Volkswagen Workshop Service and Repair Manuals

Note:

Cylinder heads which have cracks between the valve seats or between a valve seat insert and the spark plug thread can continue to be used without reducing service life, provided that the cracks do not exceed a max. width of 0.5 mm or when no more than the first spark plug threads are cracked.

• Bearing cap
• ◆ With bearing cap 4 in the case of engines with no hydraulic bucket tappets
• ◆ Pay attention to centre offset of bore => Fig. 2
• ◆ Fit cap and determine position before installing camshaft
• ◆ Installation sequence: removing and installing camshaft

• 20 Nm
• Camshaft
• ◆ Checking axial clearance => Fig. 1
• ◆ Removing and installing => page 15-26
• ◆ Check radial clearance with Plastigage
  Wear limit: 0.1 mm
• ◆ Runout: max. 0.01 mm
• ◆ Identification and valve timing => Figs.3 and 4
• Woodruff key
• ◆ Ensure tight fit
• 80 Nm
• ◆ Counterhold with 3036 for loosening and tightening

• Bucket tappet
• ◆ Check axial clearance of camshaft before installing => Fig. 1
• ◆ Oil contact surfaces
• ◆ Do not interchange
• Hydraulic bucket tappet:
• ◆ Lay aside with contact surface facing downwards
• ◆ Checking => page15-30
• Bucket tappet with shim:
• ◆ Checking and adjusting valve clearance => page 15-36
• Upper valve spring retainer
• ◆ Note version => Fig. 6
• Upper valve spring
  Inner valve spring
• ◆ Removing and installing
  Cylinder head removed: with 2037
  Cylinder head in situ:
  renewing valve stem oil seals => page 15-31

• Valve stem oil seal
• ◆ Renewing => page 15-31
• Lower valve spring retainer
• ◆ Remove and install with 3047 A
• Valve guide
• ◆ Checking
• ◆ Renewing => page 15-33
• Valves
• ◆ Valve dimensions =>Fig.5
• ◆ Note version =>Fig. 6
• ◆ Only grind in; do not rework
• ◆ Checking and adjusting valve clearance
  ( not hydraulic bucket tappets)
• Plug
• ◆ Renew
• Oil stop
• ◆ Hydraulic bucket tappets only (4 bearing caps)

• Oil seal
• ◆ Lightly lubricate sealing lip and outer edge
• ◆ Renewing
• Cylinder head
• ◆ Exchange cylinder heads with camshaft bearing shells => Fig. 7
• ◆ Reworking valve seats => page15-23
• ◆ Reworking dimension a = 132.6 mm (min. height)
• ◆ Cracked cylinder head => note onpage 15-8
• ◆ 1.6 l engine "big valve" cylinder head can be identified by casting number 1GS 103 373D

→ Fig.1     Checking axial clearance of camshaft

Wear limit: 0.15 mm

Measure with bucket tappets removed and first and last bearing caps installed.

→ Fig.2     Installation position of camshaft bearing caps

Note centre offset. Before installing camshaft, mount bearing caps and determine installation position.

→ Fig.3     Camshaft identification, valve timing

Identification with adjustable bucket tappets

• ◆ Cam base circle: a = dia. 38 mm

     1)     Not all camshafts are painted white

     2)     When performing repairs, camshaft with lug at 1st (-A-) and 3rd (-B-) cam and stamped-in code number "049J" (-C-) is to be replaced by a different version for engine code EX

     3)     Austria only (no identification)

Valve timing with 1 mm valve stroke

→ Fig.4     Camshaft identification, valve timing

Identification with hydraulic bucket tappets

• ◆ Cam base circle: a = dia. 34 mm (with adjustable bucket tappets: a = dia. 38 mm)
• ◆ Identification by way of stamped-in numbers and letters between inlet and exhaust cams

Valve timing with 1 mm valve stroke

→ Fig.5     Valve dimensions

Note:

Valves are not to be reworked. Only grinding is permitted.

     1)     Engine codes HM ä 01.97 only

(with hydraulic valve clearance compensation)

→ Fig.6     Valve types

05.81 ä installation of valves with 3 grooves

Distinguishing features

• ◆ Valve with 3 grooves on stem (previously one groove)
• ◆ Valve taper with 3 beads (previously one bead)
• ◆ Valve spring seat:

• Surface copper-plated or yellow chromation (previously steel grey) with approx. 1.5 mm inner chamfer -arrow A- (previously no chamfer) and broad outer chamfer -arrow B-

Note:

When performing repairs, 1 and 3-groove valves can be mixed. It is to be noted that the respective valves are only to be installed with the envisaged valve tapers and valve spring seats.

→ Fig.7     Exchange cylinder heads with camshaft bearing shells

Exchange cylinder heads/exchange engines are sometimes supplied with bearing shells for camshafts.

• ◆ Cylinder head with standard size camshaft
  a = 26.00 mm dia.
• ◆ Cylinder head with undersize camshaft
  a = 25.75 mm dia. and dot of yellow paint on VW-Audi emblem

Note:

Undersize camshafts are not supplied as replacements. For repairs, install a standard size camshaft with corresponding bearing shells.