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Volkswagen Touareg (2003 year). Manual - part 14

Note

Valves must not be reworked. Only lapping-in is permitted.

Valve dimensions

Dimension

Inlet valve

Exhaust valve

-∅ a-

26.8...27.0

29.8...30.0

-∅ b-

5.96...5.97

5.94...5.95

-c-

mm 104.84...105.34

103.64...104.14

-α-

∠°

Note

Worn sodium filled exhaust valves must not be disposed of with‐

out first preparing the valves.

WARNING

Wear eye protection and protective clothing to avoid eye inju‐

ries and chemical burns!

– They must be cut through in the centre of the stem with a

hacksaw. When doing this they must not come in contact with

water!

– When valves have been prepared as described, throw a max‐

imum of ten valves into a bucket filled with water and step

back!

– Due to the contact with water a sudden chemical reaction will

be initiated and the sodium fill will be burnt.

– After this treatment, the valves can be scrapped as normal

scrap.

2.1

Camshafts, checking axial clearance

Special tools and workshop equipment required
♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge
Test procedure
Perform measurements with support elements and roller rocker

fingers removed.

Touareg 2003 ➤

2. Repairing valve gear

-7-.

Inlet camshaft

– Attach dial gauge with universal dial gauge bracket to cylinder

head, as shown.

Wear limit for axial clearance: max. 0.20 mm.
Exhaust camshaft

– Attach dial gauge with universal dial gauge bracket to cylinder

head, as shown.

Wear limit for axial clearance: max. 0.20 mm.

2.2

Renewing camshaft oil seals

Special tools and workshop equipment required
♦ Oil seal extractor -3240-

♦ Fitting tool -3241-
Removing
– Remove toothed belt and camshaft sprockets

⇒ page 34

Touareg 2003 ➤

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 camshaft

until oil seal is pulled out.

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

pliers.

Installing

– Fit seal and press it in to stop using pressure sleeve -3241/1-

and bolt -3241/6- .

– Install toothed belt and camshaft sprockets

⇒ page 34

2.3

Renewing Hall sender seals

Special tools and workshop equipment required
♦ Oil seal extractor -2085-

♦ Fitting sleeves -3241-
Procedure
Left cylinder head
– Disconnect connectors from ignition coils and injectors and lay

wiring harness to side.

– Pull connector off Hall sender.
– Remove Hall sender housing with Hall sender screen and tap‐

er.

Right cylinder head
– Remove right toothed belt guard.
– Pull connector off Hall sender.

Touareg 2003 ➤

2. Repairing valve gear

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

Special tools and workshop equipment required

Touareg 2003 ➤

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