Volkswagen Touareg (2003 year). Manual — part 15
♦ Torque wrench (5…50 Nm) -V.A.G 1331-
♦ Sealant -AMV 188 001 02-
2.4.1
Removing
.
– Remove toothed belt and camshaft sprocket
; Re‐
moving, installing and tensioning toothed belt.
Left cylinder head
– Remove cylinder head cover
– Loosen securing bolts -1- and -2- and remove rear toothed belt
guard.
Right cylinder head
– Remove cylinder head cover
Touareg 2003 ➤
2. Repairing valve gear
57
guard.
Continuation for both cylinder heads
– Disconnect connector from Hall sender and remove Hall send‐
er housing with Hall sender screen and taper.
– Check TDC position of camshafts. The markings on the cam‐
shafts must be in line with the arrow on both bearing caps
-arrows-.
When reusing existing camshaft timing chain
– Mark camshaft timing chain -arrows- before removing (e.g.
with paint, arrow pointing in direction of rotation).
Note
Do not mark chain by way of centre punch, notch or the like.
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58
sioner -3366- .
Note
Camshaft adjuster can be damaged if chain tensioner is tightened
too far.
– Mark installation position of all bearing caps (e.g. using a wa‐
terproof felt-tip marker) with numbers as shown in the illustra‐
tion regardless of the existing markings on the bearing caps.
– Unscrew securing bolts for camshaft adjuster.
– Remove bearing cap -1-.
– Remove bearing caps -2-, -4-, -6-, -8- and -9- and place them
on a clean surface in sequence given.
– Loosen bearing caps -3-, -5- and -7- alternately and diagonally
and then remove.
– Carefully remove camshafts with camshaft adjusters and
place them on a clean surface.
2.4.2
Installing
– Renew half-round sealing plug.
– Renew gasket for camshaft adjuster.
– Coat hatched area lightly with sealant -AMV 188 001 02- .
– Fit camshaft timing chain onto camshaft drive gears as de‐
scribed below.
When reusing existing camshaft timing chain
Touareg 2003 ➤
2. Repairing valve gear
59
The distance between tooth -A- and tooth -B- of the camshaft ad‐
juster must be exactly 16 rollers of the camshaft roller chain. The
illustration shows the exact positions of the -1st- and -16th- rollers
on the chain sprockets. Chain rollers -1- and -16- are offset from
notches -A- and -B- by
1
/2 the width of one tooth towards left.
Continuation
– Fit camshaft adjuster to camshaft timing chain.
– Carefully position camshafts with camshaft timing chain and
camshaft adjuster in cylinder head.
– Oil the camshaft running surfaces.
Note
Dowel sleeves for bearing caps and camshaft adjuster must be
fitted in cylinder head.
– Install bearing caps -3-, -5- and -7- to locations as marked and
tighten new bolts alternately and diagonally. Specified torque:
5 Nm +
1
/4 turn (90°) further.
– Tighten camshaft adjuster -10-. Specified torque: 5 Nm +
1
/4
turn (90°) further.
– Install chain tensioner.
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60
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