Volkswagen Touareg (2003 year). Manual - part 11

equipment required
♦ Drip tray -V.A.G 1306-
♦ Torque wrench (5…50 Nm)

-V.A.G 1331-

♦ Torque wrench (40…200

Nm) -V.A.G 1332-

♦ Spring-type clip pliers -VAS

5024A-

Not illustrated:

♦ Cable ties
Prerequisite
• The engine must be no more than warm to touch.

1.5.1

Removing

– Remove engine 

⇒ page 2

 .

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.

Touareg 2003 ➤

1. Cylinder head    

41

removed must be replaced in the same position when engine

is installed.

– Remove front exhaust pipe from exhaust manifold

⇒ page 148

 .

– Unbolt guide tube for oil dipstick -arrow- from cylinder head.

– Disconnect connectors -2- and -3-.
– Remove toothed belt 

⇒ page 34

 .

– Remove camshaft pulley 

⇒ page 34

 , Removing, installing and

tensioning toothed belt.

– Loosen securing bolts -1- and -2- and remove rear toothed belt

guard.

– Disconnect vacuum hose -1- from combination valve.
– Remove bolts -2-.
– Disconnect connector -3-.
– Unscrew bolts -4- and remove oil pipe.
– Remove bolts -5- and remove combination valve.

Touareg 2003 ➤

42

– Disconnect connector -1-.
– Disconnect hose -2-.
– Remove bolts -8-.
– Disconnect connector -9-.
– Remove coolant pipe.
– Remove intake manifold 

⇒ page 132

 .

– Remove cylinder head cover 

⇒ page 32

 .

– Loosen cylinder head bolts in the sequence given starting at

the outside and working inwards and then remove completely.

– Carefully remove cylinder head.
– Place clean cloths in cylinders so that no dirt or emery cloth

particles can get in between cylinder wall and piston.

– Also prevent dirt and emery cloth particles from getting into

coolant.

– Now carefully clean sealing surfaces of cylinder head and cyl‐

inder block. When doing this, ensure that surfaces are not

scored or scratched (if abrasive paper is used, grade must not

be less than 100).

1.5.2

Installing

– Carefully remove metal particles, emery residue and cloths.

Note

♦

Do not remove new cylinder head gasket from its packing until

immediately before installing.

♦

Handle new gasket with extreme care. Damage will cause

leakage.

– Fit new cylinder head gasket. Inscription (Part No.) must be

readable.

Touareg 2003 ➤

1. Cylinder head    

43

holes and the cylinder head gasket is located.

– Fit cylinder head, screw in new cylinder head bolts and tighten

hand tight.

– Tighten cylinder head bolts in tightening sequence shown

working from inside to outside.

– Pre-tighten all bolts to 35 Nm.
– Then tighten all bolts to 60 Nm.
– Then tighten all bolts 

1

/4 turn (90°) further using a rigid wrench.

– Then tighten all bolts again 

1

/4 turn (90°) further.

Adjusting valve timing 

⇒ page 34

 .

– Installing cylinder head cover 

⇒ page 32

 .

– Install intake manifold 

⇒ page 132

 .

Further assembly is basically the reverse of the dismantling se‐

quence.

Note

It is not necessary to retighten cylinder head bolts after repairs.

1.6

Removing and installing right cylinder

head

Removing 

⇒ page 45

 .

Installing 

⇒ page 47

 .

Touareg 2003 ➤

44