Camshaft, Lifters and Push Rods: Service and Repair

Camshaft, Cylinder Head, Valves





1 - Bearing Caps
- note bore offset Fig. 7
- installation sequence, see installing camshaft, Service and Repair
2 - 20 Nm (14 ft lb)
3 - 45 Nm (33 ft lb)
4 - Outer valve springs
Inner valve springs
- install and remove with 2037
- dimensions, see below
5 - Valve stem seal
- always replace, Service and Repair
6 - Valve guide
- check for wear, Fig. 6
- replacing, Service and Repair
7 - Oil Seal
- removing/installing, Service and Repair
8 - Valves
- valves dimensions Fig. 2
- refacing intake valves Fig. 3
- adjusting valve clearance, Adjustments
9 - Cylinder head
- refacing valve seats Fig. 4
- calculating maximum refacing dimensions Fig. 5
10 - Valve spring seat
- remove and install with VW 3047
11 - Cam follower
- identify do not interchange oil contact surfaces
- checking hydraulic cam followers, Testing and Inspection
12 - Adjusting disc
- adjusting valve play with mechanical cam followers Adjustments
13 - Camshaft
- checking axial play Fig. 1
- measure radial play with plastiguage wear limit: 0.11 mm runout max. 0.01 mm
- removing/installing, Service and Repair

CAUTION: Coolant/antifreeze must not be reused when replacing engine, cylinder head, cylinder head gasket, radiator and heater core.

NOTE: Cylinder heads with cracks between the valve seats may be used again without decreasing the service life, if the crack is maximum 0.5 mm wide. When working on the cylinder head, eg. replacing and grinding valves, replacing camshaft, the valve adjustment must be checked and adjusted with the engine warm after approximately 1000 miles.

Fig. 1 Camshaft, Checking Axial Play:

^ Max. 0.15 mm

Measure with cam followers removed and caps 1 and 5 installed and torqued.

Fig. 2 Valve Dimensions:

Mechanical Lifter Engines
Intake Valve Exhaust Valve
a = 34.00 mm 31.00 mm
b = 7.97 mm 7.95 mm
c = 104.8 mm 104.6 mm
< = 45° 45°

Hydraulic Lifter Engines
Intake Valve Exhaust Valve
a = 34.00 mm 31.00 mm
b = 7.97 mm 7.95 mm
c = 95.00 mm 95.00 mm
< = 45° 45°

Fig. 3 Intake Valves, Refacing:

Valve margin d must not less then 0.5 mm

NOTE: Do not reface exhaust valves on a machine. Lap them in by hand only.

Valve Springs

NOTE: Valve springs differ between engines with mechanical valve lifters and engines with hydraulic valve lifters.

Spring dimensions, mechanical lifters
^ inner valve spring length = 33.9 mm
^ outer valve spring length = 40.2 mm
^ marking - none

Spring dimensions, mechanical lifters
^ inner valve spring length = 32.5 mm
^ outer valve spring length = 37.0 mm
^ marking - blue paint on one side

CAUTION: Replace valve springs (inner/outer) as pairs only.

Fig. 4 Valve Seats, Refacing:

Exhaust Valve Intake Valve
a = 33.2 mm 35.2 mm
b = 30.4 mm 32.8 mm
c = 2.4 mm .0 mm
d = 0.5-1.5 mm 0.5-1.5 mm
45° = valve seat angle
15° = correction angle

Fig. 5 Maximum Refacing Dimensions For Hydraulic Lifters:

- measure distance a between end of valve shaft and upper edge of cylinder head
- calculate refacing dimension using the measured distance a and subtract minimum dimension

Minimum dimension
Intake valve = 35.8 mm
Exhaust valve = 36.1 mm

NOTE: If the measured distance a is smaller than the minimum distance, replace the cylinder head because hydraulic valve lifter will not work.

Fig. 6 Valve Guides, Checking:

Check with new valves only. Valve stem end must be flush with valve guide end
^ Max play: 1.3 mm

Fig. 7 Installation Position, Camshaft And Camshaft Bearing Caps:

Note for offset. Before installing camshaft mount bearing cap and determine installation position.