Volkswagen Touareg 2004-06

Camshaft, Bearings & Lifters

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Inspection



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the camshaft from the engine.
  4.  
  5. Check the camshaft bearing journals for damage and binding.
  6.  
  7. If the journals are binding, check the cylinder head for damage.
  8.  
  9. Check the cylinder head for clogged oil holes.
  10.  
  11. Check the camshaft surface for abnormal wear and damage. Replace the camshaft, as required.
  12.  
  13. Measure the camshaft lobe surface and replace the camshaft if not within specification.
  14.  
  15. Measure the camshaft journal diameter and replace the camshaft if not within specification.
  16.  
  17. Measure the camshaft run out and replace the camshaft if not within specification.
  18.  

Removal & Installation



3.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine assembly and separate it from the transmission.
  4.  
  5. Set crankshaft to TDC of cylinder 1 by turning the vibration damper securing bolt in the direction of engine rotation. Align the mark on the vibration damper.
  6.  
  7. Remove intake manifold and cylinder head cover.
  8.  
  9. Remove the thermostat housing.
  10.  
  11. Remove the upper timing chain tensioner.
  12.  
  13. Remove the upper timing chain cover. Note that the cover has a hidden bolt that can be removed only after the thermostat housing has been removed.

    Click image to see an enlarged view

    Fig. Remove the timing chain tensioner-3.2L engines



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    Fig. Mark the position of the chains and an arrow pointing in the direction of rotation-3.2L engines

  14.  
  15. Mark the position of the timing chain before removing with paint. Also mark an arrow pointing in the direction of rotation. Do not mark chain with a center punch or similar means!
  16.  
  17. Remove the exhaust camshaft adjuster. Counter-hold the camshaft using a 32 mm open end wrench on the camshaft flats.
  18.  
  19. Remove camshaft adjuster together with the timing chain from the intake camshaft. Place the chain aside.
  20.  
  21. Remove the control housing from the cylinder head. Pull the control housing carefully off of the camshaft seals.

    Click image to see an enlarged view

    Fig. Remove the bolts securing the control housing (arrows)-3.2L engines



    Click image to see an enlarged view

    Fig. Intake camshaft (A) and exhaust (B)-3.2L engines

  22.  
  23. Remove the intake camshaft:
    1. First remove bearing caps 1 and 13.
    2.  
    3. Remove bearing caps 3 and 11.
    4.  
    5. Remove bearing cap 7.
    6.  
    7. Loosen bearing caps 5 and 9 alternately and diagonally, then remove the caps.
    8.  

  24.  
  25. Remove the exhaust camshaft:
    1. First remove bearing caps 2 and 14.
    2.  
    3. Remove bearing caps 4 and 12.
    4.  
    5. Remove bearing cap 8.
    6.  
    7. Loosen bearing caps 6 and 10 alternately and diagonally, then remove the caps.
    8.  

  26.  
  27. Carefully remove the camshafts and place them on a clean surface.
  28.  

To install:


NOTE
When installing the camshafts, the cam lobes for cylinder 1 must point upward.

  1. Lightly coat the contact surfaces of bearing caps 7 and 8 with grease G 052 723 A2 or equivalent before installing.
  2.  
  3. Ensure that all roller rocker levers seat properly on valve stem ends and are clipped onto their respective support elements.
  4.  
  5. Oil the wear surfaces of both camshafts.
  6.  
  7. Place camshafts carefully in camshaft bearings of cylinder head. Observe proper camshaft identification.
    NOTE
    Observe the installed position of the bearing caps. Points of the intake and exhaust camshaft bearing caps face outwards. The writing on the caps should be legible when viewed from the intake side.



    Click image to see an enlarged view

    Fig. Bearing cap identification. The numbers on the cap should be legible when viewing from the intake side-3.2L engines

  8.  
  9. Install the intake camshaft:
    1. Tighten bearing caps 5 and 9 alternately and diagonally to 44 inch lbs. (5 Nm), then an addition 1 / 8 turn further.
    2.  
    3. Install bearing caps 1 and 13 and tighten to 44 inch lbs. (5 Nm), then an additional 1 / 8 turn further.
    4.  
    5. Install bearing cap 7 and tighten to 44 inch lbs. (5 Nm), then an additional 1 / 8 turn further.
    6.  
    7. Install bearing caps 3 and 11 and tighten to 44 inch lbs. (5 Nm), then an additional 1 / 8 turn further.
    8.  

  10.  
  11. Install the exhaust camshaft:
    1. Tighten bearing caps 6 and 10 alternately and diagonally to 44 inch lbs. (5 Nm), then an addition 1 / 8 turn further.
    2.  
    3. Install bearing caps 2 and 14 and tighten to 44 inch lbs. (5 Nm), then an addition 1 / 8 turn further.
    4.  
    5. Install bearing cap 8 and tighten to 44 inch lbs. (5 Nm), then an addition 1 / 8 turn further.
    6.  
    7. Install bearing caps 4 and 12 and tighten to 44 inch lbs. (5 Nm), then an addition 1 / 8 turn further.
    8.  

