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
❑ Removing and installing
right cylinder head cov‐
.
❑ 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
❑ Removing and installing
right cylinder head cov‐
.
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
❑ Removing and installing right cylinder head cover
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
❑ Removing and installing left cylinder head
.
15 - Cylinder head
❑ Check for distortion
❑ Removing and installing right cylinder head
❑ Removing and installing left cylinder head
.
❑ 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-
.
– 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
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