volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

ABOUT US
Reworking valve seats > < Valve gear

Golf Mk5

Assembly overview
   
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   Renew only with camshaft installed.
q   Lightly oil sealing lip of oil seal
q   Renewing → 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   Carefully clean sealing surfaces. They must be oil and grease free.
q   Before installing, coat with sealant -D 154 103 A1-.
q   When installing, fit vertically from above onto studs and dowel pins.
6 - Oil filler neck
q   Renew if damaged.
q   Dismantling and assembling → Chapter.
q   Removing and installing → Chapter.
7 - 10 Nm + 1/4 turn (90°) further
q   Renew.
q   Tighten from inside outwards.
8 - Cap
9 - 10 Nm
10 - Roller rocker finger
q   Check roller bearing for ease of movement.
q   Oil contact surface.
q   When installing, secure to supporting element using securing clip.
11 - Cotters
12 - Cap
13 - 20 Nm
14 - Lifting eye
15 - Non-return valve, 6 Nm
q   Do not overtighten; otherwise the valve may stick
q   Clean thread and insert with sealant -D 154 102 A1-
16 - Support element
q   Do not interchange.
q   With hydraulic valve clearance compensation.
q   Oil contact surface.
q   Before installing, check camshaft axial clearance → Fig..
17 - Valve spring plate
18 - Valve spring
q   To remove and install with cylinder head removed, use valve spring tool -3362-.
q   With cylinder head installed → Chapter.
19 - Valve stem seal
q   Renewing → Chapter.
20 - Repair valve stem
q   With collar.
21 - Valve guide
q   Check → Chapter.
22 - Oil pressure switch -F1-, 25 Nm
q   Check → Chapter.
q   If seal is leaking, nip open and renew.
23 - Valves
q   Do not rework, only lapping-in is permitted.
q   Valve dimensions → Fig..
24 - Cylinder head
q   Reworking valve seat → Chapter.
q   Reworking sealing surface → Fig..
25 - 20 Nm
26 - Coupling drive tensioning roller
q   Check → Chapter.
q   Tensioning toothed belts → Chapter.
27 - Plug
q   Install with sealant -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.
28 - Camshafts
q   Checking axial clearance → Fig..
q   Coat with oil before inserting (also axial bearing shoulder).
q   After installing, renew oil seal.
q   Renewing seals → Chapter.
29 - O-ring
q   Renew.

   
Lock both camshaft sprockets with camshaft lock -T10016-
–  Guide both locking pins through camshaft pulley locking pin holes to stop in camshaft housing fitting holes.
  Note
Both locking 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.
  N13-0369
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 permissible minimum dimension is maintained → Chapter.
  N15-0080
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.
  N15-0087
Valve dimensions
  Note
Valves must not be reworked. Only lapping-in is permitted.
  V15-0024
DimensionInlet valveExhaust valve
Ø amm29.526.0
Ø bmm5.9735.953
cmm100.9100.5
α∠°4545

   

Reworking valve seats > < Valve gear