting and reconnecting batteries .
Procedure
– Remove left and right wiper arms: ⇒ Electrical system; Rep.
gr. 29 ; Removing and installing wiper system .
– Pull engine compartment seal off bulkhead.
– Remove covers -A-, -B- and -C- from engine compartment.

WARNING

Fuel supply lines are under pressure! Wear eye protection and
gloves to avoid injuries and skin contact. Before loosening
hose connections, wrap a cloth around the connection. Then
release pressure by carefully pulling hose off connection.

– Wrap a cloth around the joint to catch fuel which flows out.

1. Removing and installing engine 3


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Disconnect fuel supply line -arrow-. agen


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hole

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es, in part or in w

t to the co
– Disconnect breather line -arrow- to solenoid valve in engine
compartment.

rrectness of i
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– Disconnect small connector -A- from engine control unit -1-
C py
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and disconnect earth connection -arrow- of wiring harness.
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– Open fuse box cover in plenum chamber on left and separate


connectors -A-, -B- and -C-.
– Remove wiring harness from plenum chamber and lay it on
engine.

4 Rep. gr.10 - Removing and installing engine


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Disconnect starter wire -1- and and lay it on engine.


– Disconnect connector from air mass meter on left and remove
intake hose and air filter housing on left.
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– Separate connectors -1- to -4- for Lambda probes and lay

h re
connectors on engine.
hole

spec
es, in part or in w

t to the co
Note

rrectness of i
Connector for cylinder bank 1 = black, connector for cylinder bank
2 = brown
l purpos

– Remove intake hose on right leading to throttle valve module.

nform
ercia

– Pull intake hose leading to secondary air pump motor -V101-


m

off upper part of air filter and remove upper part of air filter.

at
om

ion
c

– Remove air filter element.

in t
or

his
ate

do
riv

– Then pull connecting line -arrow- to air suspension compres‐


p

cum
or

sor off right air filter housing downwards ⇒ page 135 .


f

en
ng

t.
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– Unclip gearbox breather hose from air filter housing. C py
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– Remove bracket for engine cover on right ⇒ page 134 . cop Vo
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– Pull lower part of air filter from air duct ⇒ Item 10 (page 134)
AG.

on right and remove it.


– Extract refrigerant from air conditioning system: ⇒ Heating, air
conditioning; Rep. gr. 87
– Remove insulation tray: ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Assembly overview - noise insulation
– Loosen double clamp between catalytic converter and centre
silencer and slide clamp forward.
– Support exhaust system between rear silencer and centre si‐
lencer using engine and gearbox jack -V.A.G 1383 A- , un‐
screw mountings and lower exhaust system.
– Remove rear propshaft tube ⇒ Transfer box and final drive;
Rep. gr. 39 ; Removing and installing propshaft .
– Remove front wheels.
– Remove front wheel housing liners ⇒ General body repairs,
exterior; Rep. gr. 66 ; Exterior equipment; Removing and in‐
stalling wheel housing liner; Front wheel housing liner
– Disconnect hose connection to vacuum reservoir in front left
wheel housing.

1. Removing and installing engine 5


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Remove heat shield -A- from steering box and separate uni‐
versal joint -B-. ⇒ Running gear, axles, steering; Rep. gr. 48 ;
Repairing steering, power-assisted steering

– Separate connectors -A- on gearbox as well as transfer box


-B- and separate selector lever cable ⇒ Automatic gearbox;
Rep. gr. 37 ; Controls, housing .
– Separate brake lines at brake hoses in wheel housings and
collect brake fluid which runs out. ⇒ Brake system; Rep. gr.
46 ; Repairing front wheel brake
– Separate all connectors between body and front axle in wheel
housings. agen
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– Unbolt connecting elines
d b of air suspension at suspensionustrut.
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ility
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ole,

spec
urposes, in part or in wh

t to the co

– Remove gearbox transverse support -A-.


rrectne

WARNING
s

Steam may escape when expansion tank is opened. Wear eye


s o

protection and protective clothing to avoid eye injuries and


cial p

f in

scalding. Cover cap with cloth and open carefully.


form
mer

atio
om

n
c

– Open and close expansion tank cap to release pressure in


i
or

n thi

cooling system.
te

sd
iva

o
pr

– Drain coolant ⇒ page 86 .


um
r
fo

en
ng

t.
– Disconnect hose connection to heat exchanger working from
yi Co
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left wheel housing side and collect escaping coolant. t. C rig
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pyri by
– Disconnect upper coolant hose from radiator and lower cool‐
co Vo
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ant hose from coolant pipe.
agen
Prote AG.

6 Rep. gr.10 - Removing and installing engine


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Disconnect lines on lower right of radiator -arrow- for gearbox


oil. Collect escaping oil.
– Now disconnect line from power steering oil cooler on bottom
left. Collect escaping oil.

– Unscrew earth cable -1- from longitudinal member on front


right.
– Disconnect coolant hose -3- and unscrew coolant pump with
bracket -2-.
– Now unscrew one of the rear securing bolts -3-.

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– Secure subframe to body ⇒ Running ed by gear, axles, steering; ara
nte
is
Rep. gr. 40 ; l - Assembly overview
thor - subframe, lower sus‐ eo
pension links, anti-roll bars a.u ra
c
s
ce
le

– Then proceed with other securing bolt -3- in the same way.
un

pt
an
d
itte

– On each side of vehicle, remove the two hard-to-access sus‐ y li


erm

ab
pension strut bolts working from plenum chamber side ⇒ ility
ot p

Running gear, axles, steering; Rep. gr. 40 ; Front suspension .


wit
is n

h re

Preparing scissor-type assembly platform -VAS 6131- for further


ole,

spec

procedure:
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

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c

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1. Removing and installing engine 7


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Install front supports -VAS 6131/6-1- left -1-, as well as -


VAS 6131/6-2- right -2- on the assembly platform. Arrows on
the supports point forwards. Secure the bolts in the following
positions: left support -1-: A5, B4 and B5. Right support -2-:
G4, H4 and H5
– Bolt both suspension supports -3- -VAS 6131/6-3- and
6131/6-4 to the assembly platform in the following positions:
left suspension support -3-: A6 and C6. Right running gear
support -3-: F6 and H6
– Screw the suspension support turntables down.
– Place supports -4- (VAS 6131/6-5) for subframe and -5- (VAS
6131/6-6) for gearbox console in appropriate positions on as‐
sembly platform.

– Position assembly platform horizontal under engine/gearbox


assembly. Supports -1- must be guided into corresponding
receptacles on left and right -arrow-.
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– At the same time, guide right and left mountings for gearbox
es, in part or in w

bracket into corresponding holes -arrow-. When all four sup‐

t to the co
ports are in the receptacle holes without pressure:
– Screw the two rotating plates of running gear supports under

rrectness of i
the suspension links applying a small amount of pre-tension.
l purpos

nform
mercia

at
om

ion
c

in t
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ate

do
riv

– Guide supports -2- into their respective receptacles in sub‐


p

cum
or

frame, correcting support height as necessary with knurled


f

en
ng

t.
nuts.
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Prote AG.

8 Rep. gr.10 - Removing and installing engine


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Loosen subframe bolts -1- and -2- as well as gearbox trans‐


verse support -4-.
– Unscrew the third bolt of each suspension strut using steplad‐
der -VAS 5085- .
– Now slowly lower engine/gearbox assembly, constantly ob‐
serving the clearance.
Procedure
– Support gearbox on assembly platform using -VAS 6131/7-6- .
– Unscrew one of the lower gearbox securing bolts.
– Insert angled guide pin of -VAS 6131/8- into threaded hole
from engine side.
– Bolt supports stress free to assembly platform.
– Now remove all gearbox securing bolts.

Note

Separating engine and gearbox: ⇒ Operating instructions for


scissor-type assembly platform VAS 6131 .

1.1.1 Securing engine on engine and gearbox


support -VAS 6095-
Special tools and workshop equipment required
♦ Shackle -10 - 222 A /12- AG. Volkswagen AG d
agen oes
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ility
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ole,

spec
urposes, in part or in wh

t to the co

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


ry out repairs.
rrectne

Note
ss o
cial p

f in

To prevent damage to engine when lifting down, additionally use


form
mer

shackles -10 - 222 A /12- .


atio
om

n
c

Vehicles with automatic gearbox


or

n thi
te

sd
a

– Secure torque converter against „falling out“ after separating


iv

o
pr

engine from gearbox.


um
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fo

en
ng

t.
yi
Continuation for all vehicles
Co
Cop py
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– Bolt shackles -10 - 222 A /12- to each lifting eye of engine.
rig ht
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cted agen
Prote AG.

1. Removing and installing engine 9


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.

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1.1.2 Notes on installing


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Note
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hole

spec

When fitting engine and gearbox to body, it is essential to position


es, in part or in w

engine carrier against body with the aid of scissor-type assembly


t to the co

platform -VAS 6131- . »Pulling up« engine carrier with securing


bolts will damage threads.
rrectness of i

Procedure
l purpos

Install in reverse order. In the process, note the following:


nform
ercia

When the engine has been separated from the gearbox:


m

at

– Check whether dowel sleeves for centring engine/gearbox are


om

io

in cylinder block and install if necessary ⇒ 5-speed automatic


n
c

in t
or

gearbox 09D, four-wheel drive; Rep. gr. 37 ; Removing and


his
ate

installing gearbox .
do
priv

cum
or

If subframe with engine carrier has been removed from assembly


f

en
ng

t.
platform:
yi Co
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co lksw
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cted agen
Prote AG.

10 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 ninAGposition.
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age does
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– Reconnect all electrical connections, lines,
yV
ol hoses and con‐ gu
db ara
nectors which were separated during
ris removal.
e nte
tho eo
– Top up ATF level ⇒ 5-speedssautomatic
au gearbox 09D, four- ra
c
wheel drive; Rep. gr. 37 ; Checking ATF level and topping-
ce
e
nl

up . pt
du

an
itte

– Reconnect air conditioning lines: ⇒ Heating, air conditioning y li


erm

ab
system; Rep. gr. 87 ; Repairing components of refrigerant cir‐ ility
ot p

cuit .
wit
, is n

h re
hole

– Recharge air conditioning system with refrigerant: ⇒ Heating,


spec

air conditioning system; Rep. gr. 87 ; Repairing components


es, in part or in w

of refrigerant circuit .
t to the co

– Replenish oil in power-assisted steering: ⇒ Running gear,


axles, steering, front and four-wheel drive; Rep. gr. 48 ;
rrectness of i

Checking power-assisted steering system oil level .


l purpos

– Replenish coolant ⇒ page 86 .


