2002-2010 Volkswagen Touareg SUV  Cylinder head, valve gear -> 1 Cylinder head User Manual
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Cylinder head, valve gear -> 1 Cylinder head for Your Volkswagen Touareg SUV First Generation (2002-2010)

Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
15 – Cylinder head, valve gear  
1
Cylinder head  
Assembly overview ⇒ page 29 .  
Removing and installing right cylinder head cover ⇒ page 30 .  
Removing and installing left cylinder head cover ⇒ page 32 .  
Removing, installing and tensioning toothed belt ⇒ page 34 .  
Removing and installing left cylinder head ⇒ page 40 .  
Removing and installing right cylinder head ⇒ page 44 .  
Checking compression ⇒ page 48 .  
Note  
To remove cylinder head, engine must first be removed  
⇒ page 3 .  
If an exchange cylinder head is installed, all the contact sur‐  
faces between the support elements, roller rocker fingers and  
the running surfaces of the cam shafts must be oiled before  
the cylinder head cover is installed.  
The plastic protectors fitted to protect the open valves must be  
removed only immediately before the cylinder head is fitted.  
When cylinder head or cylinder head gasket is renewed, the  
complete coolant must be renewed.  
Removing and installing intake manifold ⇒ page 132 ; Re‐  
moving and installing cylinder head cover.  
lk  
Checking compression ⇒ page 48 .  
28  
Rep. gr.15 - Cylinder head, valve gear  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
1.1  
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  
⇒ page 32 .  
❑ Removing and installing  
right cylinder head cov‐  
er ⇒ page 30 .  
❑ 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  
⇒ page 32 .  
❑ Removing and installing  
right cylinder head cov‐  
er ⇒ page 30 .  
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 ⇒ page 32 .  
❑ Removing and installing right cylinder head cover ⇒ page 30 .  
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.  
1. Cylinder head  
29  
lk  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
❑ Removing and installing right cylinder head ⇒ page 44 .  
❑ Removing and installing left cylinder head ⇒ page 40 .  
15 - Cylinder head  
❑ Check for distortion ⇒ page 30 .  
❑ Removing and installing right cylinder head ⇒ page 44 .  
❑ Removing and installing left cylinder head ⇒ page 40 .  
❑ 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  
30  
Rep. gr.15 - Cylinder head, valve gear  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
♦ Torque wrench (5…50 Nm) -V.A.G 1331-  
♦ 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.  
lk  
♦ 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- ⇒ page 158 .  
– Detach line -3- for secondary air system from cylinder head  
cover.  
– Disconnect crankcase breather hose.  
1. Cylinder head  
31  
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.  
lk  
– 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  
32  
Rep. gr.15 - Cylinder head, valve gear  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
♦ Torque wrench (5…50 Nm) -V.A.G 1331-  
lk  
♦ 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 ⇒ page 158 .  
– Disconnect crankcase breather hoses -1- and -2-.  
1. Cylinder head  
33  
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.  
– 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-  
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.  
lk  
– 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.  
lk  
– 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- .  
– 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.  
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  
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.  
1.6.1  
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.  
1. Cylinder head  
45  
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 .  
– 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.  
lk  
– 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 .  
46  
Rep. gr.15 - Cylinder head, valve gear  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
– Loosen cylinder head bolts in the sequence given starting at  
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.  
lk  
– 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.  
1. Cylinder head  
47  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
– 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 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-  
48  
Rep. gr.15 - Cylinder head, valve gear  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
Test prerequisites  
Engine oil temperature must be at least 30°C.  
The battery voltage must be at least 11.5 V.  
All electrical consumers, e.g. lights and rear window heating,  
must be switched off.  
If the vehicle is equipped with an air conditioner, it must be  
switched off.  
The selector lever of the must be in „P“or „N“ position.  
Test procedure  
– Remove ignition coils with output stages ⇒ page 158 .  
– Disconnect all connectors from injectors.  
lk  
– Remove spark plugs using spark plug socket and extension  
-3122B- .  
– Check compression using compression tester -V.A.G 1763- .  
Note  
Using compression tester ⇒ operating instructions .  
– Have a second mechanic fully depress accelerator and crank  
engine.  
– Operate starter until tester shows no further pressure in‐  
crease.  
Compression pressures:  
New: 10…15 bar  
Wear limit: 7.0 bar.  
Maximum permissible difference between all cylinders: 3 bar  
– Insert spark plugs using spark plug socket and extension  
-3122B- and tighten to 30 Nm.  
After the test has been completed:  
– Connect Vehicle diagnosis, testing and information system -  
VAS 5052- .  
– Carry out vehicle system test ⇒ Vehicle diagnostic tester „Gui‐  
ded fault finding“.  
– Finish the vehicle system test so that any fault entries stored  
during assembly can be deleted automatically.  
– Generate the readiness code in combination with a road test.  
Observe applicable safety precautions during road test.  
– Carry out road test.  
– Then carry out vehicle system test again and rectify any faults  
which may have occurred.  
1. Cylinder head  
49  

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