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

– Set engine to TDC 

⇒ page 34

 .

– Remove toothed belt and camshaft sprocket 

⇒ page 34

 ; Re‐

moving, installing and tensioning toothed belt.

Left cylinder head
– Remove cylinder head cover 

⇒ page 32

 .

– Loosen securing bolts -1- and -2- and remove rear toothed belt

guard.

Right cylinder head
– Remove cylinder head cover 

⇒ page 30

 .

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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.

Touareg 2003 ➤

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

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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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