– Replenish engine oil if necessary.
nform
ercia

– Connect battery.
m

at
om

ion
c

in t
or

Note
his
ate

do
priv

cum
or

Perform wheel alignment after the installation of subframe ⇒


f

en
ng

Running gear, axles, steering, front and four-wheel drive; Rep.


t.
yi Co
op
gr. 44 ; Wheel alignment . C py
ht. rig
rig ht
py by
co Vo
lksw
– Connect Vehicle diagnosis, testing and information system -
by
cted agen
Prote
VAS 5052- .
AG.

– 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 11


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 AG. Volkswagen AG d
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ho M6 10 Nm eo
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s M7 15 Nm

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M8 25 Nm

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M10 40 Nm
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ility
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M12 60 Nm

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Deviations

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spec
Engine bracket to engine M10 75 Nm
urposes, in part or in wh

mounting (nut)

t to the co
Engine mounting to en‐ M10 60 Nm
gine carrier (bolt)

rrectne
Engine carrier to body M12 100 Nm + 1/2 turn (180°).
(bolt)

ss
Drive shafts to gearbox ⇒ Running gear, axles, steer‐

o
cial p

f
ing - front and four-wheel

inform
drive; Rep. gr. 40 ; Repairing
mer

drive shaft
atio
om

Gearbox carrier to body ⇒ Differential and final drive;


n
c

i
or

Rep. gr. 34 ; Installing gear‐


thi
te

sd

box carrier and console .


iva

o
pr

cum

Drive shafts to gearbox ⇒ Running gear, axles, steer‐


r
fo

en
ng

ing; Rep. gr. 40 ; Front wheel


t.
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suspension C py
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Prote AG.

12 Rep. gr.10 - Removing and installing engine


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

13 – Crankshaft group
1 Dismantling and assembling engine
Assembly overview
Part I: toothed belt drive ⇒ page 15
Part II: cylinder block ⇒ page 17

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es, in part or in w

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or c

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1. Dismantling and assembling engine 13


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

Caution

Warning, aluminium cylinder block! The crankshaft and pistons


must not be removed. Just loosening the main bearing caps
will cause deformation of the cylinder block bearing pedestals.
This deformation will cause a reduction of the bearing clear‐
ance. Even if the bearing shells are not renewed bearing
damage could occur due to a different bearing clearance. If the
bearing cap bolts are loosened, the cylinder block must be re‐
placed complete with the crankshaft and pistons. Measuring
the main bearing clearance is not possible with normal work‐
shop equipment.

Note

♦ Secure engine to engine and gearbox support -VAS 6095- to carry out repairs.
♦ Engine must not be set down on oil sump, as this will damage the liquid gasket between the upper and lower
sump.
♦ Finding metal shavings or a large quantity of small metal particles during engine repair could indicate that
the crankshaft bearings or conrod bearings are damaged. To prevent this from causing further damage,
perform the following repairs:
♦ Thoroughly clean oil passages,
♦ Renew oil return valve,
♦ Renew oil spray jets,
♦ Renew oil cooler,
♦ Renew oil filter.

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urposes, in part or in wh

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f inform
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om

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14 Rep. gr.13 - Crankshaft group


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

1.1 Assembly overview - part I, toothed belt drive

1 - 10 Nm
2 - Bearing sleeve
3 - 20 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew.
4 - Washer
❑ For tensioning roller.
5 - 40 Nm
6 - Tensioning roller
7 - Tensioning lever
8 - 22 Nm
9 - 55 Nm
❑ Renew.
❑ Oil threads and bolt
head contact surface.
10 - Securing plate
❑ Renew.
❑ Observe installation po‐
sition: side with lettering
faces to rear.
11 - Right camshaft pulley
❑ Pull off camshaft with
two arm puller -T40001- AG. Volkswagen AG d
agen oes
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and claw -T40001/2-
by
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❑ Removingorand ise
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⇒ pageau34t Removing,
h
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installing
ss
and tensioning c
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toothed belt.
nl

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12 - 10 Nm
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ab

❑ Insert with locking fluid -


ility
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D 000 600 A2- .


wit
, is n

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13 - Toothed belt guard, rear right


hole

spec
es, in part or in w

14 - Idler roller
t to the co

15 - Pin, 6 Nm
16 - 15 Nm
rrectness of i

17 - Coolant pump
l purpos

❑ Removing and installing ⇒ page 89


nf
ercia

18 - Gasket
orm
m

❑ Renew.
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19 - Toothed belt guard, rear left


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20 - 10 Nm
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❑ Insert with locking fluid -D 000 600 A2- .


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21 - 10 Nm t. Cop py
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22 - Left camshaft pulley pyri by
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❑ Pull off camshaft with two arm puller -T40001- and claw -T40001/2- . cted agen
Prote AG.

1. Dismantling and assembling engine 15


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
❑ Removing and installing ⇒ page 34 Removing, installing and tensioning toothed belt.
23 - Securing plate
❑ Renew.
❑ Observe installation position: side with lettering faces to rear.
24 - 55 Nm
❑ Renew.
❑ Oil threads and bolt head contact surface.
25 - Toothed belt
❑ Mark direction of rotation before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing and tensioning ⇒ page 34 .
26 - Eccentric roller
27 - 45 Nm
28 - 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.
29 - 200 Nm + 1/2 turn (180°) further
❑ Renew.
❑ Do not oil.
❑ Turning further can be done in several stages.
30 - Washer AG. Volkswagen AG d
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❑ For tensioning lever
db
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31 - Tensioning element
ut
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Prote AG.

16 Rep. gr.13 - Crankshaft group


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

1.2 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.
AG. Volkswagen AG d
❑ Renew. lksw
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6 - Oil return supply valve rised ara
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❑ For cylinder head, right aut
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7 - O-ring

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❑ Renew.
d
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8 - 20 Nm
pe

ility
ot

❑ The specified torque in‐

wit
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fluences the function of
hole

the knock sensor.

spec
es, in part or in w

9 - Knock sensor 1 (G61)

t to the co
10 - Knock sensor 2 (G66)

rrectness of i
11 - Plug, 35 Nm
l purpos

12 - Seal
❑ Renew.

nform
ercia

13 - Engine bracket
m

a
❑ Engine bracket and
com

tio
specified torques

n in
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te o

⇒ page 18

thi
s
iva

do
14 - 40 Nm + 1/4 turn (90°) fur‐
r
rp

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❑ Renew. C py
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15 - Banjo bolt, 30 Nm op Vo
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16 - 10 Nm
AG.

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

1. Dismantling and assembling engine 17


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

Specified torque for engine bracket


Specified torque for securing bolt -1-: 60 Nm.
Specified torque for securing nut -2-: 75 Nm.

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.
. Volkswagen AG
wa gen AG does
– Mark direction of rotation of poly VV-belt.
olks not
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– Turn spanner clockwise until orisetensioning element can be nte
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locked using locking pinau-T10060
th
A- . ra
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– Remove poly V-belt.
ce
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Installing poly V-belt


itte

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wit

Note
is n

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spec

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


urposes, in part or in wh

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


t to the co

secured tightly.
♦ Check that idler roller turns easily.
rrectne

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


proper seating of belt in pulleys.
ss o
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mer

atio
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t.
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Cop py
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by
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Prote AG.

18 Rep. gr.13 - Crankshaft group


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Fit poly V-belt as illustrated.


After completing repairs always:
– Start engine and check that belt runs properly.

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-

AG. Volkswagen AG d
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pe

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

wit
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spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in

Procedure
r
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thi
s

– Remove power-assisted steering vane pump pulley.


iva

do
r
rp

cum
fo

– Remove poly V-belt ⇒ page 18 .


en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Dismantling and assembling engine 19


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Remove idler roller -1-.


– Position aligning gauge -3201- on air conditioning system
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.

AG. Volkswagen AG d
agen oes
olksw not
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es, in part or in w

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t.
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Cop py
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Vo
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by
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Prote AG.

20 Rep. gr.13 - Crankshaft group


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

2 Removing and installing sealing


flange and drive plate

Note
olksw
Secure engine to engine and gearbox supportsw-VAS
agen 6095- to car‐AG does
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ry out repairs. by
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Assembly overview ⇒ page 21 . aut or
ac
ss
Removing and installing drive plate ⇒ page 22 .

ce
e
nl

pt
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itte

Removing and installing sealing flange at drive plate end

y li
erm

ab
⇒ page 24

ility
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Renewing crankshaft oil seal, vibration damper end

wit
, is n

h re
⇒ page 26
hole

spec
2.1 Assembly overview
es, in part or in w

t to the co
1 - Gasket

rrectness of i
❑ Renew.
l purpos

2 - Sealing flange
❑ With seal.

nform
ercia

❑ Remove sump in order


m

to remove and install

at
om

io
⇒ page 70 .

n
c

in t
or

❑ Must seat on dowel

his
ate

sleeves.

do
priv

cum
or

❑ Before installing, re‐


f

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ng

move oil residue from


t.
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op
crankshaft journal using C py
t. rig
a clean cloth.
gh ht
pyri by
Vo
co
❑ Do not additionally oil or
by lksw
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grease the oil seal seal‐
AG.

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

2. Removing and installing sealing flange and drive plate 21


Touareg 2003 ➤
8-cylinder injection engine - EditionA11.2011
G. Volkswagen A n G do
wage es n
Volks ot g
6 - 30 Nm + 1/4 turn (90°) further ed
by ua
ran
oris tee
❑ Renew. au
th or
ac
ss
7 - 10 Nm

ce
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8 - 15 Nm
itte

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ab
9 - Cylinder block

ility
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wit
is n

10 - Oil sump

h re
ole,

❑ Removing and installing ⇒ page 70

spec
urposes, in part or in wh

11 - Securing bolt

t to the co
❑ M7 = 15 Nm
❑ M8 = 22 Nm

rrectne
12 - Timing chain

s
❑ Mark with arrow pointing in direction of rotation before removing (e.g. using paint).

s o
cial p

f
❑ Do not mark with a centre punch mark, notch or anything similar!

inform
mer

13 - Chain sprocket

atio
m

❑ For crankshaft.
o

n
c

i
or

n thi
e

14 - Thrust washer
t

sd
iva

o
r

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


p

cum
r
fo

en
ng

15 - Gasket
t.
yi Co
op py
❑ Renew.
. C rig
ht ht
rig by
opy Vo
16 - Sealing flange at belt pulley end by c lksw
cted agen
Prote AG.
❑ 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

22 Rep. gr.13 - Crankshaft group


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

♦ Locking pin -3242-

♦ 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.

