Volkswagen Touareg 2004-06

Cylinder Head

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Removal & Installation



3.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine from the vehicle.
  4.  
  5. Set the crankshaft to TDC of cylinder 1 by turning the vibration damper securing bolt in the direction of engine rotation.

    Click image to see an enlarged view

    Fig. TDC mark located on the vibration damper-3.2L engines

  6.  
  7. Screw a M8x50 bolt into the threaded hole of the tensioner to release tension on the belt. Screw the bolt in only far enough to allow removal of the belt.
  8.  
  9. Remove the belt.
  10.  
  11. Remove the intake manifold.
  12.  
  13. At front of cylinder head cover, unbolt the wiring bracket for the knock sensor and oil level thermal sensor. Unplug the fuel injector connectors.
  14.  
  15. Remove the cylinder head cover.
  16.  
  17. Unbolt the connecting line from the intake manifold support and unplug the connector for the knock sensor.
  18.  
  19. Unclip the wire harness from the retainer on cylinder head.
  20.  
  21. Unbolt the connecting line from the combination valve and pull off the coolant hose below the combination valve on the cylinder head.
  22.  
  23. Unbolt the exhaust manifold from the cylinder head.
  24.  
  25. Unplug the connectors from the camshaft adjustment valves.
  26.  
  27. Unbolt the securing clamps for the wiring harness at the bracket.
  28.  
  29. Remove the thermostat housing.
  30.  
  31. Remove the camshaft roller chain tensioner.

    Click image to see an enlarged view

    Fig. Timing chain tensioner is located in the front timing chain cover-3.2L engines

  32.  
  33. Remove the timing chain cover. Note that the cover can be removed only after the thermostat housing has been removed.
  34.  
  35. Remove the bolts for the camshaft adjuster.
    NOTE
    When loosening or tightening the camshaft adjuster, counter-hold using a 32 mm open end wrench on the camshaft flats. Make sure the camshaft is not locked using a holding bar tool.

  36.  
  37. Remove the camshaft adjuster together with the roller chain from the intake camshaft.
  38.  
  39. Remove the exhaust camshaft adjuster.
  40.  
  41. Remove the timing chain guide rail securing bolts and remove the guide rail. Place the chain aside.
  42.  
  43. First loosen the cylinder head bolts in sequence starting from the outside to the inside, then remove them completely.
    NOTE
    For Polydrive® cylinder head bolts, use Polydrive® key 3452 or equivalent.



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-3.2L engines

  44.  
  45. Carefully lift off the cylinder head with a workshop crane. Place a clean cloth 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 the coolant.
  46.  

To install:

  1. Carefully clean the cylinder head and cylinder block sealing surfaces. Ensure that no scoring or scratches are formed. Abrasive paper grade must not be less than 100.
  2.  
  3. Clean all threaded holes for the cylinder head bolts. Carefully remove any metal particles, emery remains and cloths.
  4.  
  5. If the piston for cylinder 1 is not at TDC, set it to the TDC marks by turning the vibration damper securing bolt in the direction of engine rotation. Guide the camshaft roller chain by hand with aid of an assistant while doing this.
  6.  
  7. Install a new cylinder head gasket; handle the new gasket with care to prevent damage.
  8.  
  9. Install alignment bushings into cylinder block holes 12 and 20 and that cylinder head gasket is seated.
  10.  
  11. Position the camshafts in the cylinder head to TDC of cylinder 1.
  12.  
  13. Lock the camshafts using holding bar T10068 or equivalent. It must engage in both shaft grooves.
  14.  
  15. Lower the cylinder head onto the block; insert new cylinder head bolts and tighten by hand.
    NOTE
    The longer cylinder head bolts must be inserted in the middle holes of cylinder head.



    Click image to see an enlarged view

    Fig. Cylinder head bolt installation sequence-3.2L engines

  16.  
  17. Tighten the cylinder head bolts in the proper sequence starting from the inside to the outside:

    Step 1: 22 ft. lbs. (30 Nm)
     
    Step 2: 37 ft. lbs. (50 Nm)
     
    Step 3: Tighten all bolts a 1 / 4 turn
     
    Step 4: Tighten all bolts again an additional 1 / 4 turn
     

  18.  
  19. The remaining installation is the reverse of the removal procedure. Refer to the timing chain procedures in this section to check and adjust the valve timing. Observe the following additional torque specifications:

    Cylinder head cover: 7 ft. lbs. (10 Nm)
     
    All other fasteners: Refer to the appropriate procedures in this section.
     

  20.  

4.2L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine from the vehicle.
  4.  
  5. Remove the front exhaust pipe from the exhaust manifold.
  6.  
  7. Remove the bolt securing the oil dipstick guide tube to the cylinder head.
  8.  
  9. Label and unplug the electrical connections from the front of the cylinder head.
  10.  
  11. Remove the timing belt and camshaft gear.
  12.  
  13. Remove the bolts securing the rear timing belt cover, then remove the cover.

    Click image to see an enlarged view

    Fig. Remove the bolts securing the rear timing belt cover (1 and 2)-4.2L engines, left side

  14.  
  15. Unplug the electrical connectors from the back of the cylinder heads.
  16.  
  17. Unplug the vacuum hoses, then remove the combination valves from the end of the cylinder heads.
  18.  
  19. Remove the bolts from the coolant pipes on the end of the cylinder heads.
  20.  
  21. Unplug the knock sensor connectors.
  22.  
  23. Unplug the connectors from all of the fuel injectors.
  24.  
  25. Remove the coolant pipe assembly from the cylinder heads.

