Camshaft, Lifters and Push Rods: Service and Repair

Valve train, servicing

Note: Cylinder heads with cracks between the valve seats may be used without reducing engine life, provided the cracks are small and not more than 0.5 mm wide.

1. Bearing cap
^ Installation position go to Fig 2
^ Installation sequence, Refer to Camshaft Engine, Service and Repair
2. 20 Nm (15 ft. lbs.)
3. Camshaft
^ Axial clearance, checking go to Fig. 1
^ Removing and installing, Refer to Camshaft Engine, Service and Repair
^ Checking radial clearance with plastigage Wear limit: 0 11 mm
^ Run-out: max. 0 01 mm
^ Identification and valve timing
4. Hydraulic lifter
^ Do not interchange
^ Checking, Refer to Lifter Valve, Testing and Inspection
^ Store with cam contact surface facing downward
^ Before installing, check camshaft axial clearance go to Fig.1
^ Oil contact surfaces
5. Keepers
6. Upper valve spring plate
7. Valve spring
^ Removing and installing: With cylinder head removed Use 2037 With cylinder head installed, Refer to Cylinder Head, Service and Repair
8. Valve stem seal
^ Replacing, Refer to Valve Guide Seal, Service and Repair
9. Valve guide
^ Checking, Refer to Valve Guide, Testing and Inspection
^ Replacing, Refer to Valve Guide, Service and Repair
^ Service version with collar
10. Oil seal
^ To remove and install, remove bearing cap
^ Toothed belt, Refer to Timing Belt, Service and Repair
11. Cylinder head
^ See note, Refer to Valve, Intake/Exhaust, Service and Repair
^ Valve seats, reworking, Refer to Valve Seat, Service and Repair
12. Valves
^ Valve dimensions





Fig. 1 Camshaft axial clearance, checking

Special tools and equipment
^ VW 387 Universal dial gauge bracket
^ Dial gauge

Note: Check with hydraulic lifters removed and with first and last bearing caps fitted.

^ Wear limit: max. 0.15 mm





Fig. 2 Camshaft bearing caps, installed position
Note offset. Before installing camshaft trial install the bearing caps and determine the correct position.





Fig. 3 Valve dimensions





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





Fig. 4 Camshaft identification, valve timing

Identification
^ Cam base diameter: a = 38 mm diameter





^ Camshaft is identified by stamped numbers and letters between intake and exhaust cams:





Valve timing at 1 mm valve lift