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-
mm
26.8...27.0
29.8...30.0
-∅ b-
mm
5.96...5.97
5.94...5.95
-c-
mm 104.84...105.34
103.64...104.14
-α-
∠°
45
45
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
53
-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
.
Touareg 2003 ➤
54
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
.
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
55
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 ➤
56
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