Get Cylinder head, valve gear -> 2 Repairing valve gear Guide for Volkswagen Touareg SUV First Generation (2002-2010)

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

2

Repairing valve gear

Assembly overview

Camshafts, checking axial clearance ⇒ page 53

Renewing camshaft oil seal ⇒ page 54 .

Renewing Hall sender seals ⇒ page 55

Removing and installing camshafts and variable camshaft timing

adjusters ⇒ page 56

Removing and installing roller rocker finger ⇒ page 62 .

Renewing valve stem seals ⇒ page 62 .

Checking valve guides ⇒ page 65 .

Reworking valve seats ⇒ page 66 .

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1 - Double bearing cap

❑ When installing, seal

parting surfaces of outer

bearing caps with seal‐

ant -AMV 188 001 02-

⇒ page 61 .

1

2 - 5 Nm + / turn (90°) further

4

❑ Renew.

3 - Support element

❑ Before installing, check

camshaft axial clear‐

ance ⇒ page 53 .

❑ Do not interchange.

❑ With hydraulic valve

clearance compensa‐

tion.

4 - Exhaust camshaft

❑ Checking radial clear‐

ance with Plastigage;

wear limit: 0.1 mm.

❑ Runout: max. 0.01 mm.

❑ Checking axial clear‐

ance ⇒ page 53 .

❑ Removing and installing

⇒ page 56

5 - Inlet camshaft bearing cap

❑ Removing and installing

⇒ page 56 , Removing

and installing camshafts

and variable camshaft

timing adjuster.

6 - Exhaust camshaft bearing

cap

❑ Removing and installing ⇒ page 56 , Removing and installing camshafts and variable camshaft timing

adjuster.

1

7 - 5 Nm + / turn (90°) further

4

❑ Renew.

8 - Double bearing cap

50

Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

9 - Cap

❑ Renew.

❑ Punch through using a screwdriver and lever out for removal.

❑ Install using tool 3202.

10 - Bearing cap

When installing, seal parting surfaces of outer bearing caps with sealant -AMV 188 001 02- ⇒ page 61 .

11 - Roller rocker finger

❑ For exhaust camshaft.

❑ Before installing, check camshaft axial clearance ⇒ page 53 .

❑ Do not interchange.

❑ Check roller bearing for ease of movement.

❑ Oil contact surface.

❑ Removing and installing ⇒ page 62

12 - Camshaft timing chain

❑ Before removing, mark direction of rotation (installation position) ⇒ page 56 ; Removing and installing

camshafts and variable camshaft timing adjusters.

13 - Roller rocker finger

❑ For inlet camshaft.

❑ Before installing, check camshaft axial clearance ⇒ page 53 .

❑ Do not interchange.

❑ Check roller bearing for ease of movement.

❑ Oil contact surface.

❑ Removing and installing ⇒ page 62

14 - Inlet camshaft

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❑ Checking radial clearance with Plastigage; wear limit: 0.1 mm.

❑ Runout: max. 0.01 mm.

❑ Checking axial clearance ⇒ page 53 .

❑ Removing and installing ⇒ page 56

1

15 - 5 Nm + / turn (90°) further

4

❑ Renew.

16 - Camshaft adjuster

❑ Rotate engine only with camshaft adjuster installed.

❑ Removing and installing ⇒ page 56 , Removing and installing camshafts and variable camshaft timing

adjuster.

17 - Gasket

❑ Renew.

18 - Valve cotters

19 - Valve spring plate

20 - Valve spring

❑ Note installation position.

❑ Removing and installing ⇒ page 62 , Renewing valve stem seals.

21 - Valve stem seal

❑ Renew. ⇒ page 62 .

22 - Gasket

❑ Renew.

23 - Cylinder head

❑ Check for distortion ⇒ page 30 .

2. Repairing valve gear

51

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

❑ Removing and installing right cylinder head ⇒ page 44 .

❑ Removing and installing left cylinder head ⇒ page 40 .

❑ After renewing, renew entire coolant.

24 - Exhaust valve

❑ Do not rework, only lapping-in is permitted.

❑ Valve dimensions ⇒ page 53

25 - Inlet valve

❑ Do not rework, only lapping-in is permitted.

❑ Valve dimensions ⇒ page 53

26 - Seal

❑ For Hall sender.

❑ Removing and installing ⇒ page 55

27 - Hall sender screen

❑ Note installation position.

28 - Washer

❑ Conical.

29 - 23 Nm

30 - Hall sender

31 - 10 Nm

32 - Shaft

❑ For roller rocker finger, inlet side

❑ Removing and installing ⇒ page 62 , Removing and installing roller rocker finger.

