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
Adjusting valve timing
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
65
♦ 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
♦
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
The max. permissible reworking dimension is calculated as fol‐
lows:
– Insert valve and press firmly against seat.
Touareg 2003 ➤
66
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)
mm
34.0
Inlet valve (centre)
mm
33.7
Exhaust valves
mm
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
67
1
Removing and installing parts of lu‐
brication system
Dismantling and assembling oil filter housing
.
Removing and installing oil pump
.
Removing and installing drive chain for oil pump
Checking oil pressure and oil pressure switch
Note
If large quantities of metal shavings or particles are found when
repairing the engine, the oil passages must be cleaned, and the
oil cooler renewed in order to prevent further damage occurring
.
Removing and installing oil return valves
, and
.
1.1
Engine oil
Engine oil specifications:
Use „long-life engine oil“ conforming to VW standard „503 00“ or
„504 00“.
Note
♦
The engine is factory-filled with oil which is designed for long
service intervals.
♦
Engine oils conforming to VW standard 501 01 or 502 00 can
continue to be used. These oils must be changed every 12
months or 15,000 kilometres. The service interval display must
be programmed accordingly. Procedure: ⇒ Maintenance ;
Booklet 17.1
♦
Engine oil „ILSAC GF3 with viscosity class SAE5W-40“ may
be used to change or top up oil.
♦
Engine oil „ILSAC GF3 with viscosity class SAE5W-30“ may
be used only to top up oil.
1.2
Oil capacities:
With oil filter 7.5 l
Touareg 2003 ➤
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