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Camshaft - check axial clearance > < Valve stem seals - replace|Installation

Polo Mk4

Camshaft mechanism - repair
Camshaft mechanism - repair
  Note
t  Cylinder heads with cracks between the valve seats or between a valve seat and the Spark plug -Q- thread can still be used without reducing the service life, provided that such cracks are small, maximum 0.5 mm wide or when only the first Spark plug -Q- threads have cracks.
t  All contact and working surfaces must be lubricated with oil before assembly works.
  WARNING
Always replace self-locking nuts and screws subject to angular torque
   
1 - Camshaft
q   Check axial clearance → Chapter.
q   Removal and installation → Chapter.
q   Measure radial clearance using Plastigage: - limit for wear: 0.00 in.
q   Runout: max. 0.00 in.
q   Code → Fig.
2 - 6 Nm + 90°
q   Replace after each removal.
q   Observe installation and sequence instructions when loosening and tightening → Chapter.
3 - Cylinder head cover
q   It may not be replaced separately, only together with the cylinder head.
q   Sealing surfaces cannot be ground.
q   With integrated camshaft bearings.
q   Cover and head form a pair; therefore, the pair engraving is on the exhaust manifold side, close to Hall Sensor -G40-.
q   Remove all sealant residues.
q   Apply Sealing compound for engines -AMV 188 001 02- or Sealing compound for engines -D 154 103 A1- before positioning.
q   For assembly, place in vertical position from top with guides in cylinder head holes.
q   Removal and installation → Chapter.
4 - Camshaft seal
q   Quickly lubricate with oil the sealing ring lip.
q   Replace → Chapter.
5 - Rocker arms
q   Check free operation of the roller.
q   Lubricate the contact surface with oil.
q   For installation, loosen the safety clamp on the support element.
q   Supplier „INA“ with „030“ engraving on the side near the spherical region.
q   Supplier „GTT“ with „S3011“ engraving on the side near the spherical region.
q   Do not mix, as in a single head only parts from the same supplier may be installed.
6 - Support element
q   Do not change the working position.
q   With hydraulic valve clearance compensation.
q   Lubricate the contact surface with oil.
q   Supplier „INA“ with„I“ engraving on the bottom of the support element.
q   Supplier „GTT“ with „GT“ engraving on the bottom of the support element.
q   Do not mix, as in a single head only parts from the same supplier may be installed.
7 - 25 Nm
8 - Lifting tackle/eyelet
q   Spare part numbers: Support -030 103 390 F- (pulley side) Support -030 103 390 G- (flywheel side).
9 - Engine cylinder head
q   The sealing surface on the camshaft side must not be ground.
q   The head and the cover form a pair; therefore, the engraving for the pair is on the exhaust manifold side, close to Hall sensor -G40-.
q   When replacing, check printed code on the cover and cylinder head, they must be the same.
q   Check warping → Fig.
q   After replacing, replace coolant.
q   Disassembly and assembly → Chapter.
q   Grind valve seat → Chapter.
q   Grind sealing surface on the cylinder block side → Fig.
10 - Valves
q   Do not grind, only seating is permitted.
q   Valve dimensions → Fig.
q   Remove with the Device -2036- and the Plate -VW 5541/3-.
11 - Valve guide
q   Check → Chapter.
12 - Valve stem oil seal
q   Replace → Chapter.
13 - Valve spring
q   Removal and installation with engine cylinder head removed using the Compression device -2037- → Chapter.
14 - Spring dish
15 - Keys

   
Grind sealing surface on the cylinder block side
Engine cylinder head grinding measurement: -a- = at least 135.6 mm
  Note
When grinding the surface, valve seats must be ground with the same measure; otherwise, the valves would hit the pistons. Observe the minimum elevation permitted.
  N15-0318

Camshaft - check axial clearance > < Valve stem seals - replace|Installation