R5 head gasket replacement procedures - Club Touareg Forums
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post #1 of 12 Old 10-03-2017 Thread Starter
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R5 head gasket replacement procedures

Hi, I have a UK 2006 2.5 Tdi Touareg which needs a new head gasket fitted. I've been searching high and low for a bloody manual but to no avail. I thought haynes would have had one by now. All I want is the full procedure with diagrams on how to replace the head gasket and associated seals as well as torque settings etc. I've downloaded one file and it was from an American site but didn't include the 2.5 Tdi engine, only started at 3.2litre.

Any help would be greatly appreciated.

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post #2 of 12 Old 10-03-2017 Thread Starter
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Could I use the R5 manual from the Transporter or is the layout different?
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post #3 of 12 Old 10-03-2017
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I believe they are essentially the same engine. Send 4ePikanini a PM as he has rebuilt his not so long ago.

2008 V6 TDI, with the following Retrofitted Items:
ACC, Front & Side Assist, Paddle Shift, Towbar & Trailer Module, Fiscon Bluetooth. Reversing Camera, Front Fog Lamps, Redarc TowPro Brake Controller, T1 Door Warning Lamps, T1 Under Seat Drawer, Alloy Skid Plate, 5ton Winch, Cayenne Front and Rear Sway Bars, Tuned by Oettinger, Retrofitted 6 Piston Brembo Front Brake Callipers, Sports Steering Wheel, TPMS (OEM), Dual Batteries
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post #4 of 12 Old 10-04-2017 Thread Starter
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Thanks, I've sent him a quick PM. Hoping there some documentation of use somewhere. Touaregs seem to be left behind on the manual front. If it's the same as the Transporter, haynes have a manual so here's hoping.
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post #5 of 12 Old 10-04-2017
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Lock the crank at TDC with the special tools

Take the head off
Have the head checked for straightness as well as the block
Clean thoroughly
headgasket on dry
head back on
set the timing as per factory manual

oh, the bad news.....

It's an engine out job as you need to set backlash on the cam gear and it can only be done with engine out.

PS : why did the headgasket fail in the first place. It's not a common failure.

Not at the pc with my manuals but the transporter is the same procedure.

All vw/audi engines must use 507.00 spec oil except non-DPF R5/V10 engines that must use 505.01/506.01
93 Pajero GLS 3.0 V6 LWB - SOLD
2001 Gen3 Di-D LWB - SOLD
2005 Touareg 2.5 TDi Air & Bi-Xenon
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post #6 of 12 Old 10-04-2017
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The newer (post 2000) vehicles are quite complex I think Haynes have almost given up on them for "real" mechanical work.
Its easy enough to get hold of ELSA online, and you can run it on a virtual machine on any modern PC (look up virtual box).

If you're stuck on something in particular I can probably get some screenshots from ELSA for you but that will be a pretty inefficient way to relay the information for whole procedures.
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post #7 of 12 Old 10-04-2017 Thread Starter
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The coolant level dropped and after refilling the whole lot, it went within an hour, no leaks anywhere and later when I checked the oil levels etc the dip stick was well beyond full, mayonnaise type substance on the top of the engine, and you could smell coolant being burned off through the exhaust. So the fact the coolant was leaking to that extent that extent into the engine I thought head gasket. Garage has pressure tested system and they have also suggested head gasket. I now have a manual on the Transporter R5 engine which gives loads of information etc. However Im not commencing any work until next week. So if anyone has any ideas to look at before I begin stripping the engine let me know. Also, garage and the R5 manual mention you don't need to lift entire engine out to complete the head gasket replacement. However, I have noticed this morning that there is a loud winning noise when foot is on the accelerator and when I lift off it disappears. So any ideas on that too?
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post #8 of 12 Old 10-05-2017
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You can buy all the original VW service manuals for Touaregs - including for the 2.5 R5 TDI - at https://erwin.volkswagen.de . Buy the shortest access time window available to you (depends on the country you're in), and download all the PDFs.

The file which describes the cylinder head (dis)assembly and the tandem pump removal/installation is named "K0058961720-5-cylinder_diesel_engine.pdf". But as said, just download all the repair manuals and any other files you can grab in the allowed time frame (1 hour should be more than enough), and have a look at them later, whenever you need repair instructions.
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post #9 of 12 Old 03-24-2018
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thread about ya head gasket, Did you end up doing it and all ok??
did you need to remove engine?
i only ask as mines been removed already and now the workshop is asking for the special tool, im in Thailand so it will take another 2 weeks for me to get a tool sorted here, if you havent removed the engine im presuming you managed to do the job without the tool and this is the info i was hoping for?

any help greatly appreciated.
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post #10 of 12 Old 01-12-2019
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I know I'm a village to this thread. Its not your head gasket. It will be your Water pump that's failed, mixing oil and water by poor design when failed.

This will also be the sou d you hear when accelerating. The bearing in the pump has failed causing the gear to be off centre.
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