AG. Volkswagen AG d
Note lksw
agen oes
not
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♦ The engine is cranked by turning crankshaft icentre bolt.
se nte
or eo
h
aut ra
♦ The engine must only be cranked in clockwise
ss direction. c
ce
e
nl

pt
du

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itte

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erm

ab
ility
ot p

wit
, is n

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hole

spec

– Remove screw plug -arrow-.


es, in part or in w

t to the co

Note
rrectness of i

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


l purpos

(it is possible to feel the hole).


nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
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pyri by
Vo
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by c lksw
cted
23
agen
Prote AG.
2. Removing and installing sealing flange and drive plate
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Screw locking pin -3242- into crankshaft.


n AG. Volkswagen A
– Loosen drive plate securing
olks
wage bolts diagonally and
G do
es nremove.
o V t gu
by ara
– Remove drive riplate
se
d together with washer and shim. nte
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ut
Installing ss
a ra
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Installation is carried out in the reverse order. When installing,


nl

pt
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note the following:
itte

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ab
ility
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wit
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hole

spec
es, in part or in w

t to the co
– Fit shim -1- of „2.0 mm thickness“ onto crankshaft journal.
– Then, install drive plate and washer -2- of „3.4 mm thickness“.

rrectness of i
– Insert new securing bolts and tighten by hand.
l purpos

– Tighten securing bolt to 30 Nm + 1/4 turn (The additional turn


may be performed in several steps.)

nform
ercia

– Unscrew locking pin -3242- .


m

at
om

– Install sealing plug with a new seal. Specified torque: 35 Nm

ion
c

in t
or

his
ate

do
priv

cum
for

en
g

2.3 Removing and installing sealing flange


n

t.
yi Co
op py
at drive plate end
t. C rig
gh ht
pyri by
Vo
co lksw
Removing ⇒ page 25 .
by
cted agen
Prote AG.
Installing ⇒ page 25 .
Special tools and workshop equipment required
♦ Fitting tool -T10122-

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

24 Rep. gr.13 - Crankshaft group


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

2.3.1 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.

AG. Volkswagen AG d
agen oes
olksw not
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2.3.2 Installing d b ara
rise nte
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Note
nl

pt
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itte

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♦ In the following work procedure the seal is illustrated without

ab
ility
sealing flange.
ot p

wit
, is n

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


h re
hole

completely. Use protective sleeve supplied when installing. spec


es, in part or in w

t to the co

– Clean sealing surfaces on sealing flange and cylinder block.


They must be free of oil and grease.
rrectness of i

– Remove oil residue from crankshaft journal using clean cloth.


l purpos

– Fit new gasket -1- onto dowel sleeves on cylinder block.


nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Removing and installing sealing flange and drive plate 25


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Pull oil seal with sealing flange -A- by the outside over sleeve
-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. gen AG
. Volkswagen AG
a does
lksw not
– Bolt sealing flange to cylinder block. Specified torque:
db
yV
o
10 Nm gu
ara
e nte
ris
– Install sump ⇒ page 70 . utho eo
ra
a c
ss
– Install drive plate ⇒ page 22 .

ce
le
un

pt
– Install engine ⇒ page 3 .

an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
2.4 Renewing crankshaft oil seal, vibration
l purpos

damper end
Special tools and workshop equipment required

nform
ercia

♦ Thrust piece -T40007-


m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ 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- .

26 Rep. gr.13 - Crankshaft group


AG. Volkswagen AG d Touareg 2003 ➤
agen oes
o lksw 8-cylinder injection engine not - Edition 11.2011
yV gu
db ara
rise nte
– Remove thrust washer from crankshaftujournal
tho and mark thrust eo
ra
washer front face -arrow- using a waterproof
ss a felt-tip marker. c

ce
e
nl
Installing

pt
du

an
itte

y li
– Remove oil residue from crankshaft journal and thrust washer

erm

ab
using a clean cloth.

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
– Press new seal in to stop using thrust piece -T40007- .
l purpos

– Reverse thrust washer and fit it on crankshaft journal with


marked front face towards engine.

nf
ercia

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

atio
m

Specified torque: 200 Nm + 1/2 turn (180°) further.


o

n in
or c

thi
e

– Install toothed belt. ⇒ page 34


t

sd
iva

o
r
rp

cu
– Install poly V-belt ⇒ page 18 .
o

m
f

en
ng

t.
yi
– Install noise insulation tray.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Removing and installing sealing flange and drive plate 27


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

15 – Cylinder head, valve gear


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. AG. Volkswagen AG d
agen oes
ksw
♦ Checking compression ⇒ page 48 . ol not
V gu
d by ara
ise nte
or eo
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ss c

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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
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orm
m

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om

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or c

thi
te

sd
iva

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cu
o

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f

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ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

28 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

1.1 Assembly overview

1 - Cap
❑ Renew seal if damaged.
2 - Boot
❑ Renew if damaged.
3 - Oil filler neck
❑ Renew seal if damaged.
4 - Connecting hose
❑ For crankcase ventila‐
tion.
5 - Cylinder head cover
❑ Removing and installing
left cylinder head cover n AG. Volkswagen AG do
⇒ page 32 . lkswage es n
o ot g
yV ua
❑ Removing and installing ir se
d b ran
right cylinder head cov‐ utho tee
or
er ⇒ page 30 . ss
a ac

❑ Renew if damaged.

ce
le
un

pt
an
d
itte

6 - Gasket

y li
erm

ab
❑ Note installation posi‐

ility
ot p

tion.

wit
is n

h re
❑ Renew if damaged or
ole,

spec
leaking.
urposes, in part or in wh

t to the co
7 - 10 Nm
❑ Observe tightening se‐
quence.

rrectne
❑ Removing and installing
left cylinder head cover

ss
⇒ page 32 .

o
cial p

f i
❑ Removing and installing
right cylinder head cov‐ nform
mer

er ⇒ page 30 .
atio
om

n
c

8 - Cylinder head cover gasket


i
or

n thi
te

sd

❑ Ensure proper seating of lugs in cylinder head cover.


iva

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pr

❑ Renew if damaged or leaking.


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t.
❑ Note installation position.
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❑ Removing and installing left cylinder head cover ⇒ page 32 .
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❑ Removing and installing right cylinder head cover ⇒ page 30 .
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9 - Baffle plate
10 - 5 Nm
11 - Coolant pipe
12 - Gasket
❑ Renew.
13 - Sealing grommet
❑ Insert in cylinder head cover.
❑ Renew if damaged or leaking.
14 - Cylinder head bolt
❑ Renew.
❑ Follow installation instructions and sequence when loosening and tightening.

1. Cylinder head 29
olkswagen AG
Touareg 2003 ➤ wage
n AG. V does
olks not
8-cylinder injection engine - Edition 11.2011 d by V gu
ara
e nte
ris
❑ Removing and installing right cylinder head
aut ⇒ page 44 .
ho eo
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ss ⇒ page 40 . c
❑ Removing and installing left cylinder head

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nl

pt
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15 - Cylinder head

an
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❑ Check for distortion ⇒ page 30 .

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❑ Removing and installing right cylinder head ⇒ page 44 .

wit
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❑ Removing and installing left cylinder head ⇒ page 40 .

h re
hole

spec
❑ After renewing, renew entire coolant.

es, in part or in w

t to the co
16 - Cylinder head gasket
❑ Metal gasket.
❑ Renew.

rrectness of i
❑ Must seat on dowel pins.
l purpos

❑ After renewing, renew entire coolant.

nform
ercia

17 - 10 Nm
m

18 - Combination valve

at
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ion
❑ For secondary air system
c

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19 - Coolant pipe
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20 - O-ring
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❑ Renew.
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21 - 20 Nm
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22 - Lifting eye
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23 - Seal
❑ Renew if damaged or leaking.

Checking cylinder head for distortion

Special tools and workshop equipment required


♦ Straight edge
♦ Feeler gauges
Max. permissible distortion: 0.1 mm.

1.2 Removing and installing right cylinder


head cover
Special tools and workshop equipment required

30 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

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

♦ Not illustrated:
♦ Cable ties
♦ Sealant -D 454 300 A2-
Removing

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. AG. Volkswagen A gen G do
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♦ To avoid damagebytoVolines,
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not
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– All cable ties which are opened or cut open when engine is
ce
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un

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removed must be replaced in the same position when engine


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is installed.
rm

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pe

ility

– Remove intake hose between air filter and throttle valve con‐
ot

wit
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trol module.
h re
hole

– Disconnect connectors -1- from ignition coils.


spec
es, in part or in w

t to the co

– Remove ignition coils -2- ⇒ page 158 .


– Detach line -3- for secondary air system from cylinder head
cover.
rrectness of i

– Disconnect crankcase breather hose.


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1. Cylinder head 31
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Loosen securing bolts in the sequence -12- to -1- and remove


cylinder head cover.
Installing
Installation is carried out in the reverse order. When installing,
note the following:

Note

♦ Renew gasket if damaged or leaking.


♦ Before installing ensure that all seals between cylinder head
cover and cylinder head are installed correctly and not dam‐
aged.

– Lightly coat transitions -arrows- on sealing surface of cylinder


head with sealant -D 454 300 A2- .
– Carefully install cylinder head cover.
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spec
es, in part or in w

t to the co
rrectness of i
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– Tighten securing bolts in the sequence -1- to -12-. Specified


torque: 10 Nm
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1.3 Removing and installing left cylinder
head cover
Special tools and workshop equipment required

32 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

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

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♦ Not illustrated:
es, in part or in w

t to the co
♦ Cable ties
♦ Sealant -D 454 300 A2-

rrectness of i
Removing
l purpos

Caution

nform
ercia

When doing any repair work, especially in the engine compart‐


m

a
ment, pay attention to the following due to the cramped condi‐
com

tion in
tions:
r
te o

thi

♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
s
iva

do
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vated charcoal filter system, coolant, refrigerant, brake


rp

cum
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fluid and vacuum) and electrical wiring in their original po‐


en
ng

t.
yi
sitions.
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t. rig
♦ To avoid damage to lines, ensure sufficient clearance to
gh ht
pyri by
all moving or hot components.
co Vo
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– All cable ties which are opened or cut open when engine is
removed must be replaced in the same position when engine
is installed.
– Remove intake hose between air filter and throttle valve con‐
trol module.
– Remove bracket -3-.
– Disconnect connectors -4- from ignition coils.
– Remove ignition coils ⇒ page 158 .
– Disconnect crankcase breather hoses -1- and -2-.

