Up to 11.94

Valve Train, Servicing

Valvetrain, disassembling and assembling (Up To 11.94)

Note:

Cylinder heads with cracks between the valve seats or between valve seat and 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.).

Valve Train, Servicing Up To 11.94:

1 Bearing cap
- Installation position See Fig. 2
2 20 Nm (15ft lb)
3 Camshaft
- Checking axial play See Fig. 1
- Measure radial clearance with Plastigage:
- Wear limit: 0.1 mm (0.004 in.)
- Runout (max): 0.01 mm (0.0004 in.)

CAUTION!
DO NOT turn camshaft when measuring radial clearance.

4 Woodruff key
- Check for tight fit
5 80 Nm (60ft lb)
- Use holding tool 3036 to loosen and tighten
6 Cylinder head
- Replacement cylinder heads with camshaft bearing shells: See Fig. 3
7 Seal
8 Cylinder head reworking dimension
- Minimum:
- a = 132.6 mm (5.220 in.)
9 Valves
- Do not reface by cutting or grinding, only hand- lapping is permitted
10 Valve guide
- Replacement valve guide with shoulder
11 Valve spring seat, lower
12 Valve stem oil seal
13 Valve springs
- Removing and installing with cylinder head removed: use 2037
14 Valve spring seat, upper
15 Valve keepers
16 Hydraulic valve lifters
- Do not interchange
- When removed keep camshaft contact surface pointing downward
- Before installing, check camshaft axial play: See Fig. 1
- Installing: oil camshaft contact surface

Fig. 1 Checking camshaft axial play




- Wear limit: 0.15 mm (0.0059 in.)
- Measure with valve lifters removed, and first and last bearing caps installed.

Fig. 2 Installation position of camshaft bearing cap




- Note center offset. Before installing camshaft, install bearing cap and determine installation position.

Fig. 3 Reconditioned cylinder heads with camshaft bearing shells




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

Standard camshaft:

- Dimension -a-: 26.00 mm (1.0236 in.)

Undersize camshaft:

- Dimension -a-: 25.75 mm (1.0138 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 grind valves. Only lapping is permitted.