Volkswagen Workshop Service and Repair Manuals

Assembly overview

1 -	20 Nm + 1/4 turn (90°) further

q

Renew.

q	Use camshaft lock -T10016- to loosen and tighten → Fig..

2 -	Camshaft pulley

q	Note position when installing toothed belt → Chapter.

3 -

Seal

q	Lightly oil sealing lip of oil seal

q	Renew. → Chapter.

4 -	Coupling drive toothed belt

q	Mark direction of rotation before removing.

q	Check for wear.

q	Do not kink.

q	Removing, installing and tensioning → Chapter.

5 -	Camshaft housing

q	Removing and installing → Chapter

q	Remove sealant residue.

q	Coat with D 188,003 A1 before fitting.

q	When installing, fit vertically from above onto studs and dowel pins.

6 -	10 Nm + 1/4 turn (90°) further

q

Renew.

q	Tighten from inside outwards.

7 -	Cap/ignition ignition transformer

8 -

10 Nm

9 -	Roller rocker finger

q	Check roller bearing.

q	Oil contact surface.

q	When installing, secure to supporting element using securing clip.

10 -

Cotters

11 -

Cap

12 -

20 Nm

13 -	Lifting eye

14 -	Non-return valve, 6 Nm

q	Only fitted for engine codes AHW, AKQ and APE

q	Fit with D 154 102 A1

q	Do not overtighten. Valve may otherwise jam.

15 -	Support element

q	Do not interchange.

q	With hydraulic valve clearance compensation.

q	Before installing, check camshaft axial clearance → Fig..

q	Oil contact surface.

16 -	Valve spring plate

17 -	Valve spring

q	Removing and installing:

q	With cylinder head removed use valve spring compressor -3362-

q	With cylinder head installed → Chapter.

18 -	Valve stem seal

q	Renew. → Chapter.

19 -	Repair valve stem

Not available anymore as a replacement part in → Electronic parts catalogue (ETKA).

20 -	Valve guide

q	Checking → Chapter.

21 -

Valves

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

q	Valve dimensions → Fig.

22 -	Cylinder head

q	Reworking valve seat → Chapter.

q	Reworking sealing surface → Fig..

23 -

20 Nm

24 -	Tensioning roller

q	Checking → Chapter.

q	Tensioning toothed belts → Chapter.

25 -

Bracket

26 -	Plug, 45 Nm

q	Fit with D 154 102 A1

q	Must not be screwed in too far.

q	Maximum permitted insertion depth from top of plug to camshaft housing surface = 2 mm.

27 -

Camshafts

q	Checking axial clearance → Fig..

28 -

O-ring

q

Renew.

q	Moisten with oil before inserting.

Lock both camshaft sprockets with camshaft lock -T10016- –  Guide both positioning pins through camshaft pulley locking pin holes as far as stop in camshaft housing fitting holes.   Note Both positioning pins are inserted correctly when the ends -D- align with line -A-. –  Slide retainer -B- to stop against inlet camshaft pulley -C-. –  When both camshaft pulleys are locked in the fitting holes, the camshaft pulleys can be loosened or tightened.

Reworking cylinder head sealing surface Cylinder head reworking dimension: a = at least 108.25 mm.   Note When the sealing surface has been reworked, the valves must be set deeper by the same amount (valve seat inserts reworked) or valves will contact pistons. When doing this, ensure that the dimension is not less than the permissible minimum dimension → Chapter.

Checking camshaft axial clearance Special tools and workshop equipment required t  Universal dial gauge bracket -VW 387- t  Dial gauge Perform measurements with camshaft housing removed and cap fitted. Wear limit: max. 0.40 mm Valve timing at 1 mm valve lift

Inlet opens ATDC	19,1°
Inlet closes ABDC	15,1°
Exhaust opens BBDC	20,2°
Exhaust closes BTDC	15,3°

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

Dimension		Inlet valve	Exhaust valve
Ø a	mm	29,5	26,0
Ø b	mm	5,973	5,953
c	mm	100,9	100,5
α	∠°	45	45