1. Cylinder head 33
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Loosen securing bolts in the sequence -12- to -1- and remove


cylinder head cover.
Installing
Installation is carried out in the reverse order. When installing,
note the following:

Note

♦ Renew gasket if damaged or leaking.


♦ Before installing ensure that all seals between cylinder head
cover and cylinder head are installed correctly and not dam‐
aged.

– Lightly coat transitions -arrows- on sealing surface of cylinder


head with sealant -D 454 300 A2- .
– Carefully install cylinder head cover.

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agen oes
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– Tighten securing bolts in the sequence -1- to -12-. Specified
s au ra
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torque: 10 Nm s

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spec
es, in part or in w

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rrectness of i
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1.4 Removing, installing and tensioning


toothed belt
nform
ercia

Removing ⇒ page 35 .
m

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tio

Installing and tensioning ⇒ page 38


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Prote AG.

34 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

Special tools and workshop


equipment required
♦ Locking pin -3242-
♦ Two-arm puller -T40001-
♦ Camshaft clamp -T40005-
♦ Tensioner wrench -
T40009-
♦ Locking pin -T40011-
♦ Reversible ratchet -VAS
5122-
♦ Torque wrench -V.A.G
1410-
♦ Torque wrench -V.A.G
1331-

AG. Volkswagen AG d
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spec

1.4.1 Removing
es, in part or in w

t to the co

Caution
rrectness of i

When doing any repair work, especially in the engine compart‐


l purpos

ment, pay attention to the following due to the cramped condi‐


tions:
nf
ercia

♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
rm
m

vated charcoal filter system, coolant, refrigerant, brake


atio
m

fluid and vacuum) and electrical wiring in their original po‐


o

n in
c

sitions.
or

thi
te

sd
iva

♦ To avoid damage to lines, ensure sufficient clearance to


o
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rp

cu

all moving or hot components.


o

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f

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ng

t.
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– Remove insulation tray ⇒ General body repairs, exterior; Rep.
ht
pyri by
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gr. 50 ; Noise insulation
o
by c lksw
cted agen
Prote AG.
– Remove radiator fans with radiator fan support ⇒ page 79 .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier service posi‐
tion .

1. Cylinder head 35
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Mark and remove poly V-belt. ⇒ page 18


– Remove toothed belt guards on left and right.
– Mark direction of rotation of toothed belt using a coloured felt-
tip marker.
– Turn crankshaft to TDC. Mark on toothed belt guard -A- must
align with mark on V-belt pulley -B-.

– Check position of camshaft sprockets. The larger holes in se‐


curing plates -arrows- must be positioned to the inside and
must be aligned with the horizontal camshaft centre line.

Note

If the larger holes in the securing plates are positioned to the out‐
side of the camshaft sprockets, the crankshaft must be turned one
revolution further in direction of engine rotation.
AG. Volkswagen AG d
agen oes
olksw not
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– Remove sealing plug s au-arrow- from left side of cylinder block. ra
c
The TDC drilling insthe crankshaft must be visible (or able to
ce
le

be felt) in the sealing plug hole.


un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Carefully screw locking pin -3242- into drilling to stop in order


prevent crankshaft from turning.
nform
ercia

– Remove middle part of toothed belt guard.


m

– Remove vibration damper.


com

tion in
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thi
s
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Note
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The vibration damper is secured to the crankshaft with 8 securing


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by lksw
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Prote AG.

36 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Remove securing bolts -arrows- for alternator. Move alternator


aside slightly.

– First unscrew bolt -1- from oil filter housing. Then unscrew
bolts -2- from cover for toothed belt tensioning element.
– Remove cover.

Note

♦ The toothed belt tensioning element is provided with oil damp‐


ing. It can therefore only be pushed back slowly.
♦ Use locking pin -T40011- for securing the tensioning element.

– If necessary, before tensioning align holes in housing and in


piston of tensioning element using long nose pliers or thin wire.
– Turn tensioning lever of toothed belt tensioning roller -1- in
-direction of arrow- using hexagon key.
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– Secure tensioning element with locking pin -T40011-
byV
ol
when the ot g
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tensioning lever of the toothed belt tensioning
ir se
d element -2- has ran
tee
been pushed back so that the holes uinth the housing and the
o
or
pistons align. ss
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un

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ility
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hole

spec
es, in part or in w

t to the co

– Insert camshaft clamp -T40005- into camshaft securing plates


rrectness of i

and loosen securing bolts by approx. 5 turns.


l purpos

– Remove camshaft clamp -T40005- again.


nform
mercia

a
com

tion in
r
te o

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s
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t.
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t. rig
gh ht
pyri by
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co lksw
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cted agen
Prote AG.

1. Cylinder head 37
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Now pull camshaft sprockets off camshaft tapers using two-


arm puller -T40001- and hook -T40001/2- .

AG. Volkswagen AG d
agen oes
olksw not
V gu
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nl

pt
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erm

ab
– Loosen tensioning roller -arrow- and remove toothed belt.

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at

1.4.2 Installing and tensioning


om

ion
c

in t
or

– Note marking for direction of rotation when reinstalling the ex‐


his
ate

isting toothed belt.


do
priv

cum
or

– First, fit toothed belt to crankshaft toothed belt pulley -1-, then
f

en
ng

t.
yi
to idler roller of toothed belt tensioner -2- and then to tension‐
Co
op py
ing roller -3-. After that, fit toothed belt to camshaft sprockets t. C rig
gh ht
and coolant pump pulley as shown in the illustration. pyri by
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Prote AG.

Note

It should just be possible to turn the camshaft sprockets on the


camshaft tapers.

– Fit camshaft clamp -T40005- onto camshaft pulleys again.

38 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Insert a 5 mm drill bit between the tensioning lever and the


tensioning element piston -arrow-.

– Now pre-tension tensioning roller (still in loosened condition)


using torque wrench -V.A.G 1410- with attached reversible
ratchet -VAS 5122- and tensioner wrench -T40009- in anti-
clockwise direction -arrow- to 4 Nm.
– Tighten bolt -1- to 45 Nm in this position.
– Then remove 5 mm drill.
– Turn tensioning lever of toothed belt tensioning roller -1- in
-direction of arrow- using hexagon key.

– When piston of toothed belt tensioning element -2- has been


pushed back by tensioning lever, pull out locking pin -
T40011- .

AG. Volkswagen AG d
agen oes
olksw not
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nl

pt
du

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erm

ab
– Turn tensioning lever of toothed belt tensioning roller -1- in
ility
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direction of -arrow-, using hexagon key and place a 7 mm drill


wit
, is n

between housing and tensioning lever. h re


hole

spec
– Tighten camshaft sprockets to 55 Nm.
es, in part or in w

t to the co

– Remove camshaft clamp -T40005- again.


– Pull out drill inserted between housing and tensioning lever.
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

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cum
for

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t.
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pyri by
Vo
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by c lksw
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Prote AG.

1. Cylinder head 39
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Remove clamping bolt -3242- from hole, install sealing plug


-arrow- and tighten to 30 Nm.

– Turn crankshaft two full turns in direction of engine rotation


and check setting dimension -a-: specification 5 mm.
Further assembly is basically the reverse of the dismantling se‐
quence.
AG. Volkswagen AG d
agen oes
olksw not
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ility
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1.5 Removing and installing left cylinder

h re
hole

spec
head
es, in part or in w

t to the co
Removing ⇒ page 41 .
Installing ⇒ page 43 .

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

40 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

Special tools and workshop


equipment required
♦ Drip tray -V.A.G 1306-
♦ Torque wrench (5…50 Nm)
-V.A.G 1331-
♦ Torque wrench (40…200
Nm) -V.A.G 1332-
♦ Spring-type clip pliers -VAS
5024A-

AG. Volkswagen AG d
agen oes
olksw not
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wit
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es, in part or in w

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Not illustrated:
rrectness of i
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♦ Cable ties
Prerequisite
nform
ercia

• The engine must be no more than warm to touch.


m

at
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io

1.5.1 Removing
n
c

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or

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ate

– Remove engine ⇒ page 2 .


do
priv

cum
for

en
ng

t.
Caution
Cop
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When doing any repair work, especially in the engine compart‐
pyri by
Vo
co
ment, pay attention to the following due to the cramped condi‐
by lksw
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Prote
tions:
AG.

♦ 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.

1. Cylinder head 41
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– All cable ties which are opened or cut open when engine is
removed must be replaced in the same position when engine
is installed.
– Remove front exhaust pipe from exhaust manifold
⇒ page 148 .
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– Unbolt guide tube for oil dipstick -arrow- from cylinder head.y Volks ot g
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spec
es, in part or in w

t to the co
– Disconnect connectors -2- and -3-.

rrectness of i
– Remove toothed belt ⇒ page 34 .
l purpos

– Remove camshaft pulley ⇒ page 34 , Removing, installing and


tensioning toothed belt.

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ercia

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– Loosen securing bolts -1- and -2- and remove rear toothed belt
ht
pyri by
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guard. by c lksw
cted agen
Prote AG.

– Disconnect vacuum hose -1- from combination valve.


– Remove bolts -2-.
– Disconnect connector -3-.
– Unscrew bolts -4- and remove oil pipe.
– Remove bolts -5- and remove combination valve.

42 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Remove bolts securing coolant pipe -arrow-.


– Disconnect connectors from knock sensors.
– Pull connectors off all injectors.

– Disconnect connector -1-.


– Disconnect hose -2-.
– Remove bolts -8-.
– Disconnect connector -9-.
– Remove coolant pipe.
– Remove intake manifold ⇒ page 132 .
– Remove cylinder head cover ⇒ page 32 .

