Volkswagen Touareg (2003 year). Manual - part 8

Assembly overview

1 - Cap

❑ Renew seal if damaged.

2 - Boot

❑ Renew if damaged.

3 - Oil filler neck

❑ Renew seal if damaged.

4 - Connecting hose

❑ For crankcase ventila‐

tion.

5 - Cylinder head cover

❑ Removing and installing

left cylinder head cover

⇒ page 32

 .

❑ Removing and installing

right cylinder head cov‐

er 

⇒ page 30

 .

❑ Renew if damaged.

6 - Gasket

❑ Note installation posi‐

tion.

❑ Renew if damaged or

leaking.

7 - 10 Nm

❑ Observe tightening se‐

quence.

❑ Removing and installing

left cylinder head cover

⇒ page 32

 .

❑ Removing and installing

right cylinder head cov‐

er 

⇒ page 30

 .

8 - Cylinder head cover gasket

❑ Ensure proper seating of lugs in cylinder head cover.
❑ Renew if damaged or leaking.
❑ Note installation position.
❑ Removing and installing left cylinder head cover 

⇒ page 32

 .

❑ Removing and installing right cylinder head cover 

⇒ page 30

 .

9 - Baffle plate
10 - 5 Nm
11 - Coolant pipe
12 - Gasket

❑ Renew.

13 - Sealing grommet

❑ Insert in cylinder head cover.
❑ Renew if damaged or leaking.

14 - Cylinder head bolt

❑ Renew.
❑ Follow installation instructions and sequence when loosening and tightening.

Touareg 2003 ➤

1. Cylinder head    

29

⇒ page 44

 .

❑ Removing and installing left cylinder head 

⇒ page 40

 .

15 - Cylinder head

❑ Check for distortion 

⇒ page 30

 .

❑ Removing and installing right cylinder head 

⇒ page 44

 .

❑ Removing and installing left cylinder head 

⇒ page 40

 .

❑ After renewing, renew entire coolant.

16 - Cylinder head gasket

❑ Metal gasket.
❑ Renew.
❑ Must seat on dowel pins.
❑ After renewing, renew entire coolant.

17 - 10 Nm
18 - Combination valve

❑ For secondary air system

19 - Coolant pipe
20 - O-ring

❑ Renew.

21 - 20 Nm
22 - Lifting eye
23 - Seal

❑ Renew if damaged or leaking.

Checking cylinder head for distortion

Special tools and workshop equipment required
♦ Straight edge
♦ Feeler gauges
Max. permissible distortion: 0.1 mm.

1.2

Removing and installing right cylinder

head cover

Special tools and workshop equipment required

Touareg 2003 ➤

30

♦ Not illustrated:
♦ Cable ties
♦ Sealant -D 454 300 A2-
Removing

Caution

When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐

tions:

♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐

vated charcoal filter system, coolant, refrigerant, brake

fluid and vacuum) and electrical wiring in their original po‐

sitions.

♦ To avoid damage to lines, ensure sufficient clearance to

all moving or hot components.

– All cable ties which are opened or cut open when engine is

removed must be replaced in the same position when engine

is installed.

– Remove intake hose between air filter and throttle valve con‐

trol module.

– Disconnect connectors -1- from ignition coils.
– Remove ignition coils -2- 

⇒ page 158

 .

– Detach line -3- for secondary air system from cylinder head

cover.

– Disconnect crankcase breather hose.

Touareg 2003 ➤

1. Cylinder head    

31

cylinder head cover.

Installing
Installation is carried out in the reverse order. When installing,

note the following:

Note

♦

Renew gasket if damaged or leaking.

♦

Before installing ensure that all seals between cylinder head

cover and cylinder head are installed correctly and not dam‐

aged.

– Lightly coat transitions -arrows- on sealing surface of cylinder

head with sealant -D 454 300 A2- .

– Carefully install cylinder head cover.

– Tighten securing bolts in the sequence -1- to -12-. Specified

torque: 10 Nm

1.3

Removing and installing left cylinder

head cover

Special tools and workshop equipment required

Touareg 2003 ➤

32