Volkswagen Touareg (2003 year). Manual - part 9

♦ 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.

– Remove bracket -3-.
– Disconnect connectors -4- from ignition coils.
– Remove ignition coils 

⇒ page 158

 .

– Disconnect crankcase breather hoses -1- and -2-.

Touareg 2003 ➤

1. Cylinder head    

33

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

1.4

Removing, installing and tensioning

toothed belt

Removing 

⇒ page 35

 .

Installing and tensioning 

⇒ page 38

Touareg 2003 ➤

34

equipment required
♦ Locking pin -3242-
♦ Two-arm puller -T40001-
♦ Camshaft clamp -T40005-
♦ Tensioner wrench -

T40009-

♦ Locking pin -T40011-
♦ Reversible ratchet -VAS

5122-

♦ Torque wrench -V.A.G

1410-

♦ Torque wrench -V.A.G

1331-

1.4.1

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.

gr.  50 ; Noise insulation

– Remove radiator fans with radiator fan support 

⇒ page 79

 .

– Bring lock carrier into service position ⇒  General body repairs,

exterior; Rep. gr.  50 ; Body - front; Lock carrier service posi‐

tion .

Touareg 2003 ➤

1. Cylinder head    

35

⇒ page 18

– Remove toothed belt guards on left and right.
– Mark direction of rotation of toothed belt using a coloured felt-

tip marker.

– Turn crankshaft to TDC. Mark on toothed belt guard -A- must

align with mark on V-belt pulley -B-.

– Check position of camshaft sprockets. The larger holes in se‐

curing plates -arrows- must be positioned to the inside and

must be aligned with the horizontal camshaft centre line.

Note

If the larger holes in the securing plates are positioned to the out‐

side of the camshaft sprockets, the crankshaft must be turned one

revolution further in direction of engine rotation.

– Remove sealing plug -arrow- from left side of cylinder block.

The TDC drilling in the crankshaft must be visible (or able to

be felt) in the sealing plug hole.

– Carefully screw locking pin -3242- into drilling to stop in order

prevent crankshaft from turning.

– Remove middle part of toothed belt guard.
– Remove vibration damper.

Note

The vibration damper is secured to the crankshaft with 8 securing

bolts.

Touareg 2003 ➤

36