Valve Gear (Cylinder Banks 1 and 2), Servicing
Valve gear (cylinder banks 1 and 2), servicing
Note:
^ Cylinder bank 1 is located on the right-hand side when looking toward the front.
^ Cylinder bank 2 is located on left-hand side when looking toward the front.
^ All bearing and running surfaces must be oiled before assembling.
1. 5 Nm + 1/4 turn (45°) further
2. Intake camshaft bearing cap
^ Lightly coat facing contact surfaces of bearing cap with G 052 723 A2 grease before installing - A:
^ Cylinder bank 1: Bearing cap 7
^ Cylinder bank 2: Bearing cap 27
^ Installation position:
^ Cylinder bank 1
^ Cylinder bank 2
^ Installation sequence, Refer to Camshaft, Engine, Service and Repair
3. Seal
^ If seal is leaking, replace complete
^ When installing control housing, lightly lubricate contact surfaces of seal
^ When replacing seals, do not spread too widely
^ Offset gaps by 120
4. Intake camshaft
^ Checking radial clearance with plastigage, Wear limit: 0.01 mm
^ Run-out: max. 0 01 mm
^ Checking axial clearance
^ Identification:
^ Cylinder bank 1. Fig 6
^ Cylinder bank 2 => -
^ Removing and installing, Refer to Camshaft,Engine, Service and Repair
5. Control housing
^ Lightly lubricate contact surfaces of oil seals before installing
^ Disassembling and assembling - Fig 8
^ Removing and installing, Refer to Camshaft,Engine, Service and Repair
6. 8 Nm
7. Camshaft roller chain
^ Mark direction of rotation before removing (installation position)
^ Installing, Adjusting valve timing, Refer to Intake/Exhaust Valve, Adjustments
8. Intake camshaft adjuster
^ Identification:
^ Cylinder bank 1: B1 and E7
^ Cylinder bank 2: B2 and E7
^ Rotate engine only when camshaft adjuster is installed
^ Installing, Adjusting valve timing, Refer to Intake/Exhaust Valve, Adjustments
9. 60 Nm - 1/4 turn (90°) further
^ Replace
^ Contact surface of sender wheel must be dry around bolt head when assembled
^ To remove and install, counter-hold with 32 mm open jaw wrench on camshaft.
5. Removing and installing camshafts
10. Exhaust camshaft adjuster
^ Identification:
^ Cylinder bank 1: B1 and AS
^ Cylinder bank 2: B2 and AS
^ Rotate engine only when camshaft adjuster is installed
^ Installing, Adjusting valve timing, Refer to Intake/Exhaust Valve, Adjustments
11. Cylinder head height
^ Minimum height: a = 139.9 mm
12. Valves
^ Do not rework; only lapping is permitted
^ Valve dimensions
13. Cylinder head
^ Cylinder bank 2
^ If replaced replace complete amount of engine coolant
^ See note, Refer to Intake/ Exhaust, Service and Repair
^ Check for distortion, Refer to Cylinder Head, Service and Repair, Overview / Cylinder Bank 1 (RH), or Overview / Cylinder Bank 2 (LH)
^ Removing and installing, Refer to Cylinder Head, Service and Repair, Overview / Cylinder Bank 1 (RH), or Overview / Cylinder Bank 2 (LH)
^ Reworking valve seats, Refer Valve Seat, Service and Repair
14. Support element
^ Before installing check camshaft axial clearance
^ Do not interchange
^ With hydraulic valve clearance compensation
15. Valve stem seal
^ Replacing, Refer to Seals and Gaskets, Engine, Valve Guide Seal, Service and Repair
16. Retaining clip
^ Check if seated securely
17. Roller rocker finger
^ Before installing check camshaft axial clearance
^ Do not interchange
^ Check roller for easy movement
^ Oil contact surface
^ Use securing clip to clip onto support element when installing
18. Valve spring
^ Note installation position
^ Removing and installing, Refer to Seals and Gaskets, Engine, Valve Guide Seal, Service and Repair
19. Valve spring plate
20. Valve coffers
21. Exhaust camshaft bearing cap
^ Lightly coat facing contact surface of bearing cap with G 052 723 A2 grease it:
^ Cylinder bank 1: Bearing cap 8
^ Cylinder bank 2: Bearing cap 28
^ Installation position:
^ Cylinder bank 1
^ Cylinder bank 2
^ Installation sequence, Refer to Camshaft, Engine, Service and Repair
22. Exhaust camshaft
^ Checking radial clearance with plastigage, Wear limit: 0.1 mm
^ Run-out: max. 0.01 mm
^ Checking axial clearance
^ Identification:
^ Cylinder bank 1, Refer to Fig 6
^ Cylinder bank 2, Refer to Fig 7
^ Removing and installing, Refer to Camshaft, Engine, Service and Repair
Fig. 1 Camshafts, checking axial clearance
Special tools and equipment
^ VW 387 Universal dial gauge bracket
^ Dial gauge
Test sequence
Perform measurements with support elements and roller rocker fingers removed.
Wear limit: max. 0.10 mm
Cylinder bank 1
Bearing cap 7 installed on intake camshaft
Bearing cap 8 installed on exhaust camshaft
Cylinder bank 2
Bearing cap 27 installed on intake camshaft
Bearing cap 28 installed on exhaust camshaft
Fig. 2 Lightly coat facing contact surfaces of bearing caps with grease G 052 723 A2 before installing
Cylinder bank 1
Bearing caps 7 and 8
Cylinder bank 2
Bearing caps 27 and 28
Fig. 3 Installation position of camshaft bearing caps for cylinder bank 1
Points of bearing caps (arrow -A-) of intake and exhaust camshaft bearing caps face outward.
Identification on bearing caps is legible when read from intake side.
Fig. 4 Installation position of camshaft bearing caps for cylinder
Points of bearing caps (arrow -A-) of intake and exhaust camshaft bearing caps face outward.
Identification on bearing caps is legible when read from intake side.
Fig. 5 Valve dimensions (cylinder banks 1 and 2)
Note: Valves must not be reworked. Only lapping is permitted.
Valve dimensions for intake valves
Valve dimensions for exhaust valves
Fig. 6 Camshaft identification (cylinder bank 1)
Identification between No. 2 cyl and No. 3 cyl cam pair of respective camshaft
Fig. 7 Camshaft identification (cylinder bank 2)
Identification between No. 6 cyl and No. 7 cyl cam pair of respective camshaft
Fig. 8 Disassembling and assembling control housing
Cylinder bank 1
1. Valve 1 for camshaft adjustment -N205
2. Camshaft adjustment valve 1 (exhaust) -N318
3. Guide rail: clipped onto control housing
4. Control housing
5. 8 Nm
Cylinder bank 2
1. Camshaft adjustment valve 2 (exhaust) -N319
2. Valve 2 for camshaft adjustment -N208
3. Guide rail: clipped onto control housing
4. Control housing
5. 8 Nm