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 turns of the spark plug thread are cracked.

• 10 Nm
• 6 Nm + 1/4 turn (90 °) further
• Bearing cap
• ◆ Installation sequence
  , removing and installing camshaft
• ◆ Coat bearing cap 1 and 5 seating areas lightly with sealant AMV 174 004 01

• Camshaft
• ◆ Checking axial clearance => Fig. 2
• ◆ Removing and installing
  => Page 15-29
• ◆ Checking radial clearance with plastigage
       Wear limit: 0.1 mm
• ◆ Run-out: max. 0.01 mm
• ◆ Identification and valve timing
  ▸09.94 => Page 15-18 , Fig. 4
• Bucket tappet
• ◆ Do not interchange
• ◆ With hydraulic valve clearance compensation
• ◆ Checking => Page 15-28
• ◆ Store with cam lobe contact surface downwards
• ◆ Before installing check camshaft axial clearance => Fig. 2
• ◆ Oil contact surface
• Cotters

• Upper valve spring plate
• Valve spring(s)
• ◆ Engine code letters ABD, AEA, AEE, AEX, APQ: single spring
• ◆ Removing and installing:
  Cylinder head
  removed: with 2037
  installed: => Page 15-35 , renewing valve stem seals
• Service part - valve guide
• ◆ With collar
• Valve stem seal
• ◆ Renewing=> Page 15-35
• Valve guide
• ◆ Checking => Page 15-33
• ◆ Renewing => Page 15-33
• Oil seal
• ◆ Lightly oil sealing lip of oil seal
• ◆ Renewing=> Page 15-25

• Cylinder head
• ◆ Reworking valve seats
  => Page 15-21
• ◆ Reworking sealing surface
  => Fig. 1
• Valves
• ◆ Do not rework only grinding-in is permitted
• ◆ Valve dimensions => Fig. 5
• 20 Nm
• Bracket
• ◆ For H.T. cable guide
• Lifting eye

→ Fig. 1     Reworking cylinder head sealing surface

Cylinder head reworking dimension:
     a = At least 135.6 mm

Note:

When the sealing surface has been reworked, the valves must be set deeper by the same amount (rework valve seat inserts), otherwise valves will contact pistons. Ensure when doing this that the permissible minimum dimension is maintained => Page 15-21 .

→ Fig. 2     Checking camshaft axial clearance

Special tools, testers and auxiliary items

• ◆ Universal dial gauge bracket VW 387
• ◆ Dial gauge

Check with bucket tappets removed and No. 3 bearing cap fitted.

Wear limit: max. 0.15 mm

→ Fig.3     Camshaft identification, valve timing ▸09.94

Identification

Valve timing at 1 mm valve lift

→ Fig. 4     Camshaft identification, valve timing 10.94 ▸

Identification

Valve timing at 1 mm valve lift

→ Fig. 5     Valve dimensions

Note:

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

Engine code ABD

Engine code ABU

Engine code AEA, AEE, AEX, APQ