Volkswagen Touareg (2003 year). Manual - part 10

aside slightly.

– First unscrew bolt -1- from oil filter housing. Then unscrew

bolts -2- from cover for toothed belt tensioning element.

– Remove cover.

Note

♦

The toothed belt tensioning element is provided with oil damp‐

ing. It can therefore only be pushed back slowly.

♦

Use locking pin -T40011- for securing the tensioning element.

– If necessary, before tensioning align holes in housing and in

piston of tensioning element using long nose pliers or thin wire.

– Turn tensioning lever of toothed belt tensioning roller -1- in

-direction of arrow- using hexagon key.

– Secure tensioning element with locking pin -T40011- when the

tensioning lever of the toothed belt tensioning element -2- has

been pushed back so that the holes in the housing and the

pistons align.

– Insert camshaft clamp -T40005- into camshaft securing plates

and loosen securing bolts by approx. 5 turns.

– Remove camshaft clamp -T40005- again.

Touareg 2003 ➤

1. Cylinder head    

37

arm puller -T40001- and hook -T40001/2- .

– Loosen tensioning roller -arrow- and remove toothed belt.

1.4.2

Installing and tensioning

– Note marking for direction of rotation when reinstalling the ex‐

isting toothed belt.

– First, fit toothed belt to crankshaft toothed belt pulley -1-, then

to idler roller of toothed belt tensioner -2- and then to tension‐

ing roller -3-. After that, fit toothed belt to camshaft sprockets

and coolant pump pulley as shown in the illustration.

Note

It should just be possible to turn the camshaft sprockets on the

camshaft tapers.

– Fit camshaft clamp -T40005- onto camshaft pulleys again.

Touareg 2003 ➤

38

tensioning element piston -arrow-.

– Now pre-tension tensioning roller (still in loosened condition)

using torque wrench -V.A.G 1410- with attached reversible

ratchet -VAS 5122- and tensioner wrench -T40009- in anti-

clockwise direction -arrow- to 4 Nm.

– Tighten bolt -1- to 45 Nm in this position.
– Then remove 5 mm drill.
– Turn tensioning lever of toothed belt tensioning roller -1- in

-direction of arrow- using hexagon key.

– When piston of toothed belt tensioning element -2- has been

pushed back by tensioning lever, pull out locking pin -

T40011- .

– Turn tensioning lever of toothed belt tensioning roller -1- in

direction of -arrow-, using hexagon key and place a 7 mm drill

between housing and tensioning lever.

– Tighten camshaft sprockets to 55 Nm.
– Remove camshaft clamp -T40005- again.
– Pull out drill inserted between housing and tensioning lever.

Touareg 2003 ➤

1. Cylinder head    

39

-arrow- and tighten to 30 Nm.

– Turn crankshaft two full turns in direction of engine rotation

and check setting dimension -a-: specification 5 mm.

Further assembly is basically the reverse of the dismantling se‐

quence.

1.5

Removing and installing left cylinder

head

Removing 

⇒ page 41

 .

Installing 

⇒ page 43

 .

Touareg 2003 ➤

40