Get Cylinder head, valve gear -> 2.4 Removing and installing camshafts and variable camshaft timing adjusters Guide for Volkswagen Touareg SUV First Generation (2002-2010)

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

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– Unscrew bolts -1- from Hall sender.

– Unscrew bolt -2- from rear of toothed belt guard.

– Slightly pull rear of toothed belt guard towards front and re‐

move Hall sender housing with Hall sender screen and taper.

Continuation for both cylinder heads

– Screw in pin -2085/1- as shown in the illustration.

– Unscrew inner part of oil seal extractor -2085- several turns

out of the outer part and lock with knurled screw.

– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and, exerting firm pressure, screw it into oil seal as far as

possible.

– Loosen knurled screw and turn inner part against pin -2085/1-

until seal is pulled out.

– Clamp flats of oil seal extractor in vice. Remove oil seal with

pliers.

– Then press in new seal to stop until it is flush using fitting

sleeve -3241/1- and bolt -3241/3- .

Further assembly is basically the reverse of the dismantling se‐

quence.

2.4

Removing and installing camshafts and

variable camshaft timing adjusters

Removing ⇒ page 57 .

Installing ⇒ page 59 .

Special tools and workshop equipment required

56

Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

♦ Chain tensioner retainer -3366-

♦ Torque wrench (5…50 Nm) -V.A.G 1331-

♦ Sealant -AMV 188 001 02-

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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 .

2. Repairing valve gear

57

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Remove idler roller -1-.

– Loosen securing bolts -arrows- and remove rear toothed belt

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^l^kon 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.

58

Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Hold camshaft adjuster in position using retainer for chain ten‐

sioner -3366- .

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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

2. Repairing valve gear

59

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Align coloured markings -arrows-.

When using new camshaft timing chain

The distance between tooth -A- and tooth -B- of the camshaft ad‐

juster must be exactly 16 rollers of the camshaft roller chain. The

lk

illustration shows the exact positions of the -1st- and -16th- rollers

on the chain sprockets. Chain rollers -1- and -16- are offset from

1

notches -A- and -B- by / the width of one tooth towards left.

2

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:

1

5 Nm + / turn (90°) further.

4

1

–

Tighten camshaft adjuster -10-. Specified torque: 5 Nm + /

turn (90°) further.

4

– Install chain tensioner.

60

Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Check TDC position of camshafts. The markings on the cam‐

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

1

caps. Specified torque: 5 Nm + / turn (90°) further.

4

1

–

Install remaining bearing caps. Specified torque: 5 Nm + /

turn (90°) further.

4

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– 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.

2. Repairing valve gear

61

Cylinder head, valve gear -> 2.4 Removing and installing camshafts and variable camshaft timing adjusters for Your Volkswagen Touareg SUV First Generation (2002-2010)

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