33 - 10 Nm

34 - 10 Nm

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35 - Shaft

❑ For roller rocker finger, exhaust side

❑ Removing and installing ⇒ page 62 , Removing and installing roller rocker finger.

36 - 55 Nm

37 - Camshaft pulley

❑ Removing and installing ⇒ page 34 Removing, installing and tensioning toothed belt.

38 - Seal

❑ For camshaft.

❑ Removing and installing ⇒ page 54 .

39 - O-ring

❑ Renew.

52

Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

Valve dimensions

Note

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

Valve dimensions

Dimension

-∅ a-

-∅ b-

-c-

Inlet valve

26.8...27.0

5.96...5.97

Exhaust valve

29.8...30.0

5.94...5.95

103.64...104.14

45

mm

mm 104.84...105.34

∠° 45

-α-

Note

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

lk

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.

2. Repairing valve gear

53

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Insert camshaft and secure with bearing caps -3-, -5- and

-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

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– 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 .

54

Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Unscrew inner part of oil seal extractor -3240- 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.

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– 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.

2. Repairing valve gear

55

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

lk

– Unscrew bolts -1- from Hall sender.

– Unscrew bolt -2- from rear of toothed belt guard.

– Slightly pull rear of toothed belt guard towards front and re‐

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

Removing ⇒ page 57 .

Installing ⇒ page 59 .

Special tools and workshop equipment required

56

Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

♦ Chain tensioner retainer -3366-

♦ Torque wrench (5…50 Nm) -V.A.G 1331-

♦ Sealant -AMV 188 001 02-

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2.4.1

Removing

– Set engine to TDC ⇒ page 34 .

– Remove toothed belt and camshaft sprocket ⇒ page 34 ; Re‐

moving, installing and tensioning toothed belt.

Left cylinder head

– Remove cylinder head cover ⇒ page 32 .

– Loosen securing bolts -1- and -2- and remove rear toothed belt

guard.

Right cylinder head

– Remove cylinder head cover ⇒ page 30 .

2. Repairing valve gear

57

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Remove idler roller -1-.

– Loosen securing bolts -arrows- and remove rear toothed belt

guard.

Continuation for both cylinder heads

– Disconnect connector from Hall sender and remove Hall send‐

er housing with Hall sender screen and taper.

– Check TDC position of camshafts. The markings^l^kon the cam‐

shafts must be in line with the arrow on both bearing caps

-arrows-.

When reusing existing camshaft timing chain

– Mark camshaft timing chain -arrows- before removing (e.g.

with paint, arrow pointing in direction of rotation).

Note

Do not mark chain by way of centre punch, notch or the like.

58

Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Hold camshaft adjuster in position using retainer for chain ten‐

sioner -3366- .

lk

Note

Camshaft adjuster can be damaged if chain tensioner is tightened

too far.

– Mark installation position of all bearing caps (e.g. using a wa‐

terproof felt-tip marker) with numbers as shown in the illustra‐

tion regardless of the existing markings on the bearing caps.

– Unscrew securing bolts for camshaft adjuster.

– Remove bearing cap -1-.

– Remove bearing caps -2-, -4-, -6-, -8- and -9- and place them

on a clean surface in sequence given.

– Loosen bearing caps -3-, -5- and -7- alternately and diagonally

and then remove.

– Carefully remove camshafts with camshaft adjusters and

place them on a clean surface.

2.4.2

Installing

– Renew half-round sealing plug.

– Renew gasket for camshaft adjuster.

– Coat hatched area lightly with sealant -AMV 188 001 02- .

– Fit camshaft timing chain onto camshaft drive gears as de‐

scribed below.

When reusing existing camshaft timing chain

2. Repairing valve gear

59

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Align coloured markings -arrows-.

When using new camshaft timing chain

The distance between tooth -A- and tooth -B- of the camshaft ad‐

juster must be exactly 16 rollers of the camshaft roller chain. The

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illustration shows the exact positions of the -1st- and -16th- rollers

on the chain sprockets. Chain rollers -1- and -16- are offset from

1

notches -A- and -B- by / the width of one tooth towards left.

2

Continuation

– Fit camshaft adjuster to camshaft timing chain.

– Carefully position camshafts with camshaft timing chain and

camshaft adjuster in cylinder head.

– Oil the camshaft running surfaces.

Note

Dowel sleeves for bearing caps and camshaft adjuster must be

fitted in cylinder head.

– Install bearing caps -3-, -5- and -7- to locations as marked and

tighten new bolts alternately and diagonally. Specified torque:

1

5 Nm + / turn (90°) further.

4

1

–

Tighten camshaft adjuster -10-. Specified torque: 5 Nm + /

turn (90°) further.

