Valve Train, Servicing

Valve train, servicing

1. 10 Nm
. Intake camshaft
^ Checking axial clearance see Fig. 2
^ Removing and installing, Refer to Camshaft, Lifters and Push Rods.
^ Checking radial clearance with plastigage, Wear limit: 0.1 mm
^ Runout: max. 0.01 mm
3. Drive chain
^ Before removing mark direction of rotation (installation position)
4. Chain tensioner
5. Seal
^ Rubber/metal seal
^ Always replace
6. Seal
7. Cylinder head
^ Reworking valve seats, Refer to Valve Seat.
^ Reworking sealing surfaced see Fig. 1
^ Sealing transition points see Fig. 4 and Fig. 5
8. Exhaust valves
^ Do not rework; only lapping in is permitted
^ Valve dimensions see Fig. 3
9. Intake valves
^ Do not rework; only lapping in is permitted
^ Valve dimensions see Fig. 3
10. Oil seal
^ Lightly oil sealing lip of oil seal
^ Replacing
11. Hood
^ For Camshaft Position sensor
^ When installing note component arrangement
12. Washer
^ Conical
13. 25 Nm
14. Camshaft - Position sensor - G40, Refer to Powertrain Management.
15. 10 Nm
16. 65 Nm
^ Use counterhold tool 3036 to loosen and tighten
17. Camshaft - sprocket
^ Note installation position: The small web of the camshaft sprocket points outward and the No. 1 Cyl. TDC marking is visible
18. Oil seal
^ Replacing, Refer to Camshaft, Lifters and Push Rods.
19. Valve guide
^ Checking, Refer to Valve Guide.
^ Replacing, Refer to Valve Guide.
^ Service version with collar
20. Valve stem seal
^ Replacing, Refer to Valve Guide Seal.
21. Valve spring
^ Removing and installing: Cylinder head removed with 3362 installed, Refer to Valve Guide.
22. Upper valve spring plate
23. Valve keepers
24. Hydraulic lifter
^ Do not interchange
^ With hydraulic valve clearance compensation
^ Checking, Refer to Lifter, Valve.
^ Store with cam contact surface downward
^ Before installing check camshaft axial clearance see Fig. 2
^ Oil contact surface
25. Intake camshaft bearing cap
^ Installation position and installation sequence, Refer to Camshaft, Lifters and Push Rods.
26. Double bearing cap
^ Lightly coat bearing cap contact surface with sealant AMV 174 004 01
27. Exhaust camshaft bearing cap
^ Installation position and installation sequence, Refer to Camshaft, Lifters and Push Rods.
^ Lightly coat last (outer) bearing cap contact surface with sealant AMV 174 004 01
28. Exhaust camshaft
^ Checking axial clearance see Fig. 2
^ Removing and installing, Refer to Camshaft, Lifters and Push Rods.
^ Checking radial clearance with plastigage, Wear limit: 0.1 mm
^ Runout: max. 0.01 mm





Fig. 1 Reworking cylinder head sealing surface

The dimension for reworking is measured through the holes for the cylinder head bolts
a = minimum 139.2 mm





Fig. 2 Checking camshaft axial clearance

Special tools and equipment
^ VW 387 Universal dial gauge bracket
^ Dial gauge
Check with hydraulic lifters and chain removed and No. 2 and 4 bearing caps installed.
Wear limit: max. 0.2 mm





Fig. 3 Valve dimensions





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

Note: Care must be taken when disposing of old sodium filled valves. They must be cut through in the center of the stem with a hacksaw. When doing this, the valves must be perfectly dry. Valves prepared in this way can then be thrown into a bucket of water a maximum of ten at a time. When doing this step back quickly because a sudden chemical reaction causes the sodium filling to burn. After this treatment, the valves can be disposed with normal metal scrap.





Fig. 4 Sealing transition points between double bearing cap and cylinder head

- Carefully apply a thin coat of sealant D 454 300 A2 to both edges of sealing surfaces between double bearing cap and cylinder head (arrows) using a small screwdriver.





Fig. 5 Sealing transition points between camshaft adjuster and cylinder head

- Carefully apply a thin coat of sealant D 454 300 A2 to half-moon shaped surface and both edges of sealing surfaces between camshaft adjuster and cylinder head (arrows) using a small screwdriver.