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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)
The mechanical part (petrol engines 4,2L)
Checking the valve guides
Replacing the oil seal on the side of the crankshaft vibration damper
Removing and installing drive plate
Removal and installation of the flange on the side of the drive plate
Removal, installation and tension of the toothed timing belt
Checking axial clearance of camshafts
Replacing the camshaft seals
Replacement seals Hall sensors
Removing and installing the camshaft and controls the valve timing
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
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Onboard electric
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Removal, installation and tension of the toothed timing belt



Withdrawal

ATTENTION
When all installation work, in particular in the engine compartment due to the tight layout, consider the following: the line of all kinds (such as fuel, hydraulic absorber, activated carbon, cooling system, coolant, brake lines, vacuum hoses), and and electrical wires must be routed as they were originally laid.
Provide sufficient space to all moving or hot components to avoid damage to any kind of lines.

Remove the soundproofing screen.
Remove the fan bracket with the fan cooling system.
Result a radiator framework in service position.
Mark direction of travel V-ribbed belt and remove it.
Remove the right and left cover of a gear belt.
Mark the water-resistant felt-tip direction of rotation on a gear belt.
Bring the crankshaft to top dead center. The mark on the cover of the toothed belt A must coincide with the notch on the belt pulley B.

The combination of the holes in the mounting plate
Fig. 2.106. The combination of the holes in the mounting plate


Check the position of the camshaft gears. Large holes in the mounting plate (Fig. 2.106) must be located opposite each other on the inner side.

NOTE
If larger openings are located on the outer side of the gear must rotate the crankshaft has one turn in the direction of rotation.


Screw plug
Fig. 2.100. Screw plug


Unscrew the cap to the left of the cylinder (Fig. 2.100). Crankshaft TDC hole to be seen hole for the screw plug and feel to the touch.
Gently twist the locking bolt 3242 into the hole until it stops, and thus secure the crankshaft from turning.
Remove the middle cover of the toothed belt.
Remove the vibration damper.

NOTE
Vibration damper is secured to the crankshaft by 8 bolts.


Cover bolts toothed belt tensioner
Fig. 2.107. Cover bolts toothed belt tensioner


First unscrew the screw 1 from the oil filter housing, and then the cover bolts 2 toothed belt tensioner (Fig. 2.107).
Remove the cover.

NOTE
Toothed belt tensioner is oil fence. Therefore, it is slowly shrinking.
To fix the tensioner, use the locking pin T40011.
If necessary, align the holes in the housing and on the piston to tension the tensioner via thin wires or needle-nose pliers.

Tensioner and tensioner pulley lever
Fig. 2.108. Tensioner and tensioner pulley lever


Scroll down the lever of a tension roller of a gear belt 1 hexagon socket in the direction (Fig. 2.108).
Once the lever compresses tensioner 2 so that the holes in the housing and the piston are opposite each other, lock the tensioner locking pin T40011.

Installing the camshaft clamp T4000
Fig. 2.109. Installing the camshaft clamp T4000


Insert camshaft clamp T4000 to the mounting plate and remove the camshaft securing bolts by turning them approximately 5 turns (Fig. 2.109).
Remove clamp camshaft T40005.

Tool for removing the camshaft gear
Fig. 2.110. Tool for removing the camshaft gear


Then, using a two-handed hook puller T40001 and T40001 / 2, remove the camshaft gear with the cone (Fig. 2.110).

Tension roller
Fig. 2.111. Tension roller


Unscrew the tension roller (see. Fig. 2.111) and remove the timing belt.

Installation and tension

Driving toothed belt pads
Fig. 2.112. Driving toothed belt pads


First, lay the timing belt on the crankshaft gear 1, then the slip tensioner pulley 2 and then on the tension roller 3. Further, as shown in the figure on the camshaft gear and pulley the coolant pump (Fig. 2.112).

NOTE
If the belt is operated earlier, you need to pay attention to the mark on the direction of travel.

NOTE
Camshaft gears have a little scroll on cones camshafts.

Reinstall T40005 camshaft clamp on gear.

Installing drill
Fig. 2.113. Installing drill


Put a 5 mm drill bit between the tensioner arm and the tensioner piston (Fig. 2.113).

Tightening weakened belt
Fig. 2.114. Tightening weakened belt


Tighten the attenuated tension roller torque wrench VAG 1410 with nasazhennoj ratchet wrench VAS 5122 and for idlers T40009 counterclockwise (Fig. 2.114) with a torque of 4 Nm.
In this position, tighten the bolt 1 to 22 Nm.
Then remove the 5 mm drill.
Scroll down the lever of a tension roller of a gear belt 1 hexagon socket in the direction (Fig. 2.114).
Once the lever to the piston will compress the timing belt tensioner 2, remove the locking pin T40011.

Installing drill
Fig. 2.115. Installing drill


Turn the lever of a tension roller of a gear belt 1 hexagon socket in the direction (Fig. 2.115) and place between the body and the lever 7mm drill.
Screw the camshaft gear with a torque of 55 Nm.
Remove the clip camshafts - T40005.
Again, remove the drill bit inserted between the housing and the tensioning lever.

Fixing bolt
Fig. 2.101. Fixing bolt


Remove the locking bolt 3242 out of the hole, tighten the screw plug (Fig. 2.101) and tighten it to 30 Nm.

Setting dimension A
Fig. 2.116. Setting dimension A


Turn crankshaft two times in the direction of rotation of the engine and check the installation size of A (Fig. 2.116). Setpoint 5 mm.
Further installation is performed in reverse order.




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Removal and installation of the flange on the side of the drive plate
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Checking axial clearance of camshafts

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