4

– Install chain tensioner.

60

Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Check TDC position of camshafts. The markings on the cam‐

shafts must be in line with the arrow on both bearing caps

-arrows-.

Note

If necessary, slightly turn camshaft back and forth in order to en‐

sure correct alignment of markings.

– Lightly coat double bearing cap -6- and bearing cap -1- with

sealant -AMV 188 001 02- ⇒ page 61 and install bearing

1

caps. Specified torque: 5 Nm + / turn (90°) further.

4

1

–

Install remaining bearing caps. Specified torque: 5 Nm + /

turn (90°) further.

4

lk

– Renew camshaft seals ⇒ page 54 .

– Renew Hall sender seals ⇒ page 55 .

– Carefully drive in cap ⇒ Item 9 (page 50) using thrust piece of

fitting sleeves -3202- .

Further assembly is basically the reverse of the dismantling se‐

quence.

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.

Lightly coat parting surfaces of front and rear bearing caps with

sealant -AMV 188 001 02- before installing.

2. Repairing valve gear

61

lk

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

2.5

Removing and installing roller rocker fin‐

ger

Special tools and workshop equipment required

♦ Torque wrench (5…50 Nm) -V.A.G 1331-

Procedure

– Remove engine ⇒ page 2 .

– Remove camshafts with camshaft adjuster ⇒ page 56 .

– Mark allocation of roller rocker fingers and roller rocker finger

shafts in order to ensure correct reinstallation.

– Remove securing bolts -arrows-.

– Then, screw in M6 bolts into shaft holes and pull shafts out of

cylinder head.

– Remove roller rocker fingers.

Note

♦ O-rings for shafts must always be renewed.

♦ Oil bearing points of roller rocker fingers.

– When installing, tighten shaft securing bolts to 10 Nm.

Further assembly is basically the reverse of the dismantling se‐

quence.

2.6

Renewing valve stem seals

Removing ⇒ page 63 .

Installing ⇒ page 65 .

62

Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

Special tools and workshop

equipment required

♦ Spark plug socket and ex‐

tension -3122 B-

♦ Valve stem seal puller

-3364-

♦ Valve stem seal fitting tool

-3365-

♦ Adapter -T40012-

♦ Torque wrench (5…50 Nm)

-V.A.G 1331-

♦ Dismantling and assem‐

bling device for valve cot‐

ters -VAS 5161-

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2.6.1

Removing

– Remove engine ⇒ page 2 .

– Remove camshafts with camshaft adjuster ⇒ page 56 .

– Remove spark plugs using spark plug socket and extension

-3122B- .

– Swivel roller rocker fingers upwards and secure them with a

rubber strap.

2. Repairing valve gear

63

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Fit guide plate -VAS 5161/7- onto cylinder head as shown in

illustration.

– Secure guide plate using the knurled screws -VAS 5161/12- .

– Insert drift -VAS 5161/3- into guide plate and knock valve cot‐

ters loose using a plastic hammer.

– Screw toothed piece -VAS 5161/6- with -VAS 5161/5- into

guide plate -VAS 5161/7- .

– Insert assembly cartridge -VAS 5161/8- into guide plate -VAS

5161/7- .

lk

– Screw adapter -T40012- into spark plug thread, connect to

compressed air line with commercially available adapter and

apply constant pressure (at least 6 bar).

– Attach pressure fork -VAS 5161/2- to snap-in device -VAS

5161/6- and push assembly cartridge down.

– At the same time, turn knurled screw of assembly cartridge

clockwise until tips engage in valve cotters.

– Move knurled screw back and forth lightly to press apart valve

cotters and to capture them in the assembly cartridge.

– Release pressure fork and remove assembly cartridge from

guide plate.

– Remove guide plate from cylinder head.

Note

The compressed air line remains connected.

– Pull off valve stem seals using valve stem seal puller -3364- .

64

Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

2.6.2

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.

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– 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

2. Repairing valve gear

65

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

♦ Universal dial gauge bracket -VW 387-

♦ 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

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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.

66

Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

Note

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_lkdimension.

Minimum dimension:

Inlet valves (outer)

Inlet valve (centre)

Exhaust valves

mm

34.0

33.7

34.4

Measured distance -a- minus minimum dimension = maximum

permissible reworking dimension.

Example:

Measured distance

Minimum dimension

Max. permissible reworking dimension

34.4 mm

34.0 mm

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

2. Repairing valve gear

67

Cylinder head, valve gear -> 2 Repairing valve gear for Your Volkswagen Touareg SUV First Generation (2002-2010)

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