[dapinitial]

Dope. Thanks @lachoradkov

Just came home from snowboarding and found these in the mailbox!! His turn around time was two or three days!

I’ll prob grease and just screw them in gently a little on each side at a time after I paint everything!

Sadly this project must wait until I get back from Holiday travels! It’s almost ready though!

 

[dapinitial]

Ready for paint! This is after media blasting. Best $80 I could have spent. $20 for the ultrasonic cleaning and then $60 for media blasting at local shops. Sure beats the hell outta cleaning with diesel or carb cleaner by hand! (However I did consider putting in the dishwasher)

I’ll carb clean it before i proceed then paint with bronze paint to match calipers! Couple more weeks and I’ll be able to complete!!!!

 

[bluedoggiant]

View attachment 268092


Ready for paint! This is after media blasting. Best $80 I could have spent. $20 for the ultrasonic cleaning and then $60 for media blasting at local shops. Sure beats the hell outta cleaning with diesel or carb cleaner by hand! (However I did consider putting in the dishwasher)

I’ll carb clean it before i proceed then paint with bronze paint to match calipers! Couple more weeks and I’ll be able to complete!!!! View attachment 268094
View attachment 268093

That looks incredibly clean, didn’t know media blasting is that effective.

Unfortunately I need to pull my brand new intake manifold off because the valley pan gasket is leaking BAD. I had a shop do the install last time but am going to tackle this one myself, any tips for pulling the manifold?

My tip for you in case it’s not already on your radar, do the valley pan gasket. Not thrilled about getting back in there.

 

[dapinitial]

That looks incredibly clean, didn’t know media blasting is that effective.

Unfortunately I need to pull my brand new intake manifold off because the valley pan gasket is leaking BAD. I had a shop do the install last time but am going to tackle this one myself, any tips for pulling the manifold?

My tip for you in case it’s not already on your radar, do the valley pan gasket. Not thrilled about getting back in there.

I'm glad you posted this. I am on vacation, and I am about to order all the stuff to finish the job, and install it when I return.

I did the valley pan gasket and check oil valves on my 2006 Audi S4 4.2L and was planning to do this with the Touareg, however, when I inquired with ECSTuning they said they don't have those parts and I am not seeing it on the schematics...

I meant to search on here, but I haven't had time. I am about to call VW in Seattle and see what's up and try to get those parts but I'll be doing those things in the next 2-3 weeks so I'll let you know what I learn if you haven't done it first!

Yeah, I didn't know that it would come out so good either. I've never gone this far to rehab anything, but it's been a fun project. I am stoked to revive the rageoutT. I didn't actually remove my intake manifold because I didn't want to lose use of the vehicle, so I just purchased a used one that also had frozen flaps and intake actuator (evidenced by the broken vacuum pod arm, and was utilized to negotiate a deal with the seller).

 

[lachoradkov]

I think the oil pan has sealant instead of gasket. Post the oem sealant part number if you find it, because I have to do the same…

 

[lachoradkov]

Page 73…

 

[dapinitial]

This sucks. Some are discontinued...

JHM Motorsports, FCPEuro, and ECS Tuning all have a valley pan gasket and check oil valves kit for under $200 for a 2006 Audi S4 B7 4.2l V8 (similar to the Touareg, but not the same, maybe the RS4 with FSI is more similar)... from the dealership, all the parts take 2days to 2months (backordered from Germany) to arrive if they can get them and they are to the tune of $1100 (without the valley pan gasket) but I don't know if they will work across the platforms even though the AudiS4 is a 4.2l v8...

After calling VW, here are the parts that are potentially needed:

• Engine Oil Filter Adapter Gasket
  Part Number: 077198405
  Supersession(s): 077-198-405; 77198405

• Engine Oil Cooler Gasket
  Part Number: 077198070A
  Supersession(s): 077-198-070-A; 77198070A
  
  
• Valve.
  Part Number: 059103175F
  Supersession(s): 059-103-175-F; 059103175A; 59103175F

• Jet.
  Part Number: 077103158K NEW VW TOUAREG 7L ENGINE OIL SQUITER
  Supersession(s): 077-103-158-K; 077103158H; 77103158K

Discontinued Product
No Longer Available For Purchase

Valley Pan Gasket
Part Number: 077103197C
Supersession(s): 077-103-197-C; 77103197C
Plate. Valley Pan Gasket.
Material that seals the Valley Pan to the engine block.


Looks like this is the whole plate and not the gasket alone. Can anyone confirm?

 

[New2Tregs]

This sucks. Some are discontinued...

Discontinued Product
No Longer Available For Purchase

Valley Pan Gasket
Part Number: 077103197C
Supersession(s): 077-103-197-C; 77103197C
Plate. Valley Pan Gasket.
Material that seals the Valley Pan to the engine block.


Looks like this is the whole plate and not the gasket alone. Can anyone confirm?