– Loosen cylinder head bolts in the sequence given starting at


the outside and working inwards and Athen
G. Voremove completely.
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– Carefully remove cylinderbyhead.
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– Place clean cloths in oris
cylinders so that no dirt or emery cloth tee
th or
particles can get sin between cylinder wall and piston.
au ac
s
ce
le

– Also prevent dirt and emery cloth particles from getting into
un

pt
an

coolant.
d
itte

y li
erm

ab

– Now carefully clean sealing surfaces of cylinder head and cyl‐


ility
ot p

inder block. When doing this, ensure that surfaces are not
wit
is n

scored or scratched (if abrasive paper is used, grade must not


h re
ole,

be less than 100).


spec
urposes, in part or in wh

t to the co

1.5.2 Installing
– Carefully remove metal particles, emery residue and cloths.
rrectnes

Note
s o
cial p

f in

♦ Do not remove new cylinder head gasket from its packing until
form
mer

immediately before installing.


atio
om

♦ Handle new gasket with extreme care. Damage will cause


n
c

i
or

leakage.
thi
te

sd
iva

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pr

cum

– Fit new cylinder head gasket. Inscription (Part No.) must be


r
fo

en
ng

readable.
t.
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ht. rig
rig ht
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by lksw
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Prote AG.

1. Cylinder head 43
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Ensure dowel sleeves -arrows- are inserted into cylinder block


holes and the cylinder head gasket is located.
– Fit cylinder head, screw in new cylinder head bolts and tighten
hand tight.

– Tighten cylinder head bolts in tightening sequence shown


working from inside to outside.
– Pre-tighten all bolts to 35 Nm.
– Then tighten all bolts to 60 Nm.
– Then tighten all bolts 1/4 turn (90°) further using a rigid wrench.

– Then tighten all bolts again 1/4 turn (90°) further.

Adjusting valve timing ⇒ page 34 .


– Installing cylinder head cover ⇒ page 32 .
– Install intake manifold ⇒ page 132 .
Further assembly is basically the reverse of the dismantling se‐
quence.

Note

It is not necessary to retighten cylinder head bolts after repairs. agen


AG. Volkswagen AG d
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1.6 Removing and installing right cylinder or eo
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aut ra
head ss c
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pt
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Removing ⇒ page 45 .
itte

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ab

Installing ⇒ page 47 .
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hole

spec
es, in part or in w

t to the co
rrectness of i
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Prote AG.

44 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

Special tools and workshop


equipment required
♦ Drip tray -V.A.G 1306-
♦ Torque wrench (5…50 Nm)
-V.A.G 1331-
♦ Torque wrench (40…200
Nm) -V.A.G 1332-
♦ Spring-type clip pliers -VAS
5024A-

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agen oes
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♦ Cable ties
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Prerequisite
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• The engine must be no more than warm to touch.


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1.6.1 Removing
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hole

spec

– Remove engine ⇒ page 2 .


es, in part or in w

t to the co

Caution
rrectness of i

When doing any repair work, especially in the engine compart‐


l purpos

ment, pay attention to the following due to the cramped condi‐


tions:
nform
ercia

♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
m

a
com

fluid and vacuum) and electrical wiring in their original po‐


ion in

sitions.
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♦ To avoid damage to lines, ensure sufficient clearance to


do
r

all moving or hot components.


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agen 1. Cylinder head
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– All cable ties which are opened or cut open when engine is
removed must be replaced in the same position when engine
is installed.
– Remove front exhaust pipe from exhaust manifold
⇒ page 148 .
– Disconnect connectors -1-, -2- and -3-.
– Remove toothed belt ⇒ page 34 .
– Remove camshaft pulley ⇒ page 34 , Removing, installing and
tensioning toothed belt.

– Remove idler roller -1-.


– Loosen securing bolts -arrows- and remove rear toothed belt
guard.
– Disconnect connectors from knock sensors.
– Pull connectors off all injectors.

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– Remove bolts securing coolant pipe -arrow-. byV
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t to the co

– Disconnect connector -1-.


rrectness of i

– Disconnect hose -2-.


l purpos

– Disconnect connector -4-.


nform
ercia

– Remove bolts -6-.


m

– Disconnect vacuum hose -7- from combination valve.


at
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– Remove bolts -8-.


or

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ate

– Disconnect connector -9-.


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or

– Remove coolant pipe.


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– Remove intake manifold ⇒ page 132 .
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– Remove cylinder head cover ⇒ page 30 . cop Vo
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Prote AG.

46 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Loosen cylinder head bolts in the sequence given starting at


the outside and working inwards and then remove completely.
– Carefully remove cylinder head.
– Place clean cloths in cylinders so that no dirt or emery cloth
particles can get in between cylinder wall and piston.
– Also prevent dirt and emery cloth particles from getting into
coolant.
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. When doing this, ensure that surfaces are not
scored or scratched (if abrasive paper is used, grade must not
be less than 100).

1.6.2 Installing
– Carefully remove metal particles, emery residue and cloths.

Note

♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.

– Fit new cylinder head gasket. Inscription (Part No.) must be


readable.
AG. Volkswagen AG d
agen
– Ensure dowel sleeves -arrows- are inserted
olks into cylinder block
w oes
not
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holes and the cylinder head gasketedis located.
b ara
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– Fit cylinder head, screw in newautcylinder
h
head bolts and tighten ra
hand tight. ss c ce
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spec
es, in part or in w

t to the co
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nform
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tion in
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Prote AG.

1. Cylinder head 47
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Tighten cylinder head bolts in tightening sequence shown


working from inside to outside.
– Pre-tighten all bolts to 35 Nm.
AG. Volkswagen AG d
agen oes
– Then tighten all bolts to 60 Nm. olksw not
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ara
ed
– 1
Then tighten all bolts /4 turn (90°) further using a rigid twrench.
horis nte
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– Then tighten all bolts again /4 turn (90°) further.
1 s

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an
Adjusting valve timing ⇒ page 34 .

itte

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ab
– Installing cylinder head cover ⇒ page 30 .

ility
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– Install intake manifold ⇒ page 132 .

h re
hole
Further assembly is basically the reverse of the dismantling se‐

spec
es, in part or in w

quence.

t to the co
Note

rrectness of i
It is not necessary to retighten cylinder head bolts after repairs.
l purpos

nform
ercia

1.7 Checking compression


m

at
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ion
c

in t
r

Special tools and workshop


o

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e

equipment required
at

do
priv

cum
or

♦ Spark plug socket and ex‐


f

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tension -3122 B-
n

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Cop py
♦ Torque wrench (5…50 Nm) ht. rig
rig ht
-V.A.G 1331-
py by
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♦ Compression tester -
Prote AG.

V.A.G 1763-

48 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

Test prerequisites
• Engine oil temperature must be at least 30°C.
• The battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
• If the vehicle is equipped with an air conditioner, it must be
switched off.
• The selector lever of the must be in „P“or „N“ position.
Test procedure
– Remove ignition coils with output stages ⇒ page 158 .
– Disconnect all connectors from injectors.
Volkswa
– Remove spark plugssusing
agen spark plug socket
AG. gen AG
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-3122B- . by
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– Check compression
tho
ri using compression tester -V.A.G 1763-
tee
o .
au ra
c
ss

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pt
Note

an
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ab
Using compression tester ⇒ operating instructions .
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ility
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– Have a second mechanic fully depress accelerator and crank
hole

engine.
spec
es, in part or in w

– Operate starter until tester shows no further pressure in‐


t to the co
crease.
Compression pressures:
rrectness of i

New: 10…15 bar


l purpos

Wear limit: 7.0 bar.


nform
ercia

Maximum permissible difference between all cylinders: 3 bar


m

– Insert spark plugs using spark plug socket and extension


com

tio

-3122B- and tighten to 30 Nm.


n in
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te o

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After the test has been completed:


s
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– Connect Vehicle diagnosis, testing and information system -


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VAS 5052- .
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– Finish the vehicle system test so that any fault entries stored
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during assembly can be deleted automatically.


– 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.

1. Cylinder head 49
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

2 Repairing valve gear


Assembly overview
Camshafts, checking axial clearance ⇒ page 53
Renewing camshaft oil seal ⇒ page 54 .
Renewing Hall sender seals ⇒ page 55
Removing and installing camshafts and variable camshaft timing
adjusters ⇒ page 56
Removing and installing roller rocker finger ⇒ page 62 .
Renewing valve stem seals ⇒ page 62 .
Checking valve guides ⇒ page 65 .
Reworking valve seats ⇒ page 66 .
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1 - Double bearing d bycap ua
ran
ir se
❑ Whenuthinstalling, seal
o tee
or
parting
ss
a surfaces of outer ac
bearing caps with seal‐
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nl

ant -AMV 188 001 02-


pt
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an
itte

⇒ page 61 .
y li
erm

ab
ility

2 - 5 Nm + 1/4 turn (90°) further


ot p

wit
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❑ Renew.
h re
hole

spec

3 - Support element
es, in part or in w

t to the co

❑ Before installing, check


camshaft axial clear‐
ance ⇒ page 53 .
rrectness of i

❑ Do not interchange.
l purpos

❑ With hydraulic valve


clearance compensa‐
tion.
nform
ercia

4 - Exhaust camshaft
m

at
om

❑ Checking radial clear‐


on
c

ance with Plastigage;


in t
or

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wear limit: 0.1 mm.


at

do
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❑ Runout: max. 0.01 mm.


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❑ Checking axial clear‐


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ance ⇒ page 53 . Cop py
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❑ Removing and installing
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⇒ page 56
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5 - Inlet camshaft bearing cap
❑ Removing and installing
⇒ page 56 , Removing
and installing camshafts
and variable camshaft
timing adjuster.
6 - Exhaust camshaft bearing
cap
❑ Removing and installing ⇒ page 56 , Removing and installing camshafts and variable camshaft timing
adjuster.
7 - 5 Nm + 1/4 turn (90°) further
❑ Renew.
8 - Double bearing cap

50 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

9 - Cap
❑ Renew.
❑ Punch through using a screwdriver and lever out for removal.
❑ Install using tool 3202.
10 - Bearing cap
When installing, seal parting surfaces of outer bearing caps with sealant -AMV 188 001 02- ⇒ page 61 .

