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.

• Camshaft
• ◆ Checking axial clearance
  
• ◆ Removing and installing
  => Page 15-37
• ◆ Checking radial clearance with plastigage
       Wear limit: 0.1 mm
• ◆ Run-out: max. 0.05 mm
• ◆ Identification and valve timing
  => Page 15-28 , Fig. 2

• 6 Nm + 1/4turn (90 °) further
• ◆ Renew
• ◆ Note installation instructions and sequence when loosening and tightening => Page 15-37
• Cylinder head cover
• ◆ Reworking the sealing surface is not permitted
• ◆ With integrated camshaft bearings
• ◆ Removing and installing
  => Page 15-37
• ◆ Remove remnants of old sealant
• ◆ Coat with AMV 154 103 before fitting
• ◆ Install vertically from above with dowel pins in holes in cylinder head
• Oil seal
• ◆ Lightly oil sealing lip of oil seal
• ◆ Renew=> Page 15-34

• Roller rocker finger
• ◆ Check roller bearing
• ◆ Oil contact surface
• ◆ Use securing clip to clip onto support element when installing
• Support element
• ◆ Do not interchange
• ◆ With hydraulic valve clearance compensation
• ◆ Oil contact surface
• 20 Nm + 1/4 turn (90 °) further
• ◆ Renew
• Bracket/lifting eye
• Cylinder head
• ◆ Reworking of camshaft side sealing surface is not permitted
• ◆ Reworking valve seats
  => Page 15-31
• ◆ Reworking sealing surface, cylinder block side => Fig. 1

• Valves
• ◆ Do not rework only grinding-in is permitted
• ◆ Valve dimensions => Fig. 3
• Valve guide
• ◆ Checking => Page 15-43
• ◆ Repair valve guide has a collar
• Valve stem seal
• ◆ Renewing=> Page 15-44
• Valve spring
• ◆ Removing and installing:
  Cylinder head
  removed: with 2037
  installed: => Page 15-44 , renewing valve stem seals
• Upper valve spring plate
• Cotters

→ Fig. 1     Reworking cylinder head sealing surface, cylinder block side

Cylinder head reworking dimension:
     a = At least 135.6 mm

Checking camshaft axial clearance

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

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

• ‒ → Checking camshaft axial clearance

Check with support elements and cylinder head cover removed.

• ‒ Pull camshaft seal off with 3364. Pre-load camshaft at centre bearing -arrow- using thumb pressure and check axial clearance by moving camshaft to and fro.

Wear limit: max. 0.15 mm

→ Fig.2     Camshaft identification, valve timing

Valve timing at 1 mm valve lift

→ Fig. 3     Valve dimensions

Note:

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

Engine codes ALD and AUC

Engine codes AKK, AKP and AUD