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.

• Bearing cap
• ◆ Installation position => Fig. 2
• ◆ Installation sequence
  , removing and installing camshaft
• ◆ Coat bearing cap 1 and 5 seating areas lightly with sealant D 454 300 A2
• 20 Nm

• Camshaft
• ◆ Checking axial clearance => Fig. 1
• ◆ Removing and installing
  => Page 15-27
• ◆ Checking radial clearance with plastigage
  Wear limit: 0.1 mm
• ◆ Run-out: max. 0.01 mm
• ◆ Identification and valve timing
  => Fig. 5
• Woodruff key
• ◆ Ensure tight fit
• 80 Nm
• ◆ Counter-hold with 3036 to loosen and tighten
• Plug
• ◆ Engine code: AAM, ABS, ADZ

• Bucket tappet
• ◆ Do not interchange
• ◆ With hydraulic valve clearance compensation
• ◆ Checking => Page 15-29
• ◆ Store with cam lobe contact surface downwards
• ◆ Before installing check camshaft axial clearance => Fig. 1
• ◆ Oil contact surface
• Cotters
• Upper valve spring plate
• Valve springs
• ◆ Vehicles 11.94 ▸
  only one valve spring
• ◆ Removing and installing:
  Cylinder head
  removed: with 2037
  installed: => Page 15-32 , renewing valve stem seals

• Valve stem seal
• ◆ Renewing=> Page 15-32
• Lower valve spring plate
• ◆ Remove and install with 3047A
• ◆ Vehicles ▸10.94 only
• Valve guide
• ◆ Checking => Page 15-30
• ◆ Renewing => Page 15-31
• ◆ Service version with collar
• Cylinder head
• ◆ Exchange cylinder head with camshaft bearing shells => Fig. 3
• ◆ See note
  => Page 15-9
• ◆ Reworking valve seats
  => Page 15-20

• Oil seal
• ◆ Renewing=> Page 15-23
• Reworking dimension
• ◆ Minimum height: a = 132.6 mm
• Valves
• ◆ Do not rework only grinding-in is permitted
• ◆ Valve dimensions => Fig. 4

→ 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     Exchange cylinder heads with camshaft bearing shells

Exchange cylinder heads/exchange engines are in some cases supplied with camshaft bearing shells.

•      A -     Cylinder head with standard dimension camshaft
• a = 26.00 mm ø
•      B -     Cylinder head with undersize camshaft
• a = 25.75 mm ø and yellow coloured spot on VW-Audi emblem

Note:

Undersize camshafts will not be supplied as a replacement part. In cases of repair install standard camshaft with the corresponding bearing shells.

→ Fig. 4     Valve dimensions

Note:

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

Engine code letters AAM, ABS ▸ 10.94

Engine code letters 2E and ADY ▸ 10.94

Engine code letters AAM, ADZ 11.94 ▸

Engine code ADY 11.94 ▸, AGG

→ Fig.5     Camshaft identification, valve timing

Identification

• ◆ Cam base diameter: a = 34 mm ø
• ◆ Identification by stamped numbers and letters between inlet and exhaust cams:

Valve timing at 1 mm valve lift