Volkswagen Touareg (2003 year). Manual - part 4

1

Dismantling and assembling engine

Assembly overview
Part I: toothed belt drive 

⇒ page 15

Part II: cylinder block 

⇒ page 17

Touareg 2003 ➤

1. Dismantling and assembling engine    

13

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.

Touareg 2003 ➤

14

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-

and claw -T40001/2- .

❑ Removing and installing

⇒ page 34

 Removing,

installing and tensioning

toothed belt.

12 - 10 Nm

❑ Insert with locking fluid -

D 000 600 A2- .

13 - Toothed belt guard, rear right
14 - Idler roller
15 - Pin, 6 Nm
16 - 15 Nm
17 - Coolant pump

❑ Removing and installing 

⇒ page 89

18 - Gasket

❑ Renew.

19 - Toothed belt guard, rear left
20 - 10 Nm

❑ Insert with locking fluid -D 000 600 A2- .

21 - 10 Nm
22 - Left camshaft pulley

❑ Pull off camshaft with two arm puller -T40001- and claw -T40001/2- .

Touareg 2003 ➤

1. Dismantling and assembling engine    

15

⇒ 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

❑ For tensioning lever

31 - Tensioning element

Touareg 2003 ➤

16