Volkswagen Touareg (2003 year). Manual — part 13

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.
– 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.

Touareg 2003 ➤

1. Cylinder head

49

Repairing valve gear

Assembly overview
Camshafts, checking axial clearance

⇒ page 53

Renewing camshaft oil seal

⇒ page 54

.

Renewing Hall sender seals

⇒ page 55

Removing and installing camshafts and variable camshaft timing

adjusters

⇒ page 56

Removing and installing roller rocker finger

⇒ page 62

.

Renewing valve stem seals

⇒ page 62

.

Checking valve guides

⇒ page 65

.

Reworking valve seats

⇒ page 66

.

1 - Double bearing cap

❑ When installing, seal

parting surfaces of outer

bearing caps with seal‐

ant -AMV 188 001 02-

⇒ page 61

.

2 - 5 Nm +

1

/4 turn (90°) further

❑ Renew.

3 - Support element

❑ Before installing, check

camshaft axial clear‐

ance

⇒ page 53

.

❑ Do not interchange.
❑ With hydraulic valve

clearance compensa‐

tion.

4 - Exhaust camshaft

❑ Checking radial clear‐

ance with Plastigage;

wear limit: 0.1 mm.

❑ Runout: max. 0.01 mm.
❑ Checking axial clear‐

ance

⇒ page 53

.

❑ Removing and installing

⇒ page 56

5 - Inlet camshaft bearing cap

❑ Removing and installing

⇒ page 56

, Removing

and installing camshafts

and variable camshaft

timing adjuster.

6 - Exhaust camshaft bearing

cap

❑ Removing and installing

⇒ page 56

, Removing and installing camshafts and variable camshaft timing

adjuster.

7 - 5 Nm +

1

/4 turn (90°) further

❑ Renew.

8 - Double bearing cap

Touareg 2003 ➤

50

❑ Renew.
❑ Punch through using a screwdriver and lever out for removal.
❑ Install using tool 3202.

10 - Bearing cap
When installing, seal parting surfaces of outer bearing caps with sealant -AMV 188 001 02-

⇒ page 61

.

11 - Roller rocker finger

❑ For exhaust camshaft.
❑ Before installing, check camshaft axial clearance

⇒ page 53

.

❑ Do not interchange.
❑ Check roller bearing for ease of movement.
❑ Oil contact surface.
❑ Removing and installing

⇒ page 62

12 - Camshaft timing chain

❑ Before removing, mark direction of rotation (installation position)

⇒ page 56

; Removing and installing

camshafts and variable camshaft timing adjusters.

13 - Roller rocker finger

❑ For inlet camshaft.
❑ Before installing, check camshaft axial clearance

⇒ page 53

.

❑ Do not interchange.
❑ Check roller bearing for ease of movement.
❑ Oil contact surface.
❑ Removing and installing

⇒ page 62

14 - Inlet camshaft

❑ Checking radial clearance with Plastigage; wear limit: 0.1 mm.
❑ Runout: max. 0.01 mm.
❑ Checking axial clearance

⇒ page 53

.

❑ Removing and installing

⇒ page 56

15 - 5 Nm +

1

/4 turn (90°) further

❑ Renew.

16 - Camshaft adjuster

❑ Rotate engine only with camshaft adjuster installed.
❑ Removing and installing

⇒ page 56

, Removing and installing camshafts and variable camshaft timing

adjuster.

17 - Gasket

❑ Renew.

18 - Valve cotters
19 - Valve spring plate
20 - Valve spring

❑ Note installation position.
❑ Removing and installing

⇒ page 62

, Renewing valve stem seals.

21 - Valve stem seal

❑ Renew.

⇒ page 62

.

22 - Gasket

❑ Renew.

23 - Cylinder head

❑ Check for distortion

⇒ page 30

.

Touareg 2003 ➤

2. Repairing valve gear

51

⇒ page 44

.

❑ Removing and installing left cylinder head

⇒ page 40

.

❑ After renewing, renew entire coolant.

24 - Exhaust valve

❑ Do not rework, only lapping-in is permitted.
❑ Valve dimensions

⇒ page 53

25 - Inlet valve

❑ Do not rework, only lapping-in is permitted.
❑ Valve dimensions

⇒ page 53

26 - Seal

❑ For Hall sender.
❑ Removing and installing

⇒ page 55

27 - Hall sender screen

❑ Note installation position.

28 - Washer

❑ Conical.

29 - 23 Nm
30 - Hall sender
31 - 10 Nm
32 - Shaft

❑ For roller rocker finger, inlet side
❑ Removing and installing

⇒ page 62

, Removing and installing roller rocker finger.

33 - 10 Nm
34 - 10 Nm
35 - Shaft

❑ For roller rocker finger, exhaust side
❑ Removing and installing

⇒ page 62

, Removing and installing roller rocker finger.

36 - 55 Nm
37 - Camshaft pulley

❑ Removing and installing

⇒ page 34

Removing, installing and tensioning toothed belt.

38 - Seal

❑ For camshaft.
❑ Removing and installing

⇒ page 54

.

39 - O-ring

❑ Renew.

Touareg 2003 ➤

52