  12.  
  13. Position the camshafts to TDC of cylinder 1.
  14.  
  15. Install camshaft locking bar T10068 or similar. It must engage in both shaft grooves.
  16.  
  17. Check the control housing screen for contamination. Lightly lubricate the surfaces of the control housing contacting the camshaft seals. Lightly lubricate contact surfaces of camshaft seals and slowly push control housing over camshaft seals. Tighten the fasteners to 71 inch lbs. (8 Nm).
  18.  
  19. The remaining installation is the reverse of removal. Refer to the timing chain procedures for valve timing adjustment.
  20.  

4.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the timing belt and camshaft gear.
  4.  
  5. Remove the right or left cylinder head cover as appropriate. Refer to the cylinder head removal procedure for the proper bolt removal/installation sequence of the cover(s).
  6.  
  7. For the left cylinder head unscrew bolts (1) and (2), then remove rear timing belt cover.
  8.  
  9. For the right cylinder head, remove the idler roller (1). Unscrew the bolts (arrows) and remove rear timing belt cover.
  10.  
  11. Unplug the connector from the Hall sender and remove the Hall sender housing with the cover and cone.
  12.  
  13. Verify the TDC position of the camshafts. The markings on the camshafts must be aligned with both arrows on the bearing cap.
  14.  
  15. Mark the roller chain position with paint and with an arrow pointing in direction of rotation. Do not mark the chain with a center punch or similar means!

    Click image to see an enlarged view

    Fig. Align the marks on the camshafts with the bearing caps-4.2L engines



    Click image to see an enlarged view

    Fig. Mark the position and direction of rotation of the roller chain-4.2L engines

  16.  
  17. Secure the camshaft adjuster with chain adjustment bracket 3366 or similar. Do not fasten the bracket to tightly, as the camshaft adjuster can be damaged.
  18.  
  19. Mark the installed position and sequence of all bearing caps as shown in the illustration.

    Click image to see an enlarged view

    Fig. Secure the camshaft adjuster-4.2L engines



    Click image to see an enlarged view

    Fig. Mark the bearing caps as shown-4.2L engines

  20.  
  21. Remove the mounting bolts of the camshaft adjuster.
  22.  
  23. Remove the bearing caps. Lay them on a clean surface in correct order:
    1. Remove cap 1.
    2.  
    3. Remove caps 2, 4, 6, 8 and 9.
    4.  
    5. Loosen caps 3, 5 and 7 alternately in a diagonal sequence, then remove.
    6.  

  24.  
  25. Remove both camshafts with the camshaft adjusters and place on a clean surface.
  26.  

To install:

  1. Replace the half-round sealing plugs.
  2.  
  3. Replace the seal for the camshaft adjuster.
  4.  
  5. Lightly coat the shaded area with sealant AMV 188 001 02 or equivalent.

    Click image to see an enlarged view

    Fig. Coat the shaded area with sealant-4.2L engines

  6.  
  7. Place the camshaft roller chain onto the camshaft drive sprockets as follows:
    1. When re-using the camshaft roller chain: Match the markings made during removal.
    2.  
    3. When using a new camshaft roller chain: The distance between notches (A) and (B) must be 16 rollers of the drive chain. Refer to the illustration.

      Click image to see an enlarged view

      Fig. On used chains, align the markings made during removal-4.2L engines



      Click image to see an enlarged view

      Fig. On new chains, count 16 links between (A) and (B)-4.2L engines

    4.  

  8.  
  9. Push the camshaft adjuster in between the camshaft roller chain.
  10.  
  11. Install the camshafts with the roller chain and camshaft adjuster into the cylinder head.
  12.  
  13. Oil the journal surfaces of the camshafts.
    NOTE
    Alignment bushings for the bearing caps and camshaft adjusters must be installed in cylinder head.

  14.  
  15. Install bearing caps 3, 5 and 7. Using new bolts, tighten them alternately in a diagonal sequence to 44 inch lbs. (5 Nm), plus an additional 1 / 4 turn.
  16.  
  17. Tighten the camshaft adjuster to 44 inch lbs. (5 Nm) plus an additional 1 / 4 turn.
  18.  
  19. Install the chain tensioner.
  20.  
  21. Verify the TDC position of the camshafts. The markings on the camshafts must be aligned with both arrows on the bearing cap. If necessary, turn the camshaft slightly back and forth to align them.
  22.  
  23. Lightly coat double bearing cap 6 and bearing cap 1 with grease AMV 188 001 02 or equivalent. Install the bearing caps and tighten to 44 inch lbs. (5 Nm), plus an additional 1 / 4 turn.
  24.  
  25. Install the remaining bearing caps and tighten them to 44 inch lbs. (5 Nm), plus an additional 1 / 4 turn.
  26.  
  27. If necessary, replace the camshaft seals and the seals for the Hall sender. Carefully drive in the sealing cover
  28.  
  29. The remainder of installation is the reverse of removal. Note the following:

    Refer to the cylinder head removal procedure for the proper bolt removal/installation sequence of the cylinder head cover(s).
     
    After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic valve adjusters must bleed down, otherwise the valves will crash into the pistons.
     
    Carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.
     

  30.  

 
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