2002-2010 Volkswagen Touareg SUV Cylinder head, valve gear -> 1.5 Removing and installing left cylinder head User Manual
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Cylinder head, valve gear -> 1.5 Removing and installing left cylinder head for Your Volkswagen Touareg SUV First Generation (2002-2010)

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.  
1.5  
Removing and installing left cylinder  
head  
Removing ⇒ page 41 .  
Installing ⇒ page 43 .  
40  
Rep. gr.15 - Cylinder head, valve gear  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
Special tools and workshop  
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.  
1. Cylinder head  
41  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
– 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 front exhaust pipe from exhaust manifold  
⇒ page 148 .  
lk  
– 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.  
42  
Rep. gr.15 - Cylinder head, valve gear  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
– Remove bolts securing coolant pipe -arrow-.  
– Disconnect connectors from knock sensors.  
– Pull connectors off all injectors.  
– 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.  
lk  
– 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.  
1. Cylinder head  
43  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
– 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.  
– 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.  
1
–
–
Then tighten all bolts / turn (90°) further using a rigid wrench.  
4
1
Then tighten all bolts again / turn (90°) further.  
4
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  
lk  
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 .  
44  
Rep. gr.15 - Cylinder head, valve gear  

Related Topics

Cylinder head, valve gear
1 Cylinder head 1.1 Assembly overview 1.2 Removing and installing right cylinder head cover 1.3 Removing and installing left cylinder head cover 1.4 Removing, installing and tensioning toothed belt 1.6 Removing and installing right cylinder head 1.7 Checking compression 2 Repairing valve gear 2.1 Camshafts, checking axial clearance 2.2 Renewing camshaft oil seals 2.3 Renewing Hall sender seals 2.4 Removing and installing camshafts and variable camshaft timing adjusters 2.5 Removing and installing roller rocker finger 2.6 Renewing valve stem seals 2.7 Checking valve guides 2.8 Reworking valve seats

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