Volkswagen Touareg (2003 year). Manual — part 16
shafts must be in line with the arrow on both bearing caps
-arrows-.
Note
If necessary, slightly turn camshaft back and forth in order to en‐
sure correct alignment of markings.
– Lightly coat double bearing cap -6- and bearing cap -1- with
sealant -AMV 188 001 02-
and install bearing
caps. Specified torque: 5 Nm +
1
/4 turn (90°) further.
– Install remaining bearing caps. Specified torque: 5 Nm +
1
/4
turn (90°) further.
– Renew camshaft seals
– Renew Hall sender seals
– Carefully drive in cap
using thrust piece of
fitting sleeves -3202- .
Further assembly is basically the reverse of the dismantling se‐
quence.
Note
♦
After installing camshafts wait for approx. 30 minutes before
starting engine. Hydraulic compensating elements must settle.
(Valves will otherwise contact piston).
♦
After working on valve mechanism, carefully turn engine by
hand to ensure that no valve strikes piston when engine is
started.
Lightly coat parting surfaces of front and rear bearing caps with
sealant -AMV 188 001 02- before installing.
Touareg 2003 ➤
2. Repairing valve gear
61
Removing and installing roller rocker fin‐
ger
Special tools and workshop equipment required
♦ Torque wrench (5…50 Nm) -V.A.G 1331-
Procedure
– Remove engine
.
– Remove camshafts with camshaft adjuster
.
– Mark allocation of roller rocker fingers and roller rocker finger
shafts in order to ensure correct reinstallation.
– Remove securing bolts -arrows-.
– Then, screw in M6 bolts into shaft holes and pull shafts out of
cylinder head.
– Remove roller rocker fingers.
Note
♦
O-rings for shafts must always be renewed.
♦
Oil bearing points of roller rocker fingers.
– When installing, tighten shaft securing bolts to 10 Nm.
Further assembly is basically the reverse of the dismantling se‐
quence.
2.6
Renewing valve stem seals
.
Touareg 2003 ➤
62
equipment required
♦ Spark plug socket and ex‐
tension -3122 B-
♦ Valve stem seal puller
-3364-
♦ Valve stem seal fitting tool
-3365-
♦ Adapter -T40012-
♦ Torque wrench (5…50 Nm)
-V.A.G 1331-
♦ Dismantling and assem‐
bling device for valve cot‐
ters -VAS 5161-
2.6.1
Removing
– Remove engine
– Remove camshafts with camshaft adjuster
– Remove spark plugs using spark plug socket and extension
-3122B- .
– Swivel roller rocker fingers upwards and secure them with a
rubber strap.
Touareg 2003 ➤
2. Repairing valve gear
63
illustration.
– Secure guide plate using the knurled screws -VAS 5161/12- .
– Insert drift -VAS 5161/3- into guide plate and knock valve cot‐
ters loose using a plastic hammer.
– Screw toothed piece -VAS 5161/6- with -VAS 5161/5- into
guide plate -VAS 5161/7- .
– Insert assembly cartridge -VAS 5161/8- into guide plate -VAS
5161/7- .
– Screw adapter -T40012- into spark plug thread, connect to
compressed air line with commercially available adapter and
apply constant pressure (at least 6 bar).
– Attach pressure fork -VAS 5161/2- to snap-in device -VAS
5161/6- and push assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth lightly to press apart valve
cotters and to capture them in the assembly cartridge.
– Release pressure fork and remove assembly cartridge from
guide plate.
– Remove guide plate from cylinder head.
Note
The compressed air line remains connected.
– Pull off valve stem seals using valve stem seal puller -3364- .
Touareg 2003 ➤
64
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