Removing and installing starter, 4.9 litre 10-cylinder TDI engine, automatic gearbox — VW

🧭 Before you start

Fits: VW Touareg I (7L, 2002–2010)

• Special tools named: T10126, T10126/1

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• Pin of transportation shackle must engage in hole of bracket on engine side when bolting on. — Fit transportation shackle T10126/1(1) to front of left cylinder head using M8x40 bolt (2).
• Pin of transportation shackle must engage in hole of bracket on engine side when bolting on. — Attach lifting tackle3033 to workshop hoistVAS 6100.

📋 Procedure

1. Remove engine 10-cylinder diesel engine10Removing and installing engine.
2. Remove right turbocharger 10-cylinder diesel engine21Charge air system with turbocharger; Removing and installing turbocharger.
3. Open press studs (arrows) and remove heat shield mat for solenoid switch.
4. Remove securing nut from engine bracket (arrow).
5. Bolt transportation shackle T10126(1) to rear of right cylinder head using M8x40 bolt (2).

6. ⚠ Pin of transportation shackle must engage in hole of bracket on engine side when bolting on. — Fit transportation shackle T10126/1(1) to front of left cylinder head using M8x40 bolt (2).
7. ⚠ Pin of transportation shackle must engage in hole of bracket on engine side when bolting on. — Attach lifting tackle3033 to workshop hoistVAS 6100.
8. Attach transportation shackles T10126 and T10126/1 to lifting tackle3033.
9. Raise engine using workshop hoistVAS 6100.
10. Remove the 4 securing bolts M10x95 (arrows) for right engine support and remove engine support.
11. Remove securing bolt for coolant pipes (arrow) on cylinder block.
12. Remove securing bolt for coolant pipes (arrow) on gearbox.
13. Pull protective cap (arrow) from starter solenoid switch.
14. Remove securing nut of positive wire (arrow) from starter solenoid switch.
15. Remove securing nut of terminal 50 wire (arrow) from starter solenoid switch.
16. ⚠ The threaded connections on the solenoid switch could become twisted.The solenoid switch may be damaged.When tightening or loosening connections for positive cable and terminal 50 cable, counterhold threaded connection on solenoid switch using open jaw spanner. — Remove securing bolt (arrow) for wire retainer and lay wires to side.
17. Remove lower securing bolt M12x165 for starter (arrow) on engine side.
18. Remove upper securing bolt M12x165 for starter (arrow) on gearbox side.
19. Remove starter.
20. Tighten threaded connections to specified torque .

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