Volkswagen Workshop Service and Repair Manuals

Note:

Cylinder heads which have cracks between the valve seats or between valve seat inserts and the spark plug thread can be used further without reducing service life, provided the cracks do not exceed a maximum of 0.5 mm in width, or when no more than the first spark plug thread is cracked.

• Bearing cap
• ◆ Installation position => Fig. 2
• ◆ Installation sequence
  , removing and installing camshaft
• 20 Nm

• Camshaft
• ◆ Checking axial clearance => Fig. 1
• ◆ Removing and installing
  => Page 15-22
• ◆ Checking radial clearance with plastigage
  Wear limit: 0.1 mm
• ◆ Run-out: max. 0.01 mm
• ◆ Identification and valve timing
  => Fig. 5
• Woodruff key
• ◆ Ensure tight fit
• 80 Nm
• ◆ Counter-hold with 3036 to loosen and tighten
• Cylinder head
• ◆ Exchange cylinder head with camshaft bearing shells => Fig. 3
• ◆ See note
  => Page 15-9
• ◆ Reworking valve seats
  => Page 15-17

• Oil seal
• ◆ Renewing=> Page 15-20
• Cylinder head reworking dimension
• ◆ Minimum height: a = 132.6 mm
• Valves
• ◆ Do not rework only grinding-in is permitted
• ◆ Valve dimensions => Fig. 4
• Valve guide
• ◆ Checking => Page 15-25
• ◆ Renewing => Page 15-26
• ◆ Service version with collar
• Valve stem seal
• ◆ Renewing=> Page 15-27
• ◆ Remove and install with 3047A

• Valve springs
• ◆ Removing and installing:
  Cylinder head
  removed: with 2037
  installed: => Page 15-27 , renewing valve stem seals
• Upper valve spring plate
• Cotters
• Bucket tappet
• ◆ Do not interchange
• ◆ With hydraulic valve clearance compensation
• ◆ Checking => Page 15-24
• ◆ Store with cam contact surface downwards
• ◆ Before installing check camshaft axial clearance => Fig. 1
• ◆ Oil contact surface

Special tools, testers and auxiliary items

• ◆ Universal dial gauge bracket VW 387

• ◆ Dial gauge

→ Fig. 1     Checking camshaft axial clearance

Wear limit: max. 0.15 mm

Check with bucket tappets removed and with first and last bearing caps fitted.

→ Fig. 2     Fitting position of camshaft bearing caps

Note offset. Before installing camshaft fit bearing caps and determine fitting position.

→ Fig.3     Exchange cylinder heads with camshaft bearing shells

Exchange cylinder heads/exchange engines are in some cases supplied with camshaft bearing shells.

•      A -     Cylinder head with standard dimension camshaft
• a = 26.00 mm ø
•      B -     Cylinder head with undersize camshaft
• a = 25.75 mm ø and yellow coloured spot on VW-Audi emblem

Note:

Undersize camshafts will not be supplied as a replacement part. In cases of repair install standard camshaft with the corresponding bearing shells.

→ Fig. 4     Valve dimensions

Note:

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

→ Fig.5     Camshaft identification, valve timing

Identification

• ◆ Cam base diameter: a = 34 mm ø
• ◆ Identification by stamped numbers and letters between inlet and exhaust cams:

Valve timing at 1 mm valve lift