Volkswagen Touareg (2003 year). Manual — part 5
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.
❑ Renew.
6 - Oil return supply valve
❑ For cylinder head, right
7 - O-ring
❑ Renew.
8 - 20 Nm
❑ The specified torque in‐
fluences the function of
the knock sensor.
9 - Knock sensor 1 (G61)
10 - Knock sensor 2 (G66)
11 - Plug, 35 Nm
12 - Seal
❑ Renew.
13 - Engine bracket
❑ Engine bracket and
specified torques
14 - 40 Nm +
1
/4 turn (90°) fur‐
ther
❑ Renew.
15 - Banjo bolt, 30 Nm
16 - 10 Nm
17 - Coolant drain pipe
18 - Cylinder block
19 - Thermostat
20 - Thermostat housing
21 - Oil return supply valve
❑ For cylinder head, left
Touareg 2003 ➤
1. Dismantling and assembling engine
17
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.
– Mark direction of rotation of poly V-belt.
– Turn spanner clockwise until tensioning element can be
locked using locking pin -T10060 A- .
– Remove poly V-belt.
Installing poly V-belt
Note
♦
Before installing poly V-belt, ensure that all ancillary assem‐
blies (alternator, air conditioner compressor, vane pump) are
secured tightly.
♦
Check that idler roller turns easily.
♦
When installing poly V-belt, check direction of belt rotation and
proper seating of belt in pulleys.
Touareg 2003 ➤
18
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-
♦ Torque wrench (5…50 Nm) -V.A.G 1331-
Procedure
– Remove power-assisted steering vane pump pulley.
– Remove poly V-belt
Touareg 2003 ➤
1. Dismantling and assembling engine
19
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
– Tighten power-assisted steering belt pulley securing bolts to
22 Nm.
Touareg 2003 ➤
20
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