11 - Roller rocker finger


❑ For exhaust camshaft.
❑ Before installing, check camshaft axial clearance ⇒ page 53 .
❑ Do not interchange.
❑ Check roller bearing for ease of movement.
❑ Oil contact surface.
❑ Removing and installing ⇒ page 62
12 - Camshaft timing chain
❑ Before removing, mark direction of rotation (installation position) ⇒ page 56 ; Removing and installing
camshafts and variable camshaft timing adjusters.
13 - Roller rocker finger
❑ For inlet camshaft.
❑ Before installing, check camshaft axial clearance ⇒ page 53 .
❑ Do not interchange.
❑ Check roller bearing for ease of movement.
❑ Oil contact surface.
❑ Removing and installing ⇒ page 62
14 - Inlet camshaft n AG. Volkswagen AG do
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❑ Checking radial clearanceyV
olks with Plastigage; wear olimit:
t gu 0.1 mm.
d b ara
❑ Runout: max. oris0.01 mm.
e nte
th eo
❑ Checkings axial clearance ⇒ page 53 .
au ra
c
s
❑ Removing and installing ⇒ page 56
ce
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nl

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an

15 - 5 Nm + 1/4 turn (90°) further


itte

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ab

❑ Renew.
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16 - Camshaft adjuster
h re
hole

❑ Rotate engine only with camshaft adjuster installed.


spec
es, in part or in w

❑ Removing and installing ⇒ page 56 , Removing and installing camshafts and variable camshaft timing
t to the co

adjuster.
17 - Gasket
rrectness of i

❑ Renew.
l purpos

18 - Valve cotters
19 - Valve spring plate
nf
ercia

orm

20 - Valve spring
m

atio
m

❑ Note installation position.


o

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or c

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❑ Removing and installing ⇒ page 62 , Renewing valve stem seals.


te

sd
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21 - Valve stem seal


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❑ Renew. ⇒ page 62 .
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22 - Gasket
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❑ Renew. co Vo
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Prote AG.
23 - Cylinder head
❑ Check for distortion ⇒ page 30 .

2. Repairing valve gear 51


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
❑ Removing and installing right cylinder head ⇒ page 44 .
❑ Removing and installing left cylinder head ⇒ page 40 .
❑ After renewing, renew entire coolant.
24 - Exhaust valve
❑ Do not rework, only lapping-in is permitted.
❑ Valve dimensions ⇒ page 53
25 - Inlet valve
❑ Do not rework, only lapping-in is permitted.
❑ Valve dimensions ⇒ page 53
26 - Seal
❑ For Hall sender.
❑ Removing and installing ⇒ page 55
27 - Hall sender screen
❑ Note installation position.
28 - Washer
❑ Conical.
29 - 23 Nm
30 - Hall sender
31 - 10 Nm
32 - Shaft
❑ For roller rocker finger, inlet side
❑ Removing and installing ⇒ page 62 , Removing and installing roller rocker finger.
33 - 10 Nm
34 - 10 Nm
olkswagen AG
en AG. V
35 - Shaft olks
wag does
not
yV gu
❑ For roller rocker ifinger,
sed b exhaust side ara
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or
❑ Removing and au installing ⇒ page 62 , Removing and installing r roller
th eo
a rocker finger.
ss c
36 - 55 Nm
ce
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un

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37 - Camshaft pulley
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❑ Removing and installing ⇒ page 34 Removing, installing and tensioning toothed belt.
pe

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38 - Seal
, is n

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❑ For camshaft.
hole

spec

❑ Removing and installing ⇒ page 54 .


es, in part or in w

t to the co

39 - O-ring
❑ Renew.
rrectness of i
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nform
mercia

a
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tion in
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thi
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Cop py
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by lksw
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Prote AG.

52 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

Valve dimensions

Note

Valves must not be reworked. Only lapping-in is permitted.

Valve dimensions
Dimension Inlet valve Exhaust valve
-∅ a- mm 26.8...27.0 29.8...30.0
-∅ b- mm 5.96...5.97 5.94...5.95
-c- mm 104.84...105.34 103.64...104.14
-α- ∠° 45 45

Note

Worn sodium filled exhaust valves must not be disposed of with‐


out first preparing the valves.
agen
AG. Volkswagen AG d
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d by ara
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ris
utho
WARNING eo
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Wear eye protection and protective clothing to avoid eye inju‐


nl

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ries and chemical burns!


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itte

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ility
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wit

– They must be cut through in the centre of the stem with a


, is n

h re

hacksaw. When doing this they must not come in contact with
hole

water!
spec
es, in part or in w

t to the co

– When valves have been prepared as described, throw a max‐


imum of ten valves into a bucket filled with water and step
back!
rrectness of i

– Due to the contact with water a sudden chemical reaction will


be initiated and the sodium fill will be burnt.
l purpos

– After this treatment, the valves can be scrapped as normal


nform

scrap.
mercia

at
om

2.1 Camshafts, checking axial clearance


ion
c

in t
or

his
e

Special tools and workshop equipment required


at

do
priv

♦ Universal dial gauge bracket -VW 387-


um
for

en
ng

t.
yi
♦ Dial gauge
Co
Cop py
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Test procedure
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pyri by
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Perform measurements with support elements and roller rocker
cted agen
Prote AG.
fingers removed.

2. Repairing valve gear 53


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Insert camshaft and secure with bearing caps -3-, -5- and
-7-.
Inlet camshaft

– Attach dial gauge with universal dial gauge bracket to cylinder


head, as shown.
Wear limit for axial clearance: max. 0.20 mm.
Exhaust camshaft
AG. Volkswagen AG d
agen oes
olksw not
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– Attach dial gauge with universal dial gauge bracket to cylinder

wit
is n

h re
head, as shown.
ole,

spec
urposes, in part or in wh

Wear limit for axial clearance: max. 0.20 mm.

t to the co
rrectness o
cial p

f inform
mer

atio
om

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c

2.2 Renewing camshaft oil seals


i
or

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sd
iva

Special tools and workshop equipment required


o
pr

cum
r
fo

en
ng

♦ Oil seal extractor -3240-


t.
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Cop py
t. rig
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pyri by
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Prote AG.

♦ Fitting tool -3241-


Removing
– Remove toothed belt and camshaft sprockets ⇒ page 34 .

54 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Unscrew inner part of oil seal extractor -3240- several turns


out of the outer part and lock with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against camshaftwagen AG. Volkswagen AG doe
until oil seal is pulled out. yV
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ed
– Clamp flats of oil seal extractor in vice. Removehooil
ris seal with nte
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pliers. sa
ut or
ac
s
Installing

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nl

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ility
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– Fit seal and press it in to stop using pressure sleeve -3241/1-
hole

spec
and bolt -3241/6- .
es, in part or in w

t to the co
– Install toothed belt and camshaft sprockets ⇒ page 34 .

rrectness of i
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orm
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2.3 Renewing Hall sender seals


iv

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Special tools and workshop equipment required
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♦ Oil seal extractor -2085- t. C rig
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Prote AG.

♦ Fitting sleeves -3241-


Procedure
Left cylinder head
– Disconnect connectors from ignition coils and injectors and lay
wiring harness to side.
– Pull connector off Hall sender.
– Remove Hall sender housing with Hall sender screen and tap‐
er.
Right cylinder head
– Remove right toothed belt guard.
– Pull connector off Hall sender.

2. Repairing valve gear 55


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
n AG. Volkswagen AG do
– Unscrew bolts -1- from Hall sender. lkswage es n
o ot g
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– Unscrew bolt -2- from rear of toothed belt guard. ir se
d b ran
tee
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– Slightly pull rear of toothed belt guard towards frontau and re‐ ac
ss
move Hall sender housing with Hall sender screen and taper.

ce
le
un

pt
Continuation for both cylinder heads

an
d
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spec
es, in part or in w

t to the co
– Screw in pin -2085/1- as shown in the illustration.

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
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thi
s
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t.
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Cop py
– Unscrew inner part of oil seal extractor -2085- several turns
t. rig
gh ht
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out of the outer part and lock with knurled screw. p by
co Vo
by lksw
cted agen
– Lubricate threaded head of oil seal extractor, place it in posi‐ Prote AG.
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against pin -2085/1-
until seal is pulled out.
– Clamp flats of oil seal extractor in vice. Remove oil seal with
pliers.

– Then press in new seal to stop until it is flush using fitting


sleeve -3241/1- and bolt -3241/3- .
Further assembly is basically the reverse of the dismantling se‐
quence.

2.4 Removing and installing camshafts and


variable camshaft timing adjusters
Removing ⇒ page 57 .
Installing ⇒ page 59 .
Special tools and workshop equipment required

56 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

♦ Chain tensioner retainer -3366-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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h
aut ra
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♦ Torque wrench (5…50 Nm) -V.A.G 1331- s

ce
le
un

pt
an
d
itte

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ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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♦ Sealant -AMV 188 001 02-

nform
ercia

2.4.1 Removing
m

a
com

tion in
– Set engine to TDC ⇒ page 34 .
r
te o

thi
– Remove toothed belt and camshaft sprocket ⇒ page 34 ; Re‐
s
iva

moving, installing and tensioning toothed belt. do


r
rp

cum
fo

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Left cylinder head


n

t.
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Cop py
– Remove cylinder head cover ⇒ page 32 .
t. rig
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– Loosen securing bolts -1- and -2- and remove rear toothed belt
lksw
cted agen
guard.
Prote AG.

Right cylinder head


– Remove cylinder head cover ⇒ page 30 .

2. Repairing valve gear 57


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Remove idler roller -1-.


– Loosen securing bolts -arrows- and remove rear toothed belt
guard.
Continuation for both cylinder heads
– Disconnect connector from Hall sender and remove Hall send‐
er housing with Hall sender screen and taper.

