Volkswagen Touareg (2003 year). Manual - part 12

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.

1.6.1

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    

45

removed must be replaced in the same position when engine

is installed.

– Remove front exhaust pipe from exhaust manifold

⇒ page 148

 .

– Disconnect connectors -1-, -2- and -3-.
– Remove toothed belt 

⇒ page 34

 .

– Remove camshaft pulley 

⇒ page 34

 , Removing, installing and

tensioning toothed belt.

– Remove idler roller -1-.
– Loosen securing bolts -arrows- and remove rear toothed belt

guard.

– Disconnect connectors from knock sensors.
– Pull connectors off all injectors.

– Remove bolts securing coolant pipe -arrow-.

– Disconnect connector -1-.
– Disconnect hose -2-.
– Disconnect connector -4-.
– Remove bolts -6-.
– Disconnect vacuum hose -7- from combination valve.
– Remove bolts -8-.
– Disconnect connector -9-.
– Remove coolant pipe.
– Remove intake manifold 

⇒ page 132

 .

– Remove cylinder head cover 

⇒ page 30

 .

Touareg 2003 ➤

46

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).

1.6.2

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.

– Ensure dowel sleeves -arrows- are inserted into cylinder block

holes and the cylinder head gasket is located.

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

hand tight.

Touareg 2003 ➤

1. Cylinder head    

47

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 30

 .

– 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.

1.7

Checking compression

Special tools and workshop

equipment required
♦ Spark plug socket and ex‐

tension -3122 B-

♦ Torque wrench (5…50 Nm)

-V.A.G 1331-

♦ Compression tester -

V.A.G 1763-

Touareg 2003 ➤

48