    Click image to see an enlarged view

    Fig. Remove the bolts securing the coolant pipe located below the combination valve-4.2L engines

  26.  
  27. Remove the intake manifold.
  28.  
  29. Remove the bracket from below the ignition coils.
  30.  
  31. Pull off the connectors from the ignition coils, then remove the coils from the cylinder head cover.
  32.  
  33. Disconnect the crankcase ventilation hoses.
  34.  
  35. Loosen the bolts in the sequence from 12 to 1, then remove the cylinder head cover.

    Click image to see an enlarged view

    Fig. Cylinder head cover bolt identification-4.2L engines, left side



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-4.2L engines, left side

  36.  
  37. Loosen the cylinder head socket head bolts in the given sequence, starting from the outside to the inside. Then remove the bolts completely.
  38.  
  39. Carefully lift the cylinder head off. Place a clean cloth 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 the coolant.
  40.  

To install:

  1. Carefully clean the cylinder head and cylinder block sealing surfaces. Ensure that no scoring or scratches are formed. Abrasive paper grade must not be less than 100.
  2.  
  3. Clean all threaded holes for the cylinder head bolts. Carefully remove any metal particles, emery remains and cloths.
  4.  
  5. Install a new cylinder head gasket; handle the new gasket with care to prevent damage.
  6.  
  7. Ensure that alignment bushings are inserted into the cylinder block and that cylinder head gasket is seated.
  8.  
  9. Lower the cylinder head onto the block; insert new cylinder head bolts and tighten by hand.
  10.  
  11. Tighten the cylinder head bolts in the proper sequence starting from the inside to the outside:

    Step 1: 26 ft. lbs. (35 Nm)
     
    Step 2: 44 ft. lbs. (60 Nm)
     
    Step 3: Tighten all bolts a 1 / 4 turn
     
    Step 4: Tighten all bolts again an additional 1 / 4 turn

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-4.2L engines, left side



    Click image to see an enlarged view

    Fig. Apply sealant to these points on the cylinder head-4.2L engines, left side

     

  12.  
  13. The remaining installation is the reverse of the removal procedure. Observe the following additional torque specifications:

    Cylinder head cover (tighten from 1 to 12): 7 ft. lbs. (10 Nm)
     
    All other fasteners: Refer to the appropriate procedures in this section.
     

  14.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine from the vehicle.
  4.  
  5. Remove the front exhaust pipe from the exhaust manifold.
  6.  
  7. Label and unplug the electrical connections from the front of the cylinder head.
  8.  
  9. Remove the timing belt and camshaft gear.
  10.  
  11. Remove the idler roller.

    Click image to see an enlarged view

    Fig. Remove the bolts securing the rear timing belt cover (arrows) and the idler roller (1)-4.2L engines, right side

  12.  
  13. Remove the bolts securing the rear timing belt cover, then remove the cover.
  14.  
  15. Unplug the knock sensor connectors.
  16.  
  17. Unplug the connectors from all of the fuel injectors.
  18.  
  19. Unplug the electrical connector and vacuum hose, then remove the combination valve from the end of the cylinder head.
  20.  
  21. Remove the bolts from the coolant pipe on the end of the cylinder head. Detach the pipe from the head.
  22.  
  23. Remove the intake manifold.
  24.  
  25. Pull off the connectors from the ignition coils, then remove the coils from the cylinder head cover.
  26.  
  27. Disconnect the line for the secondary air injection system from the cylinder head cover.
  28.  
  29. Disconnect the crankcase ventilation hose.
  30.  
  31. Loosen the bolts in the sequence from 12 through 1, then remove the cylinder head cover.
  32.  
  33. Loosen the cylinder head socket head bolts in the given sequence, starting from the outside to the inside. Then remove the bolts completely.

    Click image to see an enlarged view

    Fig. Cylinder head cover bolt identification-4.2L engines, right side



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-4.2L engines, right side

  34.  
  35. Carefully lift the cylinder head off. Place a clean cloth 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 the coolant.
  36.  

To install:

  1. Carefully clean the cylinder head and cylinder block sealing surfaces. Ensure that no scoring or scratches are formed. Abrasive paper grade must not be less than 100.
  2.  
  3. Clean all threaded holes for the cylinder head bolts. Carefully remove any metal particles, emery remains and cloths.
  4.  
  5. Install a new cylinder head gasket; handle the new gasket with care to prevent damage.
  6.  
  7. Ensure that alignment bushings are inserted into the cylinder block and that cylinder head gasket is seated.
  8.  
  9. Lower the cylinder head onto the block; insert new cylinder head bolts and tighten by hand.
  10.  
  11. Tighten the cylinder head bolts in the proper sequence starting from the inside to the outside:

    Step 1: 26 ft. lbs. (35 Nm)
     
    Step 2: 44 ft. lbs. (60 Nm)
     
    Step 3: Tighten all bolts a 1 / 4 turn
     
    Step 4: Tighten all bolts again an additional 1 / 4 turn

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-4.2L engines, right side



    Click image to see an enlarged view

    Fig. Apply sealant to these points on the cylinder head-4.2L engines, right side

     

  12.  
  13. The remaining installation is the reverse of the removal procedure. Observe the following additional torque specifications:

    Cylinder head cover: 7 ft. lbs. (10 Nm)
     
    All other fasteners: Refer to the appropriate procedures in this section.
     

  14.  

 
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