Volkswagen Workshop Service and Repair Manuals

Note:

Cylinder heads with cracks between the valve seats may be used without reducing engine life, provided the cracks are small and not more than 0.5 mm wide.

• Bearing cap
• ◆ Installation position => Fig. 2
• ◆ Installation sequence
  , removing and installing camshaft
• 20 Nm

• Camshaft
• ◆ Checking axial clearance => Fig. 1
• ◆ Removing and installing
  => Page 15-31
• ◆ Checking radial clearance with plastigage
       Wear limit: 0.11 mm
• ◆ Run-out: max. 0.01 mm
• ◆ Identification and valve timing
  => Fig. 4
• Bucket tappet
• ◆ Do not interchange
• ◆ With hydraulic valve clearance compensation
• ◆ Checking => Page 15-33
• ◆ Store with cam lobe contact surface downwards
• ◆ Before installing check camshaft axial clearance => Fig. 1
• ◆ Oil contact surface
• Cotters

• Upper valve spring plate
• Valve spring
• ◆ 10.94▸only one-part valve spring
• ◆ Removing and installing:
  Cylinder head
  removed: with 2037
  installed: => Page 15-29 , renewing valve stem seals
• Inner valve spring
• ◆ ▸09.94
• ◆ Removing and installing:
  Cylinder head
  removed: with 2037
  installed: => Page 15-29 , renewing valve stem seals
• Valve stem seal
• ◆ Renewing=> Page 15-29
• Lower valve spring plate
• ◆ Remove and install with 3047A
• ◆ ▸09.94

• Valve guide
• ◆ Checking => Page 15-27
• ◆ Renewing => Page 15-27
• ◆ Service version with collar
• Oil seal
• ◆ To remove and install, remove bearing cap
• ◆ Removing and installing toothed belt
• Cylinder head
• ◆ See note
  => Page 15-16
• ◆ Reworking valve seats
  => Page 15-24
• Valves
• ◆ Valve dimensions => Fig. 3
• Swirl chamber
• ◆ Engine codes
  1Z, AAZ
• ◆ Renew if damaged
• ◆ Renewing => Page 15-35
• Lower sealing cone

→ Fig. 1     Checking camshaft axial clearance

Wear limit: max. 0.15 mm

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

→ Fig. 2     Fitting position of camshaft bearing caps

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

→ Fig. 3     Valve dimensions

Note:

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

Engine codes 1Z, AHU, AEY, AFN, AVG, ALE

Engine codes 1Y, AAZ

→ Fig.4     Camshaft identification, valve timing

Identification

• ◆ Cam base diameter: a = 38 mm ø
• ◆ Identification by stamped numbers and letters between inlet and exhaust cams:

Valve timing at 1 mm valve lift