Get Cylinder head, valve gear -> 1.4 Removing, installing and tensioning toothed belt Guide for Volkswagen Touareg SUV First Generation (2002-2010)

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Loosen securing bolts in the sequence -12- to -1- and remove

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.

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– Tighten securing bolts in the sequence -1- to -12-. Specified

torque: 10 Nm

1.4

Removing, installing and tensioning

toothed belt

Removing ⇒ page 35 .

Installing and tensioning ⇒ page 38

34

Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

Special tools and workshop

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-

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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.

– Remove insulation tray ⇒ General body repairs, exterior; Rep.

gr. 50 ; Noise insulation

– Remove radiator fans with radiator fan support ⇒ page 79 .

– Bring lock carrier into service position ⇒ General body repairs,

exterior; Rep. gr. 50 ; Body - front; Lock carrier service posi‐

tion .

1. Cylinder head

35

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Mark and remove poly V-belt. ⇒ page 18

– 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.

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– 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.

36

Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Remove securing bolts -arrows- for alternator. Move alternator

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.

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– 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.

1. Cylinder head

37

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Now pull camshaft sprockets off camshaft tapers using two-

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

lk

– 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.

38

Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Insert a 5 mm drill bit between the tensioning lever and the

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- .

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– 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.

1. Cylinder head

39

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Remove clamping bolt -3242- from hole, install sealing plug

-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.

lk

1.5

Removing and installing left cylinder

head

Removing ⇒ page 41 .

Installing ⇒ page 43 .

40

Rep. gr.15 - Cylinder head, valve gear

Cylinder head, valve gear -> 1.4 Removing, installing and tensioning toothed belt for Your Volkswagen Touareg SUV First Generation (2002-2010)

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