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Volkswagen Touareg (2003 year). Manual - part 17

Installing

– To prevent damage to new valve stem seals, place plastic

sleeve -A- on valve stem.

– Lubricate sealing lip of valve stem seal -B-, place it in the valve

stem oil seal fitting tool -3365- and push carefully onto valve

guide.

– Remove plastic sleeve -A-.

If the valve cotters have been removed from the assembly item

then they must be inserted into the insertion device -VAS

5161/18- .

Note

Larger diameter faces upwards.

– Insert valve spring and valve spring plate.
– Secure guide plate -VAS 5161/7- back to cylinder head.

– Insert assembly cartridge -VAS 5161/8- into guide plate.
– Press pressure fork down and pull knurled screw upwards.

This causes the valve cotters to be inserted.

– Release pressure fork with knurled screw still in pulled posi‐

tion.

– Install camshafts with camshaft adjuster

⇒ page 56

Adjusting valve timing

⇒ page 34

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.

2.7

Checking valve guides

Special tools and workshop equipment required

Touareg 2003 ➤

2. Repairing valve gear

♦ Dial gauge
Test procedure
– Insert new valve into guide. The end of the valve stem must

be flush with the guide. On account of differing stem diame‐

ters, only use inlet valve in inlet guide and exhaust valve in

exhaust guide.

– Determine rock. Wear limit: 0.8 mm
If rock tolerance is exceeded:
– Renew cylinder head.

2.8

Reworking valve seats

Special tools and workshop equipment required
♦ Depth gauge
♦ Valve seat refacing tool
Procedure

Note

♦

When repairing engines with leaking valves, it is not sufficient

to rework or renew valve seats and valves. Particularly on high

mileage engines, it is necessary also to check valve guides for

wear

⇒ page 65

♦

Valve seats are only to be reworked to the extent required to

yield a proper surface appearance. Before beginning to rework

valve seats, calculate the maximum permissible reworking di‐

mensions. If the reworking dimension is exceeded, the hy‐

draulic valve clearance compensation can no longer be

guaranteed and the cylinder head must be renewed.

– Remove camshafts

⇒ page 56

The max. permissible reworking dimension is calculated as fol‐

lows:
– Insert valve and press firmly against seat.

Touareg 2003 ➤

If the valve is to be renewed as part of a repair, use a new valve

for the calculation.

– Measure distance -a- between end of valve stem and upper

edge of cylinder head.

– Calculate maximum permissible reworking dimension from

measured distance -a- and minimum dimension.

Minimum dimension:

Inlet valves (outer)

34.0

Inlet valve (centre)

33.7

Exhaust valves

34.4

Measured distance -a- minus minimum dimension = maximum

permissible reworking dimension.
Example:

Measured distance

34.4 mm

— Minimum dimension

34.0 mm

Max. permissible reworking dimension

0.4 mm

Note

If the max. permissible reworking dimension is 0 mm or below 0

mm, repeat measurement using new valves. If the result does not

change renew cylinder head.

Reworking valve seats
Reworking inlet valve seat
a - = ∅ 26.2 mm
b - = 1.5…1.8 mm
Z - = bottom surface of cylinder head
α - 45° valve seat angle
β - 30° upper correction angle
γ - 60° lower correction angle
Reworking exhaust valve seat
a - = ∅ 29.0 mm
b - = approx. 1.8 mm
Z - = bottom surface of cylinder head
α - 45° valve seat angle
β - 30° upper correction angle
γ - 60° lower correction angle

Touareg 2003 ➤

2. Repairing valve gear