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Reworking valve seats > < Valve gear

Polo Mk5

Assembly overview
   
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 of oil seal
q   Renewing → 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 residue.
q   Before installing, coat with sealant -D 188 003 A1-.
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 - Cap/ignition ignition transformer
8 - 10 Nm
9 - Roller rocker finger
q   Check roller bearing.
q   Oil contact surface.
q   When installing, secure to supporting element using securing clip.
10 - Cotters
11 - Cap
12 - 20 Nm
13 - Lifting eye
14 - Non-return valve, 6 Nm
q   Do not overtighten, otherwise the valve can stick.
q   Clean thread and insert with sealant -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   Renewing → Chapter.
19 - Valve guide
q   Check → Chapter.
20 - 0.3…0.7 bar oil pressure switch -F1-, 25 Nm
q   Check → 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 seat → Chapter.
q   Reworking sealing surface → Fig..
23 - 20 Nm
24 - Tensioning roller
q   Check → Chapter.
q   Tensioning toothed belts → Chapter.
25 - Plug, 45 Nm
q   Install with sealant -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   After installing, renew oil seal.
q   Renewing seals → Chapter.
27 - O-ring
q   Renew.
q   Moisten with oil before inserting.

   
Lock both camshaft sprockets with camshaft lock -T10016-
–  Guide both positioning pins through camshaft pulley locking pin holes as far as stop in camshaft housing fitting holes.
  Note
Both positioning 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.
  N13-0369
Reworking cylinder head sealing surface
Cylinder head reworking dimension: a = at least 108.25 mm
  N15-0080
Checking camshaft axial clearance
Special tools and workshop equipment required
  N15-0087
t  Universal dial gauge bracket -VW 387-
t  Dial gauge
Perform measurements with camshaft housing removed and cap fitted.
Wear limit: max. 0.40 mm
  W00-0037
Valve dimensions
  Note
Valves must not be reworked. Only lapping-in is permitted.
  V15-0024
DimensionInlet valveExhaust valve
Ø amm29.526.0
Ø bmm5.9735.953
cmm100.9100.5
α∠°4545

   

Reworking valve seats > < Valve gear