I checked on Ebay and it does look like the gasket comes with the plate, not the gasket alone.
Some sellers overseas say they each have one on hand.
I guess if you don't want to buy the whole thing you could try making a gasket from a good quality RTV gasket maker product.

Link >>>> 077103197C for sale | eBay

 

[dapinitial]

I'm probably going to push this project out a month or so until I can gather all the parts that I might need... and then I'll test and integrity check everything that I can along the way... I don't have any leaks, etc, it's just something that I want to do while I'm in there but "if it ain't broke; don't fix" principles apply

 

[lachoradkov]

So the manual says to use sealant and but there is a gasket part number as well? It’s strange why they aren’t showing the gasket in the manual diagrams…

The gasket is in stock in autohausaz Link but it might be false information…and it’s pretty expensive for a gasket…

Thanks for sharing all the part numbers. I have to order all of them too…

 

[dapinitial]

As much as this sucks to say… I might be considering fixing it and then in a year or two getting a 2016 TDI Luxe and doing some mild upgrades. Lift, subframe drop, Apple car play, w7 sub and amp, second battery, cooler, solar panel, tires And winch front and new control arm bushings… gonna miss the 2006 but if parts are being discontinued idk if I’m ready to continue maintaining…

 

[bluedoggiant]

Page 73…

This looks like the engine oil pan. I actually cant find any information on the valley pan in that document. Let me know if you find anything. I need the torque specs for the gasket pan and the oil valves. Unfortunately the detail on the removing the manifold is limited except for a few torque specs. I am curious if Bentley or some other resource has better instructions for the intake manifold removal. Just dont want to break any brittle vacuum lines.

This sucks. Some are discontinued...

JHM Motorsports, FCPEuro, and ECS Tuning all have a valley pan gasket and check oil valves kit for under $200 for a 2006 Audi S4 B7 4.2l V8 (similar to the Touareg, but not the same, maybe the RS4 with FSI is more similar)... from the dealership, all the parts take 2days to 2months (backordered from Germany) to arrive if they can get them and they are to the tune of $1100 (without the valley pan gasket) but I don't know if they will work across the platforms even though the AudiS4 is a 4.2l v8...

After calling VW, here are the parts that are potentially needed:

• Engine Oil Filter Adapter Gasket
  Part Number: 077198405
  Supersession(s): 077-198-405; 77198405

• Engine Oil Cooler Gasket
  Part Number: 077198070A
  Supersession(s): 077-198-070-A; 77198070A
  
  
• Valve.
  Part Number: 059103175F
  Supersession(s): 059-103-175-F; 059103175A; 59103175F

• Jet.
  Part Number: 077103158K NEW VW TOUAREG 7L ENGINE OIL SQUITER
  Supersession(s): 077-103-158-K; 077103158H; 77103158K

Discontinued Product
No Longer Available For Purchase

Valley Pan Gasket
Part Number: 077103197C
Supersession(s): 077-103-197-C; 77103197C
Plate. Valley Pan Gasket.
Material that seals the Valley Pan to the engine block.


Looks like this is the whole plate and not the gasket alone. Can anyone confirm?

The engine oil cooler gasket is in an entirely different location, behind the alternator. As for the oil squirter jet, I’ve never seen that part before, do you know where it goes?

So the 197C part is unavailable domestically but I’m checking with my euro source. Even though ETKA does not show interchangeability, I suspect 197D will be a fit. ETKA is often not comprehensive in their interchangeability and I’ve had a lot of success outsmarting the system in the past. I can’t imagine the part is any different than the 40v belt 4.2 in the D2 A8 and C5 A6. Either way the part will be far more cost effective, potentially sub $100, from the European vendors.

The 40v 4.2 is in my opinion definitely the most difficult to keep on the road today. Mostly due to a lack of availability of the Touareg specific coolant and vacuum lines. I’ve amassed a small collection of those NLA parts at home to keep the truck on the road. With a little bit of tenacity I am confident we can enjoy these engines for another 10 years so long as they are in good shape.

This thread should be another good resource: https://www.clubtouareg.com/threads...ds/diy-t1-v8-intake-manifold-removal.214753/page-2?post_id=2227478#post-2227478

 

[dapinitial]

It’s gonna take a village… I’m in — at least for another one or two when I complete this. Let’s go!

 

[bluedoggiant]

Wanted to drop this here in case any of you need it but will make a separate thread about it at some point. Below are the parts I plan to order to do the valley pan gasket and oil check valves. It's a conservative list (meaning a lot of this may not be necessary if you want to be cheap) but if you wish to be even more conservative, there are probably a couple spring clips I didn't include that could use replacing. Some will say to also replace the oil squirter but I'm not sure of the point of doing this, I believe it's an all metal pipe unless someone can correct me.

