Cylinder Head, Disassembling and Assembling

Cylinder Head, Disassembling And Assembling





Note:
Cylinder heads with cracks between the valve seats or between a valve seat and the spark plug threads can be used without decreasing the service life. Also cracks at the first few threads of the spark plug thread are permissible. Cracks may not be wider than 0.5 mm (0.020 in.).

1 - Bearing cap
^ Installation position - Fig. 2
^ Installation sequence - refer to Camshaft Removing and Installing

2 - 20 Nm (15 ft lb)

3 - Camshaft
^ Axial play, checking - Fig. 1
^ Removing and installing - refer to Camshaft Removing and Installing
^ Check radial clearance with Plastigage
^ Wear limit: 0.1 mm (0.004 in.)
^ Runout: max. 0.01 mm (0.0004 in.)
^ Identification and valve timing specifications - Fig. 5
^ Undersize camshaft for replacement cylinder head with camshaft bearing shells - Fig. 3

4 - Woodruff key
^ Check for tight fit

5 - 80 Nm (60 ft lb)
^ Use holding tool 3036 to loosen and tighten

6 - Cylinder head
^ Replacement cylinder heads with camshaft bearing shells - Fig. 3
^ See Note - above
^ Valve seats, refacing - refer to Valve Seat Refacing.

7 - Seal
^ Replacing - refer to Camshaft Seal, Removing and Installing

8 - Cylinder head refacing dimension
^ Minimum height -a- 132.6 mm (5.220 in.)

9 - Valves
^ DO NOT reface by cutting or grinding, only hand-lapping is permitted
^ Valve dimensions - Fig. 4

10 - Valve guide
^ Replacement valve guides supplied with shoulder
^ Checking - refer to Valve Guide Wear, Checking
^ Replacing - refer to Valve Guides, Removing and Replacing

11 - Valve spring seat, lower

12 - Valve seal
^ Replacing - refer to Valve Stem Seals, Replacing
^ Remove and install with 3047A

13 - Valve springs
^ Removing and installing with cylinder head removed: use valve spring compressor 2037

^ Removing and installing with cylinder head installed - refer to Valve Stem Seals, Replacing

14 - Valve spring seat, upper

15 - Valve keepers

16 - Hydraulic valve lifters
^ Do not interchange
^ Checking - refer to Hydraulic Valve Lifters, Checking
^ When removed, store with camshaft contact surface pointing downward
^ Before installing check camshaft axial play - Fig. 1
^ Installing: oil camshaft contact surface

Special tools, testers and auxiliary items
^ Dial indicator
^ Holder VW 387

Fig. 1 Checking camshaft axial play





^ Measure with valve lifters removed, and first and last bearing caps installed

^ Wear limit: max. 0.15 mm (0.0059 in.)

Fig. 2 Camshaft bearing cap installation position





Note that caps have offset bore.

Before installing camshaft, test fit bearing cap and determine proper installation position.

Fig. 3 Camshaft for reconditioned cylinder head with camshaft bearing shells





Reconditioned cylinder heads or replacement engines are sometimes supplied with camshaft bearing shells.

Standard camshaft:
^ Dimension -a- 26.00 mm (1.024 in.)
Undersize camshaft:
^ Dimension -a- = 25.75 mm (1.014 in.)
^ Marked with yellow paint dot on VW-Audi logo

Note:
Undersize camshafts are not supplied as replacement parts. For replacement, install standard dimension camshaft with appropriate bearing shells.

Fig. 4 Valve dimensions








Caution!
DO NOT recondition valves by cutting or grinding; only hand lapping is permitted.

Fig. 5 Camshaft identification and valve timing Identification





Identification
^ Cam lobe base circle -a- = 34 mm
^ Identification number and letter markings are stamped between intake and exhaust cam lobes for cylinders 1 and 3.




Markings




Valve timing at 1 mm valve lift