Volkswagen Workshop Service and Repair Manuals

Notes:

• ◆ Cylinder heads with cracks between valve seats may be further used without reducing engine life if the cracks are small, maximum 0.5 mm wide.
• ◆ All bearing and running surfaces must be oiled before assembling.

• 20 Nm + 1/4 turn (90 °) further
• ◆ Renew
• ◆ Note sequence when loosening and tightening
  , Removing and installing camshaft
• Injector rocker arm shaft

• Cylinder head bolt
• ◆ Renew
• ◆ Note sequence when loosening and tightening
  => Page 15-21, removing and installing cylinder head
• ◆ Before installing, set washers -item 4- in cylinder head
• Washer
• ◆ For cylinder head bolts
• Bucket tappet
• ◆ Do not interchange
• ◆ With hydraulic valve clearance compensation
• ◆ Store with cam lobe contact surface downwards
• ◆ Before installing check camshaft axial clearance => Fig. 1
• ◆ Oil contact surface
• ◆ Before removing, remove camshaft bearing caps

• Cotters
• Upper valve spring plate
• Valve spring
• ◆ Removing and installing:
  Cylinder head
  removed: with 2037
  installed: => Page 15-44, renewing valve stem seals
• Inner valve spring
• ◆ Removing and installing:
  Cylinder head
  removed: with 2037
  installed: => Page 15-44, renewing valve stem seals
• ◆ Set in cylinder head before fitting bearing caps
• Valve stem seal
• ◆ Renewing=> Page 15-44

• Valve guide
• ◆ Checking => Page 15-41
• ◆ Renewing => Page 15-42
• ◆ Service version with collar
• Unit injector
• ◆ Removing and installing

=> Repair group 23; Servicing diesel direct injection system; Removing and installing unit injectors

• Cylinder head
• ◆ See note
  => Page 15-29
• ◆ Reworking valve seats
  => Page 15-38

• Oil seal
• ◆ Do not additionally oil or grease the oil seal sealing lip
• ◆ Before installing, remove oil remains from crankshaft journal with a clean cloth
• ◆ To install, cover grove on camshaft taper (Sellotape)
• ◆ Removing and installing
  => Page 15-53
• Valves
• ◆ Valve dimensions => Fig. 3
• Bearing shell
• ◆ Do not interchange used bearing shells (mark)
• ◆ Ensure proper seating of retaining lugs in bearing caps and cylinder head

• Camshaft
• ◆ Checking axial clearance => Fig. 1
• ◆ Removing and installing
  => Page 15-47
• ◆ Checking radial clearance with plastigage
      Wear limit: 0.11 mm
• ◆ Run-out: max. 0.01 mm
• ◆ Identification and valve timing
  => Fig. 4
• Bearing cap
• ◆ Installation sequence
  => Page 15-47, removing and installing camshaft
• ◆ Bearing cap 4 is identified as bearing cap 5
• ◆ When installing, use AMV 17400401 to seal surfaces of bearing caps 1 and 4 which contact cylinder head
  => Fig. 2
• 8 Nm + 1/4 turn (90 °) further
• ◆ Renew

→ Fig. 1    Checking camshaft axial clearance

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ Universal dial gauge bracket VW 387
• ◆ Dial gauge

Check with bucket tappets removed and with bearing caps fitted.

Wear limit: max. 0.15 mm

→ Fig. 2    Seal contact surfaces of camshaft bearing caps 1 and 4 with AMV 17400401

Apply sealant AMV 17400401 thin and evenly on surfaces -1-.

Notes:

• ◆ Ensure that no sealant enters grooves -arrows-.
• ◆ Bearing cap 4 is identified as bearing cap 5.

→ Fig. 3    Valve dimensions

Note:

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

→ Fig.4    Camshaft identification, valve timing

Identification

• ◆ Cam base diameter: a = 52.8 mm ø
• ◆ Identification by stamped numbers and letters on outer surface of exhaust valve cam of cylinder 3:

Valve timing at 1 mm valve lift