Volkswagen Workshop Service and Repair Manuals

Note:

Cylinder heads which have cracks between the valve seats or between valve seat inserts and the spark plug thread can be used further without reducing service life, provided the cracks do not exceed a maximum of 0.5 mm in width, or when no more than the first spark plug thread is cracked.

• Bearing cap
• ◆ Installation position => Fig. 2
• ◆ Installation sequence removing and installing camshaft.
• 20 Nm
• Camshaft
• ◆ Checking axial clearance => Fig. 1
• ◆ Removing and installing
  => Page 15-22.
• ◆ Checking radial clearance with plastigage.
  Wear limit: 0.1 mm.
• ◆ Run-out: max. 0.01 mm.
• ◆ Identification and valve timing
  => Fig. 5

• Woodruff key
• ◆ Ensure tight fit.
• 80 Nm
• ◆ Counter-hold with 3036 to loosen and tighten.
• Bucket tappet
• ◆ Do not interchange.
• ◆ With hydraulic valve clearance compensation.
• ◆ Store with cam contact surface downwards.
• ◆ Before installing check camshaft axial clearance => Fig. 1
• ◆ Oil contact surface.
• Upper valve spring plate
• Valve spring
• ◆ Removing and installing
  Cylinder head removed: with 2037
  Cylinder head installed:
  => Page 15-28 renewing valve stem seals.

• Valve steam seal
• ◆ Renewing => Page 15-28.
• Lower valve spring plate
• ◆ Remove and install with 3047A.
• Valve guide
• ◆ Checking => Page 15-26.
• ◆ Renewing => Page 15-27.
• ◆ Service version with collar.
• Valves
• ◆ Do not rework only grinding in is permitted.
• ◆ Valve dimensions => Fig. 4
• Sealing plug
• ◆ Renew.
• Oil return stop jet
• Oil seal
• ◆ Renewing => Page 15-20.

• Cylinder head
• ◆ Exchange cylinder head with camshaft bearing caps => Fig. 3
• ◆ Reworking valve seats
  => Page 15-17.
• ◆ See note => Page 15-28.
• Rework dimensions
• ◆ Minimum heigh: a
  Engine code:
  AFX (1.6 L) = 130.83
  AGY (1.4 L) = 132.60
• Cotters

→ Fig.1    Checking camshaft axial clearance

• ‒ Check with bucket tappets removed and with first and last bearing caps fitted.

• Wear limit: 0.15 mm.

→ Fig.2    Fitting position of camshaft bearing caps

• ‒ Note offset. Before installing camshaft fit bearing caps and determine fitting position.

→ Fig.3    Exchange cylinder heads with camshaft bearing shells

• ‒ Exchange cylinder heads/exchange engines are in some cases supplied with camshaft bearing shells.

• ● Cylinder head with standard dimension camshaft:
  a = 26.00 mm ø.
• ● Cylinder head with undersize camshaft:
  a = 25.75 mm øand yellow coloured spot on VW-Audi emblem.

Note:

Undersize camshafts will not be supplied as a replacement part. In cases of repair install camshaft with the corresponding bearing shells.

→ Fig.4    Valve dimensions

Note:

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

Engine code AFX

Engine code AGY

→ Fig.5    Camshaft identification and valve timing

Identification

• ‒ Cam base diameter: a = 34 mm ø.
• ‒ Identification by numbers and letters stamped between inlet and exhaust cams.

Valve timing at 1 mm valve lift