Volkswagen Workshop Service and Repair Manuals

Repairing valve gear   Note t  Cylinder heads which have cracks between the valve seats or between a valve seat insert and the spark plug thread can be used further without reducing service life, provided the cracks do not exceed a maximum of 0.3 mm in width, or when no more than the first 4 turns of the spark plug thread are cracked. t  When new bucket tappets have been installed the engine must not be started for about 30 minutes. (Otherwise valves will contact pistons.) Then turn crankshaft two full revolutions.

1 -

100 Nm

q	Use counterhold tool -3415- to loosen and tighten.

2 -	Camshaft toothed belt pulley

3 -

Seal

q	Renew → Chapter.

4 -	Woodruff key

q	Check for secure seating.

5 -

20 Nm

6 -	Bearing cap

q	Installation position → Fig..

q	Installation sequence → Chapter, removing and installing camshaft.

q	Lightly coat contact surface of bearing cap 1 with sealant -AMV 174 004 01-.

7 -

Camshaft

q	Checking axial clearance → Fig..

q	Removing and installing → Chapter.

q	Check radial clearance with plastigage, wear limit: 0.1 mm.

q	Runout: max. 0.05 mm.

8 -	Bucket tappet

q	Do not interchange.

q	With hydraulic valve clearance compensation.

q	Checking → Chapter.

q	Store with cam contact surface downwards.

q	Before installing check camshaft axial clearance → Fig..

q	Oil contact surface.

9 -

Cotters

10 -	Upper valve spring plate

11 -	Valve spring

q	Removing and installing: with cylinder head removed, use valve spring compressor -2037-; with cylinder head installed → Chapter

12 -	Valve stem seal

q	Renew → Chapter.

13 -	Valve guide

q	Checking → Chapter.

q	Renew → Chapter.

q	Service version with collar.

14 -	Cylinder head

q	Reworking sealing surface → Fig..

q	Reworking valve seats → Chapter.

15 -

Valves

q	Do not rework, only lapping-in is permitted.

q	Valve dimensions → Fig.

Reworking cylinder head sealing surface Cylinder head reworking dimension: a = at least 132.6 mm.   Note If sealing surface is reworked, valves must be set deeper by the same distance.

Checking camshaft axial clearance Special tools and workshop equipment required

t  Universal dial gauge bracket -VW 387- t  Dial gauge Check with bucket tappets removed and first and last bearing caps fitted. Wear limit: max. 0.15 mm.

Fitting position of camshaft bearing caps Note that bearing caps are not symmetrical. Before installing camshaft, fit bearing caps and determine installation positions.

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

Dimension		Inlet valve	Exhaust valve
Ø a	mm	39,5 ± 0,15	32,9 ± 0,15
Ø b	mm	6,98 ± 0,007	6,96 ± 0,007
c	mm	91,85	91,15
α	∠°	45	45