Valve Gear, Servicing

Valve gear, servicing





1. Double bearing cap
- Lightly coat bearing cap contact surface with sealant AMV 1 74 004 01
2. 10 Nm
3. Exhaust camshaft bearing cap
- Installation position and installation sequence
- Lightly coat last (outer) bearing cap contact surface with sealant AMV 1 74 004 01
4. Exhaust camshaft
- Checking axial clearance see Fig. 2
- Removing and installing
- Checking radial clearance with plastigage:
- Wear limit: 0.1 mm
- Runout: max. 0.01 mm
5. Cap
- Always replace
- Take off bearing cap to remove
- With bearing cap installed drive in carefully using 3202 and synthetic head hammer
6. Inlet camshaft bearing cap
- Installation position
7. Inlet camshaft
- Checking axial clearance see Fig. 2
- Removing and installing
- Checking radial clearance with plastigage
- Wear limit: 0.1 mm
- Runout: max. 0.01 mm
8. Camshaft adjuster
- Secure with 3366 before removing
- Check camshaft adjustment
9. Drive chain
- Before removing mark direction of rotation (installation position)
10. 10 Nm
11. O-ring
- Always replace
12. Camshaft adjuster valve
- Check camshaft adjustment
13. Gasket
- Rubber/metal seal
- Always replace
14. Gasket
- Always replace
15. Valve lifter
- Do not interchange
- With hydraulic valve clearance compensation
- Checking
- Store with cam contact surface downward
- Before installing check camshaft axial clearance see Fig. 2
- Oil contact surface
16. Valve keepers
17. Upper valve spring plate
18. Valve spring
- Removing and installing: see, Replacing valve stem seals
19. Valve stem seal
- Replacing
20. Valve guide
- Checking
- Replacing
- Service version with collar
21. Cylinder head
- Reworking valve seats
- Reworking sealing surface see Fig. 1
22. Valves
- Do not rework only grinding-in is permitted
- Valve dimensions see Fig. 3
23. Oil seal
- Replacing
- Lightly oil sealing lip of oil seal (spring seals only)
- If PTFE (teflon) seal was used, it must be replaced only with another PTFE seal
- Install PTFE seals without oil or grease.
24. Hood
- For Camshaft Position sensor
- When installing note installation position
25. Washer
- Conical
26. 25 Nm
27. Camshaft - Position sensor
28. 10 Nm
29. Guide sleeve

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 valve lifters and chain removed and No. 2 and 4 bearing caps fitted.
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 they must be perfectly dry. The 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 bum. After treatment, the valves can be put in with the normal scrap.

Fig. 4 Removing and installing PTFE seals for camshafts





Instead of the spring seal -1-, a PTFE (teflon) seal -2- is used on some engines. The PTFE seal has a wider sealing lip.
If a PTFE seal was used, it must be replaced only with another PTFE seal. Install PTFE seals without oil or grease.