Volkswagen Workshop Service and Repair Manuals

Note:

Cylinder heads with cracks between valve seats or between a valve seat insert and spark plug thread can continue to be used without reducing service life when these are surface cracks with a maximum width of 5.0, or when only outer threads of the spark plug socket are damaged.

• Bearing cap
• ◆ Without bearing cap 4 with hydraulic tappets
• ◆ Watch bore offset =>fig.2
• ◆ For installation sequence see Camshaft installation
• 20 Nm
• Woodruff key
• ◆ Ensure tight fit

• 80 Nm
• Valve stem oil seal
• ◆ Renewing => page 15-30
• Lower spring seat
• ◆ Remove and install with 3047
• Valve guide
• ◆ Checking wear
• ◆ Renewing => page 15-29
• Injector insert, 20 Nm
• ◆ Coat thread with -D6-
• ◆ ▸7/83 short version
  8/83...7/84 as shown
  8/84 ▸ two part version
• ◆ Remove and install two-part version with 3135
• Oil seal
• ◆ Renew

• Cylinder head
• ◆ Exchange cylinder heads with camshaft bearing shells => fig.5
• ◆ Reworking valve seats
• ◆ Reworking dimension => fig.6
• Valves
• ◆ Grind in only, do not rework
• ◆ Valve dimensions => fig.8
• ◆ Checking and adjusting valve clearance
  Engine Code:
  DX and KT ▸7/85,
  JH ▸ 7/87, EG, JJ
• Sealing ring
• Air conection
• ◆ 8/83 ▸
• ◆ For air-shoulders injectors

• 10 Nm
• Sealing plug
• ◆ Renew
• Outer valve spring
  Inner valve spring
• ◆ Removal and installation:
• ‒ Cylinder head removed with 2037
• ‒ Cylinder head installed
• Upper valve spring seat
• ◆ Identification => fig.7
• Bucket tappets
• ◆ Check axial clearance of camshaft before installation
• ◆ Lubricate contact surfaces
• ◆ Do not interchange

•      -     Hydraulic tappets
• ◆ Place with working surface downwards
• ◆ Checking

• Shim
• ◆ Not with hydraulic tappets
• ◆ Checking and adjusting valve clearance
• Camshaft
• ◆ Checking axial clearance fig.1
• ◆ Removing and installing
  
• ◆ Camshaft identification
  => fig.3 and4
• ◆ Check radial clearance with Plastigage. Wear limit: 0.1 mm
• ◆ Run-out: max. 0.01 mm

→ Fig.1     Camshaft, checking axial clearance

Wear limit: 0.15 mm

Check clearance with bucket tappets removed and bearings caps 1 and 5 installed.

→ Fig.2     Position of camshaft bearing shells

Watch bore offset. Before installing camshaft, place bearing caps in position to determine correct installation position

→ Fig.3     Camshaft identification

For tappets with shim:

• ◆ Pitch a circle of cams a = 38 mm diameter.

Identification - Engine Code EG

• ◆ Up to Engine No. EG 186 191:
  Cast ring on first and third cams
  => Camshaft A -Arrow-.
• ◆ from Engine No. EG 186 192:
  Stamped letter -G- or -N- between the cams of No.1 cylinder
  => Camshaft B -Arrow-.

Identification - Engine Codes, DX and KT ▸ 7/85, JJ

• ◆ Stamped letter -G- or -N- between the cams of No. 1 cylinder
  => Camshaft B -Arrow-.

Identification - Engine Code JH ▸ 7/87

• ◆ Cast on third cam
  => Camshaft A - right hand arrow

→ Fig.4     Camshaft identification

For hydraulic tappets

• ◆ Pitch circle of cams a = 34 mm diameter
• ◆ Identification mark between cams

→ Fig.5     Replacement cylinder heads with camshaft bearing shells for the camshaft

In some cases replacement cylinder heads and replacement engines are suplied with bearing shells for the camshaft.

A - Cylinder head with normal-sized camshaft
     a = 26.00 mm diameter

B - Cylinder head with undersized camshaft
     b = 25.75 mm diameter and yellow paint spot on the VW-Audi emblem

Note:

The undersized camshaft is not supplied as a replacement part. When necessary, use normal camshaft with suitable bearing shells.

→ Fig.6     Cylinder head - reworking dimension

Minimum height: a = 132.6 mm

→ Fig.7     Valve versions

Engine Code EG:
     Single-groove valve (right)

Engine Codes DX, JH, JJ, KT, 2H:
     Three-groove valve (left)

Ensure that correct cotters and upper spring seats are installed.

Identification of upper spring seats for three-groove vale:

• ◆ wide chamfer at the inside -Arrow A-
• ◆ wide chamfer at the outside -Arrow B-

→ Fig.8     Valve dimensions