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Discussion starter · #41 ·
Got to put in a little time this afternoon.


Drained all the fluids as well. Probably half quart of water came out of the oil drain before sludgey oil drained out.
 
Discussion starter · #44 ·
I agree I'd be upset also. Mines currently got its cams out front end off etc to take rocker shafts out. That's annoying enough

Worn rocker shafts? That's more of a bummer in my opinion since it could be indicative of lubrication problems.

I've had a lot of VWs (12) from '84-'10, so I'm not unfamiliar with doing work. This is my first Touareg though, so I'm taking it a lot slower. Plus taking care of the house, toddler, etc... takes time away.

Helps that the Touareg isn't our daily driver. I will say that the Touareg uses a lot more Torx head screws than other VWs, which is annoying, but they definitely resist stripping better than Allen head screws.
 
Lifters jammed. Thought I'd dropped a valve to start with. Shafts being replaced along with rockers and lifters just to make sure. Recently put in a new manifold as both sets of flaps were seized beyond getting out. 5k for a complete one. Was looking good before the lifter went hahaha

 
Discussion starter · #47 ·
TLDR: Engine is out. Pictures throughout...




My father is in town for a few weeks and has been anxious to help me work on my Touareg. He has more of a woodworking background but loves to tinker and work, plus he's one of my best friends as well. So today we really tore into it.

First up was setting up the work area. It's hot and humid in north Florida, so shade helps a lot.




We rolled slowly but steadily through wiring disconnections, hose disconnections, and exhaust disconnections. Then came time to remove the starter in order to access the torque converter bolts. Here it is, half behind the motor mount bracket in the passenger side...




Damnit. So much for leaving the front cradles in place. Down goes the suspension cradle to make room.




Once that was lowered we squeezed the engine cradle with mounts attached out and removed the starter bolts. One is below the starter and very obvious. The other comes from the transmission side and is terrible to access. There aren't any pictures of the during, but here's a shot of where the bolt goes. This is from the top of the trans on the passenger side. That raised portion is for the starter bolt.

{this picture is taken after the engine was removed}


Took about 2' of extension, with the wrench wedged between the trans and tunnel to access the bolt successfully. But, here is the starter out without removing the engine completely, and without removing the exhaust manifold as others have done.





After that rolling the engine out was cake. Remove the TC bolts and engine/trans bolts and pull it straight out.

Side by side with the replacement.




So this weekend I'll probably work to get the replacement in then start replacing consumables (timing belt, water pump/thermostat), rollers, etc...). Then it's just a matter of getting everything back in.

And still a little evidence of my shame in the throttle body pipe.



And if anyone is wondering, here are the breathers for the trans and transfer case. Black tubes with breather ends on them in the middle of the picture.

 
Discussion starter · #48 ·
Also, if anyone wants pictures of anything in there while the engine is out let me know ASAP! I'll snap what I can for you. There's a lot that can't be seen unless the engine is out of the way.
 
Crazy, man. Looks like quite a tedious job. Glad to see you're rolling through it pretty smoothly. Keep up the good work.
 
Discussion starter · #52 ·
Just maintenance on the replacement engine. It has just a few thousand miles less than my truck so it's due for timing belt job and all that's included in that. Plus new plugs/coils and making sure all the wiring, sensors , and hoses look to be in good shape.

I was at roughly Xtra height, and I'm running 32" tires. The water came halfway up the hood with the nose down a few degrees, so I'd say the hole was about 3.5-4' deep in that spot I hit.

New timing belt will be here tomorrow just in case the old one stretched due to the lock-up. Upgrading to a Gates Racing Blue belt. Plan to try getting the engine in and start putting things back together while waiting for Fedex.
 
Discussion starter · #53 ·
Got up early Saturday and started working.



Timing belt would arrive by later in the day, so in the mean time we verified the TC was completely in the transmission to prevent smashing the pump and mated the two together.



Everything went fairly smooth going back in, just time consuming because there is so much.

Timing belt showed up mid day during lunch so the timing covers went on shortly after installing the pretty Racing Blue Gates belt.



Started buttoning up the front so I could add fluids to test for leaks.



Added coolant first, which promptly poured out of the alternator. I tackled that a different day. Worked until 2130, I was beat.
 
Discussion starter · #54 ·
Sunday is church day, and with family in town that meant lunch afterwards. Too much food intake means burning it off figuring out this coolant leak.

Fortunately, some folks around here figured out that removing the airbox on the passenger side will gain you access to the back side of the alternator.







If you can tell in the above pic, the coolant line got bent when installing the alternator on the replacement engine. Took 1 try to get that front pipe correct, but about 11 tries to get the inner pipe correct. I hate this water cooled alternator.

After filling with water (why waste coolant if it leaks) on the 11th time and it didn't leak. I added oil and power steering fluid as well, then turned it over a few times with the fuel fuses removed to get some oil moving. Installed the fuses for the third try and she fired pretty quickly, revealing Some nasty exhaust leakage.

I'm beat so that'll be another day. But it is ALIVE!
 
Well done. I admire your patience!
 
Discussion starter · #58 ·
Maybe in the future, for now I'll just stay out of the water. ;)

Been thinking about this exhaust leak. I'm hoping I just got in a hurry and didn't tighten something down completely. Barring that, I'm curious about these 3-bolt comics flanges. Do they need to be torqued in sequence to ensure even pressure? Do these v8 manifolds leak often (I hope not!)?

If it's not a loose or poorly fitted flange then my next hope is its just the flex pipe that gave way in all the movement of replacing the engine.
 
Discussion starter · #59 ·
The exhaust leak ate at my psyche all day, so I hit the garage after getting the wife and boy settled this evening and started getting into it.

First check was the flange nuts. Turns out I was in a hurry, because I found the top nut on the passenger side loose, so I fixed that. Everything else was in order so the intake piping went back on and fired it up. No. More. Leaks!

Let it run and build heat while I put the bumper cover and tires back on, put it on the ground and check fluids then gave it a once around the block. Everything was good.

Verified the air suspension was good, put it in load mode and took the family for a ride.



So far so good. Plan to put lots of miles on over the next few months as the engine seller gave a 6 month warranty.
 
Well done Joshua, as good as new. Glad it all went together, from afar it seemed pretty easy but I am sure it was really a big job even for somebody obviously capable. do you know how many hours you spent changing the engine?
 
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