– Check TDC position of camshafts. The markings


en AG. V
olkson
wagthe
en Acam‐
G
shafts must be in line with the arrowolkson
wagboth bearing caps does not
-arrows-. ed
by
V gu
ara
is nte
or
When reusing existing camshaft
au
th timing chain eo
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ility
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spec
es, in part or in w

t to the co
rrectness of i
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nf
ercia

orm

– Mark camshaft timing chain -arrows- before removing (e.g.


m

atio
m

with paint, arrow pointing in direction of rotation).


o

n in
or c

thi
te

sd
iva

Note
o
r
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cu
o

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f

en
ng

t.
Do not mark chain by way of centre punch, notch or the like.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

58 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Hold camshaft adjuster in position using retainer for chain ten‐


sioner -3366- .
AG. Volkswagen AG d
agen oes
ksw
Note by Vol not
gu
ara
d
rise nte
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Camshaft aadjuster
ut
h
can be damaged if chain tensioner is tightened ra
too far. ss c

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
– Mark installation position of all bearing caps (e.g. using a wa‐
es, in part or in w

terproof felt-tip marker) with numbers as shown in the illustra‐

t to the co
tion regardless of the existing markings on the bearing caps.
– Unscrew securing bolts for camshaft adjuster.

rrectness of i
– Remove bearing cap -1-.
l purpos

– Remove bearing caps -2-, -4-, -6-, -8- and -9- and place them
on a clean surface in sequence given.

nform
ercia

– Loosen bearing caps -3-, -5- and -7- alternately and diagonally
m

and then remove.

a
com

tion in
– Carefully remove camshafts with camshaft adjusters and
r
te o

thi
place them on a clean surface.
s
iva

do
r
rp

cum
fo

2.4.2 Installing
en
ng

t.
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Cop py
– Renew half-round sealing plug.
t. rig
gh ht
pyri by
Vo
o
– Renew gasket for camshaft adjuster.
c by lksw
cted agen
Prote AG.
– Coat hatched area lightly with sealant -AMV 188 001 02- .
– Fit camshaft timing chain onto camshaft drive gears as de‐
scribed below.
When reusing existing camshaft timing chain

2. Repairing valve gear 59


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Align coloured markings -arrows-.


When using new camshaft timing chain

The distance between tooth -A- and tooth -B- of the camshaft ad‐
juster must be exactly 16 rollers of the camshaft roller chain. The
illustration shows the exact positions of the -1st- and -16th- Arollers
G. Volkswagen AG d
agen
on the chain sprockets. Chain rollers -1- and -16- o are
lksw offset from
oes
not
1 yV gu
notches -A- and -B- by /2 the width of one stooth
ed b towards left. ara
n ri tee
ho
Continuation aut or
ac
ss

ce
e

– Fit camshaft adjuster to camshaft timing chain.


nl

pt
du

an
itte

– Carefully position camshafts with camshaft timing chain and

y li
erm

ab
camshaft adjuster in cylinder head.

ility
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wit
– Oil the camshaft running surfaces.
, is n

h re
hole

spec
es, in part or in w

Note
t to the co
Dowel sleeves for bearing caps and camshaft adjuster must be
fitted in cylinder head.
rrectness of i
l purpos

– Install bearing caps -3-, -5- and -7- to locations as marked and
tighten new bolts alternately and diagonally. Specified torque:
nf
ercia

5 Nm + 1/4 turn (90°) further.


orm
m

atio
m

– Tighten camshaft adjuster -10-. Specified torque: 5 Nm + 1/4


o

n in
or c

turn (90°) further.


thi
te

sd
iva

– Install chain tensioner.


o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

60 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Check TDC position of camshafts. The markings on the cam‐


shafts must be in line with the arrow on both bearing caps
-arrows-.

Note

If necessary, slightly turn camshaft back and forth in order to en‐


sure correct alignment of markings.

– Lightly coat double bearing cap -6- and bearing cap -1- with
sealant -AMV 188 001 02- ⇒ page 61 and install bearing
caps. Specified torque: 5 Nm + 1/4 turn (90°) further.
– Install remaining bearing caps. Specified torque: 5 Nm + 1/4
turn (90°) further. wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
– Renew camshaft seals ⇒ page 54 . ed by ara
ris nte
– Renew Hall sender seals ⇒ page 55 . utho eo
ra
a c
ss
– Carefully drive in cap ⇒ Item 9 (page 50) using thrust piece of

ce
le
un

pt
fitting sleeves -3202- .

an
d
itte

y li
erm

Further assembly is basically the reverse of the dismantling se‐

ab
ility
quence.
ot p

wit
is n

h re
ole,

spec
Note
urposes, in part or in wh

t to the co
♦ After installing camshafts wait for approx. 30 minutes before
starting engine. Hydraulic compensating elements must settle.
(Valves will otherwise contact piston).
♦ After working on valve mechanism, carefully turn engine by rrectne
hand to ensure that no valve strikes piston when engine is
ss o

started.
cial p

f inform
mer

atio

Lightly coat parting surfaces of front and rear bearing caps with
om

sealant -AMV 188 001 02- before installing.


c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Repairing valve gear 61


AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Touareg 2003 ➤ ut
ho eo
ra
a
8-cylinder injection engine
ss - Edition 11.2011 c

ce
le
un

pt
an
d
2.5 Removing and installing roller rocker fin‐

itte

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erm

ab
ger

ility
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wit
is n
Special tools and workshop equipment required

h re
ole,

spec
♦ Torque wrench (5…50 Nm) -V.A.G 1331-
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
Procedure
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fo

en
ng

t.
yi Co
– Remove engine ⇒ page 2 . t. Cop py
rig
gh ht
– Remove camshafts with camshaft adjuster ⇒ page 56 . yri
p by
o Vo
by c lksw
cted
– Mark allocation of roller rocker fingers and roller rocker finger
agen
Prote AG.
shafts in order to ensure correct reinstallation.
– Remove securing bolts -arrows-.
– Then, screw in M6 bolts into shaft holes and pull shafts out of
cylinder head.
– Remove roller rocker fingers.

Note

♦ O-rings for shafts must always be renewed.


♦ Oil bearing points of roller rocker fingers.

– When installing, tighten shaft securing bolts to 10 Nm.


Further assembly is basically the reverse of the dismantling se‐
quence.

2.6 Renewing valve stem seals


Removing ⇒ page 63 .
Installing ⇒ page 65 .

62 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

Special tools and workshop


equipment required
♦ Spark plug socket and ex‐
tension -3122 B-
♦ Valve stem seal puller
-3364-
♦ Valve stem seal fitting tool
-3365-
♦ Adapter -T40012-
♦ Torque wrench (5…50 Nm)
-V.A.G 1331-
♦ Dismantling and assem‐
bling device for valve cot‐
ters -VAS 5161-

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
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aut ra
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nl

pt
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itte

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ab
ility
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wit
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hole

spec
es, in part or in w

2.6.1 Removing
t to the co

– Remove engine ⇒ page 2 .


rrectness of i

– Remove camshafts with camshaft adjuster ⇒ page 56 .


l purpos

– Remove spark plugs using spark plug socket and extension


-3122B- .
nform
ercia

– Swivel roller rocker fingers upwards and secure them with a


rubber strap.
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Repairing valve gear 63


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– Fit guide plate -VAS 5161/7- onto cylinder head as shown in


illustration.
– Secure guide plate using the knurled screws -VAS 5161/12- .
– Insert drift -VAS 5161/3- into guide plate and knock valve cot‐
ters loose using a plastic hammer.

– Screw toothed piece -VAS 5161/6- with -VAS 5161/5- into


guide plate -VAS 5161/7- .
– Insert assembly cartridge -VAS 5161/8- into guide plate -VAS
5161/7- . swage
n AG. Volkswagen AG do
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yV
– Screw adapter -T40012- into spark plug thread, connect d to
b ua
ran
ir se
compressed air line with commercially available adapter
tho and tee
or
apply constant pressure (at least 6 bar). au ac
ss

ce
le

– Attach pressure fork -VAS 5161/2- to snap-in device -VAS


un

pt
5161/6- and push assembly cartridge down.

an
d
itte

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erm

ab
– At the same time, turn knurled screw of assembly cartridge

ility
ot p

clockwise until tips engage in valve cotters.

wit
is n

h re
– Move knurled screw back and forth lightly to press apart valve
ole,

spec
cotters and to capture them in the assembly cartridge.
urposes, in part or in wh

t to the co
– Release pressure fork and remove assembly cartridge from
guide plate.
– Remove guide plate from cylinder head.

rrectness
Note

o
cial p

f inform
The compressed air line remains connected.
mer

atio
om

n
c

i
or

n
– Pull off valve stem seals using valve stem seal puller -3364- . thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

64 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

2.6.2 Installing
– To prevent damage to new valve stem seals, place plastic
sleeve -A- on valve stem.
– Lubricate sealing lip of valve stem seal -B-, place it in the valve
stem oil seal fitting tool -3365- and push carefully onto valve
guide.
– Remove plastic sleeve -A-.

If the valve cotters have been removed from the assembly item
then they must be inserted into the insertion device -VAS
5161/18- .

Note

Larger diameter faces upwards. AG. Volkswagen AG d


agen oes
olksw not
y V gu
– Insert valve spring and valve spring plate. ise
d b ara
nte
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h
– Secure guide plate -VAS 5161/7- back to cylinder
s aut
head. ra
c
s

ce
le
un

pt
an
d
itte

– Insert assembly cartridge -VAS 5161/8- into guide plate.

y li
rm

ab
pe

ility
– Press pressure fork down and pull knurled screw upwards.
ot

This causes the valve cotters to be inserted.

wit
, is n

h re
hole

– Release pressure fork with knurled screw still in pulled posi‐

spec
tion.
es, in part or in w

t to the co
– Install camshafts with camshaft adjuster ⇒ page 56 .
Adjusting valve timing ⇒ page 34 .

rrectness of i
l purpos

Note

nform
ercia

♦ After installing camshafts wait for approx. 30 minutes before


starting engine. Hydraulic compensating elements must settle.
m

(Valves will otherwise contact piston).


com

tion in
r

♦ After working on valve mechanism, carefully turn engine by


te o

thi
s

hand to ensure that no valve strikes piston when engine is


iva

do
r

started.
rp

cum
fo

en
ng

t.
yi Co
Cop py
2.7 Checking valve guides
t. rig
gh ht
pyri by
Vo
co lksw
by
Special tools and workshop equipment required cted agen
Prote AG.

