Volkswagen Workshop Service and Repair Manuals

• Plug, 25Nm
• O-ring
• ◆ Renew if damaged
• Central bolt for camshaft adjuster     40 Nm + 1/4 turn. (90 °) further
• ◆ Left-hand thread
• ◆ Removing and installing,
• ◆ Oil threads and bolt head contact surface before fitting
• Washer
• ◆ Renew
• Camshaft adjuster
• ◆ Must not be taken apart
• ◆ Removing and installing,
• ◆ Check camshaft adjustment

• Inlet camshaft oil seal
• ◆ Only replace with camshaft installed
• ◆ Lightly oil sealing lip of oil seal
• ◆ Renewing=> Page 15-81
• Coupling drive toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing and installing
  => Page 15-19
• Exhaust camshaft sprocket
• ◆ When installing note fixing arrangement
• ◆ Removing and installing,

• Exhaust camshaft oil seal
• ◆ Only replace with camshaft installed
• ◆ Lightly oil sealing lip of oil seal
• ◆ Renewing=> Page 15-81
• Camshaft adjustment valve (N205)
• ◆ Checking => Page 15-61
• 10 Nm
• 10 Nm + 1/4 turn (90 °) further
• ◆ Renew
• ◆ Tighten from centre outwards
• Camshaft housing
• ◆ Removing and installing
  => Page 15-31
• ◆ Remove sealant remnants
• ◆ Coat with AMV 188 003 before fitting
• ◆ When installing fit vertically from above onto studs and dowel pins

• Sealing cap/ignition transformer retainer
• Roller rocker finger
• ◆ Check roller bearing
• ◆ Oil contact surface
• ◆ Use securing clip to clip onto support element when installing
• Cotters
• Support element
• ◆ Do not interchange
• ◆ With hydraulic valve clearance compensation
• ◆ Before installing check camshaft axial clearance => Page 15-55 , Fig. 2
• ◆ Oil contact surface
• Upper valve spring plate

• Valve spring
• ◆ Removing and installing:
  Cylinder head
  removed: with 3362
  installed: => Page 15-89 , Renewing valve stem seals
• Valve stem seal
• ◆ Renewing=> Page 15-89
• Service part - valve guide
• ◆ With collar
• Valve guide
• ◆ Checking => Page 15-86
• ◆ Renewing => Page 15-86
• Valves
• ◆ Do not rework only grinding-in is permitted
• ◆ Valve dimensions => Fig. 4

• Cylinder head
• ◆ Reworking valve seats
  => Page 15-58
• ◆ Reworking sealing surface
  => Fig. 1
• 20 Nm
• Coupling drive tensioning roller
• ◆ Checking => Page 15-12
• ◆ Tensioning toothed belts
  => Page 15-19
• Retainer
• Oil strainer
• ◆ Clean if soiled
• ◆ Note installation position
• Cap

• Exhaust camshaft
• ◆ Checking axial clearance => Fig. 2
• ◆ Coat with oil before inserting (also axle bearing shoulder)
• ◆ Identification and valve timing
  => Page 15-56 , Fig. 3
• ◆ After installing, replace oil seal
• ◆ Renewing seals=> Page 15-81
• Inlet camshaft
• ◆ Checking axial clearance => Fig. 2
• ◆ Coat with oil before inserting (also axle bearing shoulder)
• ◆ Identification and valve timing
  => Page 15-56 , Fig. 3
• ◆ After installing, replace oil seal
• ◆ Renewing oil seal=> Page 15-81

• O-ring
• ◆ Renew
• ◆ Coat with oil before inserting
• 20 Nm + 1/4 turn (90 °) further
• ◆ Renew

→ Fig. 1     Reworking cylinder head sealing surface

Cylinder head reworking dimension:
     a = At least 108.25 mm

Note:

When the sealing surface has been reworked, the valves must be set deeper by the same amount (rework valve seat inserts), otherwise valves will contact pistons. Ensure when doing this that the permissible minimum dimension is maintained => Page 15-58 .

→ Fig. 2     Checking camshaft axial clearance

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

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

Perform measurements with camshaft housing removed and sealing cover fitted.

Wear limit: max. 0.40 mm

→ Fig.3     Camshaft identification, valve timing

Identification

Valve timing at 1 mm valve lift

→ Fig. 4     Valve dimensions

Note:

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