Volkswagen Workshop Service and Repair Manuals

• 20 Nm + 1/4 turn (90 °) further
• ◆ Renew
• ◆ Use camshaft locking tool T 10016 to loosen and tighten , Fig.1
• Camshaft sprocket
• ◆ Note position when installing the toothed belt
  
• Oil seal
• ◆ Only replace with camshaft installed
• ◆ Lightly oil sealing lip of oil seal
• ◆ Renewing=> Page 15-34
• Coupling drive toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing and installing
  => Page 13-14

• Camshaft housing
• ◆ Removing and installing
  => Page 15-6
• ◆ Remove sealant remnants
• ◆ Coat with AMV 188 003 before fitting
• ◆ When installing fit vertically from above onto studs and dowel pins
• 10 Nm + 1/4 turn (90 °) further
• ◆ Renew
• ◆ Tighten from centre outwards
• Sealing cap/ignition transformer retainer
• 10 Nm
• Roller rocker finger
• ◆ Check roller bearing
• ◆ Oil contact surface
• ◆ Use securing clip to clip onto support element when installing

• Cotters
• Cap
• 20 Nm
• Lifting eye
• Non-return valve, 6 Nm
• ◆ Do not overtighten, otherwise the valve can stick
• ◆ Clean threads and insert with
  D 154 102 A1
• Support element
• ◆ Check oil spray drillings
• ◆ With hydraulic valve clearance compensation
• ◆ Do not interchange
• ◆ Before installing check camshaft axial clearance => Page 15-29 , Fig. 3
• ◆ Oil contact surface

• Upper valve spring plate
• Valve spring
• ◆ Removing and installing:
  Cylinder head
  removed: with valve spring compressor 3362
  installed: => Page 15-40 , Renewing valve stem seals
• Valve stem seal
• ◆ Renewing=> Page 15-40
• Service part - valve guide
• ◆ With collar
• Valve guide
• ◆ Checking => Page 15-37
• Valves
• ◆ Do not rework only grinding-in is permitted
• ◆ Valve dimensions => Fig. 5

• Cylinder head
• ◆ Reworking valve seats
  => Page 15-31
• ◆ Reworking sealing surface
  => Fig. 2
• 20 Nm
• Tensioner
• ◆ Checking => Page 13-26
• ◆ Tensioning toothed belts
  => Page 13-14
• Sealing plug, 45 Nm
• ◆ Insert with D 154 102 A1
• ◆ Must not be screwed in too far
• ◆ Maximum permitted insertion depth from top of plug to camshaft housing surface = 2 mm

• Camshafts
• ◆ Checking axial clearance => Fig. 3
• ◆ Coat with oil before inserting (also axle bearing shoulder)
• ◆ Identification and valve timing
  => Page 15-29 , Fig. 4
• ◆ After installing, replace seals
• ◆ Renewing seals=> Page 15-34
• O-ring
• ◆ Renew
• ◆ Coat with oil before inserting

→ Fig. 1     Locking both camshaft sprockets with camshaft locking tool T 10016

• ‒ Guide both locking pins through camshaft sprocket locking pin holes onto stop in camshaft housing fitting holes.

Note:

Both locking pins are inserted correctly when the ends -D- align with line -A-.

• ‒ Slide retainer -B- onto stop on inlet camshaft sprocket -C-.
• ‒ When both camshaft sprockets are locked in the fitting holes the camshaft pulleys can be loosened or tightened.

→ Fig. 2     Reworking cylinder head sealing surface

Cylinder head reworking dimension:
     a = At least 108.25 mm

→ Fig. 3     Checking camshaft axial clearance

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

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

Perform measurements with camshaft housing removed and sealing cover fitted.

Wear limit: max. 0.40 mm

→ Fig.4     Camshaft identification, valve timing

Valve timing at 1 mm valve lift

→ Fig. 5     Valve dimensions

Note:

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