Volkswagen Touareg (2003 year). Manual — part 3
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-
Secure engine to engine and gearbox support -VAS 6095- to car‐
ry out repairs.
Note
To prevent damage to engine when lifting down, additionally use
shackles -10 - 222 A /12- .
Vehicles with automatic gearbox
– Secure torque converter against „falling out“ after separating
engine from gearbox.
Continuation for all vehicles
– Bolt shackles -10 - 222 A /12- to each lifting eye of engine.
Touareg 2003 ➤
1. Removing and installing engine
9
gine from scissor-type assembly platform using workshop
crane -VAS 6100- .
– Lift engine using workshop crane -VAS 6100- until the centre
of the flywheel is at the same height as the assembly plate of
the engine and gearbox support -VAS 6095- . Then bolt sup‐
port to cylinder block as shown in the illustration using univer‐
sal fastening elements.
1.1.2
Notes on installing
Note
When fitting engine and gearbox to body, it is essential to position
engine carrier against body with the aid of scissor-type assembly
platform -VAS 6131- . »Pulling up« engine carrier with securing
bolts will damage threads.
Procedure
Install in reverse order. In the process, note the following:
When the engine has been separated from the gearbox:
– Check whether dowel sleeves for centring engine/gearbox are
in cylinder block and install if necessary ⇒ 5-speed automatic
gearbox 09D, four-wheel drive; Rep. gr. 37 ; Removing and
installing gearbox .
If subframe with engine carrier has been removed from assembly
platform:
Touareg 2003 ➤
10
sembly platform.
– Set engine on subframe.
If gearbox is not yet bolted on:
– Support engine from below using support -VAS 6131/8- .
– Before installing assembly, install exhaust manifold with cat‐
alytic converters to engine.
Caution
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.
Vehicles with automatic gearbox
– When installing engine, first raise scissor-type assembly plat‐
form only sufficiently to clip selector lever cable in position.
– Reconnect all electrical connections, lines, hoses and con‐
nectors which were separated during removal.
– Top up ATF level ⇒ 5-speed automatic gearbox 09D, four-
wheel drive; Rep. gr. 37 ; Checking ATF level and topping-
up .
– Reconnect air conditioning lines: ⇒ Heating, air conditioning
cuit .
– Recharge air conditioning system with refrigerant: ⇒ Heating,
air conditioning system; Rep. gr. 87 ; Repairing components
of refrigerant circuit .
– Replenish oil in power-assisted steering: ⇒ Running gear,
axles, steering, front and four-wheel drive; Rep. gr. 48 ;
Checking power-assisted steering system oil level .
– Replenish coolant
.
– Replenish engine oil if necessary.
– Connect battery.
Note
Perform wheel alignment after the installation of subframe ⇒
Running gear, axles, steering, front and four-wheel drive; Rep.
gr. 44 ; Wheel alignment .
– Connect Vehicle diagnosis, testing and information system -
VAS 5052- .
– Carry out vehicle system test ⇒ Vehicle diagnostic tester „Gui‐
ded fault finding“.
– Finish the vehicle system test so that any fault entries stored
during assembly can be deleted automatically.
Touareg 2003 ➤
1. Removing and installing engine
11
which may have occurred.
Specified torques
Threaded connection
Specified torque
Bolts, nuts
M6
10 Nm
M7
15 Nm
M8
25 Nm
M10
40 Nm
M12
60 Nm
Deviations
Engine bracket to engine
mounting (nut)
M10
75 Nm
Engine mounting to en‐
gine carrier (bolt)
M10
60 Nm
Engine carrier to body
(bolt)
M12
100 Nm +
1
/2 turn (180°).
Drive shafts to gearbox
⇒ Running gear, axles, steer‐
ing - front and four-wheel
drive shaft
Gearbox carrier to body
⇒ Differential and final drive;
Rep. gr. 34 ; Installing gear‐
box carrier and console .
Drive shafts to gearbox
⇒ Running gear, axles, steer‐
suspension
Touareg 2003 ➤
12
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