Volkswagen Workshop Service and Repair Manuals

Assembly overview

1 -	20 Nm + 1/4 turn (90°) further

q

Renew.

q	Use camshaft lock -T10016- to loosen and tighten → Fig..

2 -	Camshaft pulley

q	Note position when installing toothed belt → Chapter.

3 -

Seal

q	Renew only with camshaft installed.

q	Lightly oil sealing lip.

q	Renew → Chapter.

4 -	Coupling drive toothed belt

q	Mark direction of rotation before removing.

q	Check for wear.

q	Do not kink.

q	Removing, installing and tensioning → Chapter.

5 -	Camshaft housing

q	Removing and installing → Chapter.

q	Remove sealant remnants.

q	Coat with AMV 188 003 A1 before fitting.

q	When installing, fit vertically from above onto studs and dowel pins.

6 -	10 Nm + 1/4 turn (90°) further

q

Renew.

q	Tighten from inside outwards.

7 -	Sealing cap/ignition transformer retainer

8 -

10 Nm

9 -	Roller rocker finger

q	Check roller bearing.

q	Oil contact surface.

q	When installing, secure to support element using securing clip.

10 -

Cotters

11 -	Sealing cover

12 -

20 Nm

13 -	Lifting eye

14 -	Non-return valve, 6 Nm

q	Do not overtighten, otherwise the valve can stick.

q	Clean thread. Insert with D 154 102 A1.

15 -	Support element

q	Check oil spray holes.

q	With hydraulic valve clearance compensation.

q	Do not interchange.

q	Before installing check camshaft axial clearance → Fig..

q	Oil contact surface.

16 -	Valve spring plate

17 -	Valve spring

q	Cylinder head removed: use valve spring tool -3362-.

q	Cylinder head installed → Chapter.

18 -	Valve stem seal

q	Renew → Chapter.

19 -	Valve guide

q	Checking → Chapter.

20 -	0.3...0.7 bar oil pressure switch -F1-, 25 Nm

q	Checking → Chapter.

q	If seal is leaking, nip open and renew.

21 -

Valves

q	Do not rework, only lapping-in is permitted.

q	Valve dimensions → Fig..

22 -	Cylinder head

q	Reworking valve seats → Chapter.

q	Reworking sealing surface → Fig..

23 -

20 Nm

24 -	Tensioning roller

q	Checking → Chapter.

q	Tensioning toothed belts → Chapter.

25 -	Plug, 45 Nm

q	Insert with D 154 102 A1.

q	Must not be screwed in too far.

q	Maximum permitted insertion depth from top of plug to camshaft housing surface = 2 mm.

26 -

Camshafts

q	Checking axial clearance → Fig..

q	Coat with oil before inserting (also axial bearing shoulder).

q	Identification → Fig..

q	After installing, renew oil seal.

q	Renewing seals → Chapter.

27 -

O-ring

q

Renew.

q	Moisten with oil before inserting.

Locking both camshaft pulleys with camshaft locking tool -T10016-. –  Guide both locking pins through camshaft pulley locking pin holes to stop in camshaft housing fitting holes.   Note Both locking pins are inserted correctly when the ends -D- align with line -A-. –  Slide retainer -B- to stop against inlet camshaft pulley -C-. –  When both camshaft pulleys are locked in the fitting holes, the camshaft pulleys can be loosened or tightened.

Reworking cylinder head sealing surface Cylinder head reworking dimension: a = at least 108.25 mm.

Checking camshaft axial clearance Special tools and workshop equipment required t  Universal dial gauge bracket -VW 387- t  Dial gauge Perform measurements with camshaft housing removed and sealing cover fitted. Wear limit: max. 0.40 mm.

Camshaft identification

Identification between cam pairs
Engine code	AUA, BBY, BKY	AUB, BBZ
	Cyl. 1 and 2	Cyl. 1 and 2
Inlet shaft -E-	“036AC”	“036AF”
Exhaust shaft -A-	“036AA”	“036AG”

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

Dimension		Inlet valve	Exhaust valve
Ø a	mm	29.5	26.0
Ø b	mm	5.973	5.953
c	mm	100.9	100.5
α	∠°	45	45