Volkswagen Touareg 2004-06

Exhaust Manifold

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Removal & Installation



3.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the intake manifold.
  4.  
  5. Unbolt the heat shield with the intake manifold support from the cylinder head.
  6.  
  7. Unplug the oxygen sensor connectors. Unclip the wires from the harness guides.

    Click image to see an enlarged view

    Fig. Unplug the oxygen sensor connectors-3.2L engines

  8.  
  9. Remove the oxygen sensors from the catalytic converters.
  10.  
  11. Raise the vehicle.
  12.  
  13. Remove the securing nuts from the main catalytic converter flange.
  14.  
  15. Unbolt the support to the transmission.
  16.  
  17. Unbolt the flange to the exhaust manifold. Remove the exhaust manifold.
  18.  

To install:


NOTE
When installing the exhaust pipes, ensure that the flange connection after the catalytic converter seals tightly. Leaks in this area allow ambient air to reach the oxygen sensors after the catalytic converter, resulting in false readings.

  1. Installation is the reverse of removal. Observe the following:

    Adjust the exhaust system so that there is sufficient clearance to the transmission and subframe.
     
    Use new exhaust manifold gaskets
     
    M8 securing nuts: 18 ft. lbs. (25 Nm)
     
    M10 securing nuts: 30 ft. lbs. (40 Nm)
     
    Heat shield center bolt: 15 ft. lbs. (20 Nm)
     
    Other heat shield bolts: 17 ft. lbs. (23 Nm)
     

  2.  

4.2L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine from the vehicle.
  4.  
  5. To remove the exhaust manifold from the left cylinder bank, unfasten the bracket for the oil dipstick guide tube and disconnect the refrigerant line. Close off the connections with a clean rag.

    Click image to see an enlarged view

    Fig. On the left exhaust manifold, remove the dipstick tube bolt (1) and refrigerant line bolt (2)-4.2L engines



    Click image to see an enlarged view

    Fig. Remove the nuts securing the exhaust manifold-4.2L engines

  6.  
  7. Remove the nuts from the exhaust flange and exhaust manifold. Remove the manifold.
  8.  
  9. Installation is the reverse of removal. Observe the following:

    Use new exhaust manifold gaskets
     
    Exhaust manifold securing nuts: 18 ft. lbs. (25 Nm)
     
    M8 exhaust flange securing nuts: 18 ft. lbs. (25 Nm)
     
    M10 exhaust flange securing nuts: 30 ft. lbs. (40 Nm)
     

  10.  

 
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