2. Repairing valve gear 65


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

♦ Universal dial gauge bracket -VW 387-

♦ Dial gauge
Test procedure
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. On account of differing stem diame‐
ters, only use inlet valve in inlet guide and exhaust valve in
exhaust guide.
– Determine rock. Wear limit: 0.8 mm
If rock tolerance is exceeded: AG. Volkswagen AG d
agen oes
lksw not
– Renew cylinder head. d byV
o gu
ara
ise nte
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aut ra
ss c
ce
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un

pt
an
d
itte

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rm

ab

2.8 Reworking valve seats


pe

ility
ot

wit
, is n

Special tools and workshop equipment required


h re
hole

spec

♦ Depth gauge
es, in part or in w

t to the co

♦ Valve seat refacing tool


Procedure
rrectness of i
l purpos

Note

♦ When repairing engines with leaking valves, it is not sufficient


nform
ercia

to rework or renew valve seats and valves. Particularly on high


m

mileage engines, it is necessary also to check valve guides for


a
com

tio

wear ⇒ page 65 .
n in
r
te o

thi

♦ Valve seats are only to be reworked to the extent required to


s
iva

do

yield a proper surface appearance. Before beginning to rework


r
rp

cum

valve seats, calculate the maximum permissible reworking di‐


fo

en
g

mensions. If the reworking dimension is exceeded, the hy‐


n

t.
yi Co
op
draulic valve clearance compensation can no longer be C py
ht. rig
guaranteed and the cylinder head must be renewed. rig ht
py by
co Vo
by lksw
cted agen
Prote
– Remove camshafts ⇒ page 56 .
AG.

The max. permissible reworking dimension is calculated as fol‐


lows:
– Insert valve and press firmly against seat.

66 Rep. gr.15 - Cylinder head, valve gear


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

Note

If the valve is to be renewed as part of a repair, use a new valve


for the calculation.

– Measure distance -a- between end of valve stem and upper


edge of cylinder head.
– Calculate maximum permissible reworking dimension from
measured distance -a- and minimum dimension.
Volkswa n AG. gen AG
wage does
Minimum dimension: Volks not
gu
by ara
ed nte
Inlet valves (outer) oris mm 34.0 eo
th
au ra
Inlet valve (centre)
ss mm 33.7 c

ce
le

Exhaust valves mm 34.4


un

pt
an
d
itte

y li
Measured distance -a- minus minimum dimension = maximum
rm

ab
pe

ility
permissible reworking dimension.
ot

wit
, is n

Example:

h re
hole

spec
Measured distance 34.4 mm
es, in part or in w

t to the co
— Minimum dimension 34.0 mm
= Max. permissible reworking dimension 0.4 mm

rrectness of i
l purpos

Note

If the max. permissible reworking dimension is 0 mm or below 0 nform


ercia

mm, repeat measurement using new valves. If the result does not
m

change renew cylinder head.


a
com

tion in
r
te o

thi
s

Reworking valve seats


iva

do
r
rp

cum
fo

Reworking inlet valve seat


en
ng

t.
yi Co
a - = ∅ 26.2 mm Cop py
t. rig
gh ht
yri
b - = 1.5…1.8 mm p by
co Vo
by lksw
cted agen
Z - = bottom surface of cylinder head Prote AG.

α - 45° valve seat angle


β - 30° upper correction angle
γ - 60° lower correction angle
Reworking exhaust valve seat
a - = ∅ 29.0 mm
b - = approx. 1.8 mm
Z - = bottom surface of cylinder head
α - 45° valve seat angle
β - 30° upper correction angle
γ - 60° lower correction angle

2. Repairing valve gear 67


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
oil cooler renewed in order to aprevent
n AG. Vofurther
lkswagedamage
n AG d occurring
later ⇒ page 69 . lksw ge oes
not
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by ua
ed ran
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Removing and installing
utho oil return valves ⇒ Item 6 (page 17) , and or
⇒ Item 21 (page
ss 17) .
a ac
ce
e
nl

1.1 Engine oil


pt
du

an
itte

y li
erm

ab

Engine oil specifications:


ility
ot p

wit

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


, is n

h re

„504 00“.
hole

spec
es, in part or in w

t to the co

Note

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


rrectness of i

service intervals.
l purpos

♦ 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
nf
ercia

be programmed accordingly. Procedure: ⇒ Maintenance ;


rm
m

atio

Booklet 17.1
om

n in
c

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


or

thi
e

be used to change or top up oil.


t

sd
iva

o
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rp

cu

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


o

m
f

en
ng

be used only to top up oil.


t.
yi Co
Cop py
t. rig
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1.2 Oil capacities:
pyri by
Vo
co lksw
by
cted agen
Prote
With oil filter 7.5 l
AG.

68 Rep. gr.17 - Lubrication


Touareg 2003 ➤
AG. Volkswagen AG d 8-cylinder injection engine - Edition 11.2011
agen oes
olksw not
V
Markings onedoil by dipstick gu
ara
ris nte
o
1 - Max.aut mark
h eo
ra
ss c
2 - Min. mark

ce
le
un

pt
an
d

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


itte

y li
engine oil!
erm

ab
ility
ot p

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

wit
is n

up.

h re
ole,

spec
c - Area from min. mark up to hatched field: Must be topped up,
urposes, in part or in wh

max. 0.5 l of engine oil!

t to the co
rrectne
1.3 Dismantling and assembling oil filter
housing

ss o
Assembly overview
cial p

f inform
mer

atio
m

Note
o

n
c

i
or

n thi
e

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

sd
va

engine removed ⇒ page 2 .


i

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
. rig
1 - Dowel sleeve
ht ht
rig by
copy Vo
2 - Gasket
by lksw
cted agen
Prote AG.
❑ 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 69


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

17 - 50 Nm + 1/4 turn (90°) further


❑ Renew.
AG. Volkswagen AG d
agen oes
18 - Engine mounting Volksw not
gu
d by ara
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or eo
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aut ra
1.4 Removing and installing oil sump ss c

ce
le
un

pt
an
d
itte

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rm

ab
Note
pe

ility
ot

wit
, is n

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

h re
only with the oil filter housing removed ⇒ page 69 .
hole

spec
es, in part or in w

t to the co
1 - Oil pump
❑ Removing and installing

rrectness of i
⇒ page 71
l purpos

2 - Pipe connection
3 - 10 Nm

nform
ercia

4 - Chain tensioner
m

a
com

tio
❑ Secure with locking pin -

n in
r

T40011- before remov‐


te o

thi
s
al.
iva

do
r
rp

cum
5 - 10 Nm
fo

en
ng

t.
yi Co
6 - Chain sprocket Cop py
t. rig
gh
❑ Note installation posi‐
ht
pyri by
Vo
o
tion ⇒ page 71 . by c lksw
cted agen
Prote AG.
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.

70 Rep. gr.17 - Lubrication


AG. Volkswagen AG d
agen oes
olksw not
d byV gu
ara Touareg 2003 ➤
e
horis 8-cylinder nte injection
eo engine - Edition 11.2011
aut ra
ss c
21 - 10 Nm

ce
le
un

pt
an
22 - 25 Nm

d
itte

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erm

ab
23 - Oil suction pipe

ility
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❑ For sump, upper part

wit
is n

h re
ole,

spec
urposes, in part or in wh

Installation position of oil pump chain drive sprocket

t to the co
– Fit chain sprocket onto oil pump shaft. The flattened side
-arrow- faces oil pump shaft and the inscription on the chain

rrectne
sprocket faces towards front.

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

1.4.1 Removing and installing oil pump

en
ng

t.
yi Co
Cop py
. rig
Special tools and workshop equipment required
ht ht
rig by
copy Vo
♦ Engine and gearbox support -VAS 6095-
by lksw
cted agen
Prote AG.
♦ 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


n AG. Volkswagen AG do
lkswage es n
o ot g
Touareg 2003 ➤ byV ua
d ran
ir se
8-cylinder injection engine - Edition 11.2011 tho tee
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ss
– Unscrew bracket for coolant drain pipe -from- upper part of

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le
un

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

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– Now unscrew lower part and upper part of sump.

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

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light leverage with a lever, if necessary.

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

es, in part or in w
cure it with pin -T40011- -1-.

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rrectness of i
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– Now unscrew chain sprocket -2- from oil pump.

nform
ercia
– Unscrew the three oil pump securing bolts m
⇒ Item 9 (page 70) and the oil suction pipe securing bolts

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⇒ Item 22 (page 71) .

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– Now oil pump can be removed.

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– Remove sealant residue from cylinder block.

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– 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

72 Rep. gr.17 - Lubrication


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

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

Note
olkswagen AG
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The sealant bead must not be thicker, otherwise olkexcess
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sealing does
not
compound will enter the oil sump and mayeblock
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line strainer. tho
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– Fit upper part of sump immediately and lightly tighten all sump

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bolts „diagonally“.

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spec
es, in part or in w

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

-2- to 22 Nm.

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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 73


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011

– 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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1.4.2 ss Removing and installing drive chain for

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oil pump

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♦ Engine removed

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♦ Engine is secured on engine and gearbox support -VAS

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hole

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– Remove toothed belt ⇒ page 34 .
es, in part or in w

t to the co
– Drain engine oil from lower part and upper part of sump.

Note rrectness of i
l purpos

Observe environmental regulations for disposal.


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– Remove lower part and upper part of sump.


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– Remove front sealing flange ⇒ page 21 .


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


t

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coloured felt-tip marker.


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f

– Remove oil pump ⇒ page 71 .


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– Remove thrust washer from crankshaft journal. t. C rig
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pyri by
– Mark direction of rotation of drive chain using a coloured felt-
co Vo
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tip marker.
agen
Prote AG.

– 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 .

74 Rep. gr.17 - Lubrication


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 agen oes
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♦ Oil pressure tester -V.A.G aut
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1342- ss c

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♦ Adapter -V.A.G 1342/14-

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♦ Voltage tester -V.A.G
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1527B-
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♦ Auxiliary measuring set -

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hole

V.A.G 1594C-

spec
es, in part or in w

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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 75


Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
AG. Volkswagen AG d
agen oes
lksw not
Checking oil pressure switch d by
Vo gu
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ise nte
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– Remove oil pressure switch -F1- and screw into tester. ut
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ra
s a c
– Screw oil pressure tester -V.A.G 1342- with adapter - s

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

un

pt
an
d
switch. ⇒ Item 16 (page 69) .

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ility
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Note

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Observe installation position of adapter: the conical connecting

es, in part or in w
piece of adapter must be screwed into pressure hose of tester.

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

rrectness of i
– Connect voltage tester -V.A.G 1527B- using test cables from
l purpos
-V.A.G 1594 C- to battery positive (+) and oil pressure switch.
LED must not light up.

nform
ercia

If the LED lights up:


m

– Renew oil pressure switch -F1- .

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tion in
If LED does not light up:
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te o

thi
s
iva

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

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rp

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

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