Removing and installing lower part of sump: VW Touareg I (BAN, BAP, BAR, BGH, …)

🧭 Before you start

Remove the belt and tensioner, left coolant pipe and air filter housing, then set up the support bracket and lifting tackle and take the weight of the engine evenly. Pin the subframe, lower it on the jack and place the engine carrier on it. Drain the oil, remove G266, unbolt the lower sump, turn it through 180° and remove it forwards. Clean both faces, apply a sealant bead with the nozzle cut at about 1.5 mm, fit the sump and tighten the bolts to 5 Nm and then to final torque in diagonal sequence. Refit G266, the subframe and ancillaries, then fill with oil.

Fits: VW Touareg I (7L, 2002–2010)

• Opens: engine oil
• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: T40091/3, T40091/2, T40093/5, T40093/4
• Renewed: seals

Don't miss

• Secure all support hooks and retaining pins on the lifting tackle with locking pins before lifting.
• Fix the subframe position with locating pins; if that fails, check wheel alignment afterwards.
• Cut the nozzle at about 1.5 mm; an oversized bead pushes sealant into the sump.
• The bead must seal against the tapered web on the upper part of the sump.
• Initial 5 Nm, then final torque, both in diagonal sequence.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Remove poly V-belt .
2. Remove tensioning element for poly V-belt .
3. Remove left coolant pipe .
4. Remove air filter housing.
5. Remove nuts (arrows) for left and right engine mountings.

6. Remove front left wheel housing liner 66.
7. Remove nuts and bolts (arrows) of refrigerant line retaining clips. [Note: To position the adapters10 - 222 A /19 onto longitudinal members, the refrigerant lines can slightly be moved to side with loose threaded connections.]
8. Set support bracket10 - 222 A with connections T40091/3 and 2 spindles on wing panel flanges. Contrary to what is shown in the picture, the spindle must be pointing to the rear.
9. Fit the spindle to the rear of the engine lifting eye.
10. Assemble further parts of support bracket10 - 222 A as shown in the illustration. To do this fit adapters10 - 222 A /19 on the plate fold of the longitudinal member.
11. Move support T40091/2 with slide T40093/5 in both connections T40093/4.
12. ⚠ Secure support T40091/2 with pins and split pins of connections T40093/4. — Screw retainer T10014 into mounting hole for poly V-belt tensioning element.
13. Remove eye of lifting tackle2024 A.
14. Reinsert pin (1) in centre hole of lifting tackle and secure with split pin.
15. Attach the pin of lifting tackle to front spindle of support bracket.
16. Fit extension 2024 A/1 on the left side of lifting tackle.
17. Attach lifting tackle2024 A to front right lifting eye and to retainer T10014.
18. ⚠ The support hooks and retaining pins on the lifting tackle must be secured with locking pins (arrows). — Lift engine until the engine supports are above the studs of the engine mounting, tighten all spindles evenly to ensure the weight is distributed evenly.
19. Fit engine and gearbox jackV.A.G 1383 A to subframe underneath.
20. Fix position of subframe using locating pins T10300Running gear, axles, steering40
21. Unscrew bolts (4) and carefully lower subframe using engine and gearbox jackV.A.G 1383 A.
22. Remove bolts (3) for engine carrier and place engine carrier on subframe. [Note: Disregard (item 1) and (item 2).]
23. Disconnect electrical connector at oil level and oil temperature sender G266(item 1).
24. Place used oil collection and extraction unitV.A.G 1782 under engine.
25. Drain engine oil.
26. Remove oil level and oil temperature sender G266.
27. Unbolt lower part of sump (arrow).
28. Turn lower part of sump through 180° and remove it forwards. [Note: When removing lower part of sump, note that it still contains a residual amount of oil.] [Note: Renew seals.]
29. ⚠ Wear eye protection. — Remove sealant residues from upper and lower parts of sump, e.g. with a rotating plastic brush.
30. Clean sealing surfaces; they must be free of oil and grease.
31. Cut off tube nozzle at forward marking (∅ of nozzle approx. 1.5 mm).
32. Apply bead of sealant (arrow) onto clean sealing surface of lower part of sump as illustrated. [Note: Ensure that the sealant bead on the lower part of the sump is applied so that it properly seals against the tapered web on the upper part of the sump.] [Note: The sealant bead must not be thicker than specified, or excess sealant could enter the sump and block the strainer in the oil pump.The lower part of sump must be installed within 5 minutes after applying sealant.]
33. Fit lower part of sump and tighten all bolts initially to 5 Nm in diagonal sequence. — 5 Nm (3.7 lb-ft)
34. Tighten bolts on lower part of sump in diagonal sequence.
35. Install oil level and oil temperature sender G266.
36. Install subframe 40. [Note: If the position of the subframe on the body could not be fixed, check wheel alignment on the vehicle after reinstalling.]
37. Install air filter housing.
38. Install left coolant pipe .
39. Install poly V-belt tensioner .
40. Install poly V-belt .
41. Fill with engine oil and check oil level .

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