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- 

⇒ page 61

 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 

⇒ page 54

 .

– Renew Hall sender seals 

⇒ page 55

 .

– Carefully drive in cap 

⇒ Item 9 (page 50)

 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 

⇒ page 2

 .

– Remove camshafts with camshaft adjuster 

⇒ page 56

 .

– 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

Removing 

⇒ page 63

 .

Installing 

⇒ page 65

 .

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 

⇒ page 2

 .

– Remove camshafts with camshaft adjuster 

⇒ page 56

 .

– 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