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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Touareg (from 2003 to 2006, the year of issue)

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Volkswagen Touareg
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Volkswagen
Touareg
Operation and maintenance of car
Engine
Preliminary checks on the car
The mechanical part (petrol engines 3,2L)
Removal of the power unit
Removal and installation of the left and right engine support cushions
Removing and installing drive plate
Removing and installing oil seal on the flywheel side
Replacing the oil seal on the side of the crankshaft vibration damper
Replacement of sealing flange on the side of the crankshaft vibration damper
Removing and installing crankshaft
Removing and installing the side cover
Removing and installing cylinder head cover
Removal and installation of the cylinder head
Checking the valve timing
The timing
Removing camshafts
Installing the camshaft
Checking the axial displacement of the camshaft
Marking camshafts
Replacing valve stem seals
Checking the valve guides
Processing valve seat
Valve sizes
Checking the pistons, piston rings and cylinder bore
The mechanical part (petrol engines 4,2L)
The mechanical part (diesel engines 5,0L)
Removing and installing subframe
Pressurization system (diesel engines)
Cooling system (petrol engines)
The cooling system (diesel engines)
Lubrication (petrol engines)
Lubrication system (diesel engines)
Injection System (petrol engines)
Fuel injection system (diesel engines)
Exhaust
FUEL (beninovye engines)
Tables
Transmission
Chassis
Steering Gear
Brakes
Onboard electric
Body
diagrams
 


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Removal and installation of the cylinder head



Withdrawal

NOTE
The operation to remove the cylinder head is carried out on the removed engine.
The engine should be warm to the touch.

ATTENTION
In any assembly work, particularly in the engine compartment due to the tight layout, consider the following:
- All line types (such as fuel, hydraulic absorber, activated carbon, cooling systems, circuit conditioning systems, brake lines, vacuum tubes), and also necessary to lay electric wires as they were originally laid.
- Provide space for all moving or hot components.
- After installation, you must reinstall all fasteners cable, remove or cut during removal.

Withdrawal

Installation 1 cyl. TDC
Fig. 2.58. Installation 1 cyl. TDC


Give the crankshaft via a fixing bolt vibration damper in direction of rotation of the engine to the level of TDC cyl. 1 (Fig. 2.58).
Remove ribbed belt.
Remove the cylinder head cover and intake manifold.

Plug knock sensor
Fig. 2.59. Plug knock sensor


Remove the connecting wire 1 on the bracket support the intake manifold, and free plug knock sensor 1 G61 2 from its holder (Fig. 2.59).
Then rasklipsuyte harness of mounting on the cylinder head.

Pressure port combination valve and a water hose
Fig. 2.60. Pressure port combination valve and a water hose


Unscrew the discharge nozzle from the combination valve 1, and then disconnect the water hose 2 by a combined valve of the cylinder head (Fig. 2.60).
Remove the exhaust manifold from the cylinder head.
Remove the plugs from the valve of 1 system of variable valve timing and valve N205 1 of variable valve timing exhaust valves N318.

NOTE
Before disconnecting the plug mark belonging to detail.

Remove fixing collars harness from the bracket.
Remove the thermostat housing and the cooling system installed on the engine.

Timing chain tensioner
Fig. 2.61. Timing chain tensioner


Remove the timing chain tensioner (Fig. 2.61).
Remove the side cover.

NOTE
Side cover is "hidden bolt." Access to it is provided only after the removal of the thermostat housing.

Unscrew all the mounting screws, gently pry the side cover down.
Remove the mounting bolts of phase shifters.

Installation locations spanner
Fig. 2.62. Installation locations spanner



NOTE
When loosening and tightening the camshaft phase shifters must be held only with the spanner 32 (Fig. 2.62). Ruler camshaft T10068 A should not be embedded in the groove.

Remove the coupling permutations camshaft with roller chain timing from the intake shaft.
Then remove the exhaust camshaft phaser.

Fixing screws strap pacifier
Fig. 2.63. Fixing screws strap pacifier


Turn off fixing bolts and remove the pacifier 1 bar (Fig. 2.63).
Put the timing chain to the side, putting her side.

Order of easing of the cylinder head cover bolts
Fig. 2.64. Order of easing of the cylinder head cover bolts


Loosen the cylinder head cover bolts in the sequence from outside to inside and unscrew them (Fig. 2.64).

NOTE
For screws with heads Polydrive use key 3452.

Hang the hanging device for 3033, as shown in Figure 2.65, and carefully lift the cylinder head by a crane VAS 6100 or VAG 1202 A.
Side vibration damper: 3 position.
Flywheel side: 11 position.

Lifting cylinder head
Fig. 2.65. Lifting cylinder head



NOTE
Marked 1 to 12 positions for hanging fixtures 3033 point in the direction of the flywheel (Fig. 2.65).
Spindles are regulated if appropriate length.

Carefully remove the cylinder head.
Put into the cylinders a clean cloth to between the piston and the cylinder bore no dirt and the remains of emery.
Check that the cooling liquid is also no dirt and the remains of emery.
Carefully clean the sealing surfaces of cylinder head and cylinder block.
Thus there should be no longer scratches and burrs (using grit sandpaper it should be less than "100").
Clean all threaded holes for the cylinder head cover bolts.

Setting
Carefully remove remaining emery and sandpaper and rags of the cylinders.
If the piston of 1st cylinder is not in TDC turn the crankshaft with the mounting bolt vibration damper in direction of rotation of the engine to the level of TDC cyl. 1. In this case, an assistant must move the hands of the timing chain synchronously in the same direction.

NOTE
A new cylinder head gasket must be removed from the packaging until immediately before installation.
Handle the new gasket very carefully. It will lead to further damage to the leak.

Install the new cylinder head gasket. Marking (part number) has to be readable.

To install bushings
Fig. 2.66. To install bushings


Check-fitting sleeves inserted in the holes 12 and 20 and the cylinder head gasket is fixed (Fig. 2.66).
Turn the camshafts in cylinder head to TDC cylinder 1.

The experimental setup lock line
Fig. 2.67. The experimental setup lock line


Ruler camshaft T10068 A should be included in both grooves (Fig. 2.67).
Prepare cylinder head gasket to be installed.
Install the cylinder head to the engine block, insert new cylinder head bolts and tighten them by hand.
Tighten the cylinder head bolts in the shown in Figure 2.66 sequence from inside to outside.

NOTE
Long cylinder head bolts are inserted into the middle hole in the cylinder head.

Tighten all screws with a preliminary torque of 30 Nm.
Then tighten all the bolts to a torque of 50 Nm.
Then tighten all the bolts 1/4 turn (90 ?�), the usual key.
Finally, tighten all bolts again a 1/4 turn (90 ?�).
Further installation and assembly is performed in reverse sequence to removal.

NOTE
Check inserted into the end cap O-ring of the oil channel.

Install the cylinder head cover and intake manifold.
Dotyazhka bolts of the cylinder head after a repair is not necessary.

Checking cylinder head for warpage
Fig. 2.68. Checking cylinder head for warpage


Check the curvature of the contact surface of the cylinder head (Fig. 2.68).
The maximum permissible bending: 0.05 mm.




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Removing and installing cylinder head cover
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Checking the valve timing

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