Camshaft, Lifters and Push Rods: Service and Repair

Valve gear, repairing

Note: If cracks are small, and no more than 0.5 mm wide, cylinder heads with cracks between the valve seats or between the valve seat ring and the spark plug thread can continue to be used without a reduction in life.





1. Bearing cover
- Installation position
- Order of installation
2. 20 Nm
3. Camshafts
- Checking axial clearance
- Installing and removing
- Check radial clearance using Plastigage. Max. wear: 0.10 mm
- Runout: max. 0.01 mm
4. Camshaft sprocket
- Removing and installing
5. Pickup wheel
- For Hall generator (G40)
- Contact area at camshaft sprocket and pickup wheel must be dry during installation
- Removing and installing
6. 100 Nm
- Place against camshaft using fork wrench SW 24 for removal and installation
- Oil screw head contact area during installation
7. Cylinder head height
- Min. height: a = 139.5
8. Cylinder head
- Observe Note
- Finishing valve seats
9. Valves
- Do not finish, only grinding is allowable
- Valve measurements Refer to Specifications.
10. Valve guide
- Checking
- Replacing
- Repair guide with collar
11. Valve stem seal
- Replacing
12. Valve springs
- Removing and installing:
- With cylinder head removed: use 2037
- With cylinder head installed:
13. Valve spring retainer
14. Valve collets
15. Valve lifters
- Do not mix up
- With hydraulic valve clearance balancing
- Checking
- For storage, lay down with the running face facing down
- Prior to installation, check camshaft axial clearance Refer to Specifications.
- Oil running face

Fig. 1 Camshafts, checking axial clearance
Special tools, equipment, test and inspection devices; required accessories





- Universal gauge retainer VW 387
- Gauge

Test procedure
Max. wear: 0.15 mm
Measure with valve lifters removed and first and last bearing cover of each camshaft installed.

Fig. 2 Installation position camshaft bearing cover





The bearing cover markings (arrows) must point toward the oscillation damper side.

Fig. 3 Valve measurements








Note: Do not finish valves. Only grinding is allowable.