Genuine 2005 Volkswagen Passat Cylinder Head

2005 Volkswagen Passat Cylinder Head Parts and Q&A

• Q: How should the cylinder head be prepared and reassembled after valve servicing on 2005 Volkswagen Passat?

  A: Whether the valve had been taken to an automotive repair shop to get the head serviced or not, make sure the head is clean before starting the reassembly. Even in the case when the head is sent out to be serviced with the valves, then the valves and other parts will already be fitted hence you can start reassembling the process. In case not dispatched to service, the valves are to be lapped then reassembled. To fit valves into their respective guides in the cylinder head, apply a small portion of fine grinding paste on the sealing surface of each valve and fit them in their respective guides. Install a valve lapping tool onto the end of a valve head and grind the valve head into its seat with a back and forth rotating motion, e.g. periodically raising and rotating the valve to redistribute the grinding paste. Once the lapping process has been accomplished on each set of valves clean the valves and seats of any lapping compound, label the valves and remove them remembering which guides the valves must be reinstalled. Starting at one end of the head lubricate and fit in the first valve and apply moly-base grease or clean engine oil to the stem of the valve. Install the spring seat and shims, should originally installed, in front of the valve seals. Install new seals on the valve guides, insertion of each seal in the guide is done lightly by tapping with the hand pressure so that the seal is completely in position and not pressed too deep or twisted when installing. The parts of the valve can be fitted in the following sequence: valves, valve spring seat, valve stem seals, valve spring shims, valve springs, retainers and keepers. Load up the springs using a valve spring compressor, insert the keepers in the groove carefully with a valve spring compressor and ensure that the compressor is released slowly to allow the keepers to be inserted. A little grease put on each keeper can be used to keep them in place in case of need, and one can make the keepers seat by tapping the tips of the valve stems with a plastic hammer. Perform the same on the other valves making sure that all parts are left in their appropriate places. Lastly, test the installed height of valve by a straight edge and a dial, or vernier caliper; in case the head was repaired out-of-shop, the installed height should be correct, but it is always worth checking. The height is measured between the top of each of the stem of the valves and the cover of the valve cover and when it is lower than the height is taken as an indication that the valve seats have been overworked and require replacement of these seats or replacement of the cylinder head.