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
– 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
Installing and tensioning
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
.
– 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
– 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
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