Disassembly and Assembly

Component Notes And Information

NOTE:
^ During service procedures, refer to the illustration above and the information below.
^ Cylinder heads which have cracks between the valve seats or between valve seat inserts and the spark plug thread can continue to be used without reducing service life, provided the cracks do not exceed a maximum width of 0.50 mm.

1 Bearing Cap
- Installed position : refer to Fig. 2 below
- Installation sequence, refer to procedures below
2 Cam Bearing Cap Nut
- Tighten to: 20 Nm (15 ft lb)
3 Camshafts
- Axial clearance checking, refer to Fig. 1 below
- Removing and installing, refer to procedures below.
- Checking radial clearance with Plastigage:
Wear limit: 0.10 mm
Run-out: max. 0.01 mm
- Identification and valve timing, refer to Fig. 4 below
4 Camshaft Sprocket
- Removing and installing, refer to procedures below
5 Sensor wheel
- For Camshaft Position sensor
- When installing, contact surfaces on timing chain and sensor wheel must be dry
- Removing and installing, refer to procedures below
6 Camshaft Sprocket Bolt
- Tighten to: 100 Nm (74 ft lb)
- To remove and install: counter-hold with 24 mm open end wrench on camshaft, refer to procedures below
- Oil bulkhead contact surface when installing
7 Cylinder head deck height
- Minimum: a = 139.5 mm
8 Cylinder head
- See NOTE at top of article.
- Re-working valve seats refer to Refinish. Service and Repair
9 Valves
- Do not rework, only lapping-in is permitted
- Valve dimensions, refer to Fig. 3 below
10 Valve guide
- Service version with collar
- Checking. Testing and Inspection
- Replacing refer to Replacement. Service and Repair
11 Valve stem seal
- Replacing, refer to Replacement. Service and Repair
12 Valve springs
- Removing and installing:
- Cylinder head removed: use 2037 valve spring compressor
- Cylinder head installed, refer to Replacement. Service and Repair
13 Valve spring plate
14 Valve keepers
15 Hydraulic lifter
- With hydraulic valve clearance compensation
- Do not interchange
- Store with cam contacting surface facing downwards
- Oil contacting surfaces checking. Testing and Inspection
- Before installing; check camshaft axial clearance: refer to Fig. 1 below

Procedures





Fig. 1 Camshaft Axial Clearance, Checking
Special tools, testers and auxiliary items
- VW 387 Universal dial gauge bracket
- Dial gauge

Test sequence
- Wear limit: maximum 0.15 mm
- Perform check with hydraulic lifters removed and with first and last bearing caps installed on the appropriate camshaft





Fig. 2 Camshaft Bearing Caps, Installed Position

NOTE: Bearing cap identification must be readable from the exhaust side of the cylinder head and the arrow pointing to vibration damper end.

Part 1 Of 2:

Fig. 3 Valve Dimensions

Part 2 Of 2:

NOTE: Valves may not be reworked. Only lapping-in is permitted.





Fig. 4 Camshaft Identification Valve Timing
- Item 1 = Camshaft for cylinders 1, 3 and 5
- Item 2 = Camshaft for cylinders 2, 4 and 6

Identification





- Cam base diameter: a = 34 mm
- Identification by numbers and letters stamped on camshaft





Valve timing table (at 1 mm valve lift)