• 8x ELR-893889
• 1x ELR-530982
• 14x N10695301
• 1x 077103197D (C revision is correct, but D should work)
• 2x 059103175F - 20nm torque spec
• 5x N10418001
• 1x N90851401
• 1x N10201901 - not necessary
• 6x N10117405

The Touareg manual does not specify the torque spec on the oil check valve, but the b5 s4 with the 2.7 uses the same part number and that manual indicates a 25nm spec.

While I have not done the repair yet, I strong urge anyone pulling their intake manifold to replace this part for cheap insurance as it could cause the chain tensioners to not operate at their best. I spent a lot of time on AudiZine and Audiworld last few days and this valve fixed chain rattle issues many had that is often diagnosed as failing chain tensioner.

 

[dapinitial]

Circling back. I’ve been relocated to tejas and I’m waiting for my life to appear end of next month from relocation services. Looking like end of February / March to begin again

 

[bluedoggiant]

Circling back. I’ve been relocated to tejas and I’m waiting for my life to appear end of next month from relocation services. Looking like end of February / March to begin again

Love TEJAS. Enjoy your time out there.

 

[bluedoggiant]

I just did this repair. I found install/removal of the intake manifold to be easy, just take your time. It's self explanatory what needs to be removed once you start tearing into it. The Bosch electrical connectors from this era are very annoying to work with, and probably what I spent the most time dealing with especially on install. I was luckily able to lift the fuel rail out using finger strength with all pintle caps intact. Be sure to clean the area around the intake manifold with compressed air to prevent debris falling on your intake valves upon removal.

I updated my parts list above with everything I needed/used. Interestingly, I did not have the O-ring on my vehicle where the PCV hose drains into the valley pan through the metal pipe, maybe it disintegrated at some point.

 

[dapinitial]

I just did this repair. I found install/removal of the intake manifold to be easy, just take your time. It's self explanatory what needs to be removed once you start tearing into it. The Bosch electrical connectors from this era are very annoying to work with, and probably what I spent the most time dealing with especially on install. I was luckily able to lift the fuel rail out using finger strength with all pintle caps intact. Be sure to clean the area around the intake manifold with compressed air to prevent debris falling on your intake valves upon removal.

I updated my parts list above with everything I needed/used. Interestingly, I did not have the O-ring on my vehicle where the PCV hose drains into the valley pan through the metal pipe, maybe it disintegrated at some point.

Did you do the valley pan gasket? I just settled down and into my new life after moving out of state and I plan to do this Labor Day weekend. One thing is I noticed the plastic washer at the end of the inside flapper roller plastic swirl flap thing is showing signs of wear and I suspect it will break — looking for a replacement but no luck… I may try to epoxy something like a washer to it if I can’t find one… but stoked to get mine back to super!!! Getting tons of compliments in Texas saying it’s the cleanest 2006 on the road! Soon it’ll be mechanically the soundest as well!!!

 

[dapinitial]

Wanted to drop this here in case any of you need it but will make a separate thread about it at some point. Below are the parts I plan to order to do the valley pan gasket and oil check valves. It's a conservative list (meaning a lot of this may not be necessary if you want to be cheap) but if you wish to be even more conservative, there are probably a couple spring clips I didn't include that could use replacing. Some will say to also replace the oil squirter but I'm not sure of the point of doing this, I believe it's an all metal pipe unless someone can correct me.

• 8x ELR-893889
• 1x ELR-530982
• 14x N10695301
• 1x 077103197D (C revision is correct, but D should work)
• 2x 059103175F - 20nm torque spec
• 5x N10418001
• 1x N90851401
• 1x N10201901 - not necessary
• 6x N10117405

The Touareg manual does not specify the torque spec on the oil check valve, but the b5 s4 with the 2.7 uses the same part number and that manual indicates a 25nm spec.

While I have not done the repair yet, I strong urge anyone pulling their intake manifold to replace this part for cheap insurance as it could cause the chain tensioners to not operate at their best. I spent a lot of time on AudiZine and Audiworld last few days and this valve fixed chain rattle issues many had that is often diagnosed as failing chain tensioner.

As a B7 S4 owner (twice) I can certify that I’ve never had a bad timing chain with over 400K miles collectively between both B7s — however the check oil valves and valley pan gasket replacement stopped mystery oil leak and a weird sound at cold start — hope I can get to this in the Touareg because I really haven’t found the part — did you do this??

 

[dapinitial]

I just did this repair. I found install/removal of the intake manifold to be easy, just take your time. It's self explanatory what needs to be removed once you start tearing into it. The Bosch electrical connectors from this era are very annoying to work with, and probably what I spent the most time dealing with especially on install. I was luckily able to lift the fuel rail out using finger strength with all pintle caps intact. Be sure to clean the area around the intake manifold with compressed air to prevent debris falling on your intake valves upon removal.

I updated my parts list above with everything I needed/used. Interestingly, I did not have the O-ring on my vehicle where the PCV hose drains into the valley pan through the metal pipe, maybe it disintegrated at some point.

Thanks for the write up and parts list. Doing this next weekend. Did you do valley pan gasket and if so where did you source it???