Valve Train, Servicing

Valve train, servicing

Notes:
^ Cylinder heads which have cracks between the valve seats or between valve seats inserts and the spark plug thread can be used further without reducing service life, provided the cracks do not exceed a maximum of O.3 mm in width, or when no more than the first four spark plug threads are cracked.
^ After installing new valve lifters the engine must not be started for approx. 30 minutes (otherwise valves will strike pistons), then turn crankshaft two rotations.





1-10 Nm
2-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
3-Drive chain
^ Before removing mark D.O.R. (installation position)
4-10 Nm
5-O ring
^ Replace
^ Only for engine codes: AWP, AWW
6-Camshaft adjustment valve (N205)
^ Only for engine codes: AWP, AWW
^ Check camshaft adjustment
7-3 Nm
^ Only for engine codes: AWP, AWW
8-Camshaft adjuster
^ Only for engine codes: AWP, AWW
^ For vehicles with engine code AWD: Chain tensioner
^ Secure with 3366 before removing
^ Check camshaft adjustment
9-Gasket
^ Rubber/metal seal
^ Replace
10-Cylinder head
^ Removing and installing
^ Refacing valve seats
^ Refacing sealing surface see Fig. 1
^ Sealing transition points see Fig. 4 and Fig. 5
11-Valves
^ Do not reface only grinding In Is permitted
^ Valve Dimensions see Fig. 3
^ Sodium filled exhaust valves: Observe disposal instructions
12-Oil seal
^ Replacing
13-Hood
^ For Hall sender
^ When installing note fixing arrangement
14-Washer
^ Conical
15-25 Nm
16-Hall sender (G40)
17-10 Nm
18-65 Nm
^ Use counterhold 3036 to loosen and tighten
19-Camshaft sprocket
^ Note installation position: The small web of the camshaft sprocket points outwards and the No. 1 Cyl. TDC marking is visible
^ Note position when installing toothed belt
20-Oil seal
^ Replacing
21-Valve guide
^ Checking
22-Valve stem seal
^ Replacing
23-Valve spring
^ Removing and installing: Cylinder head Removed: with 3362 Installing.
24-Upper valve spring plate
25-Cotters
26-Valve lifter
^ Do not interchange
^ With hydraulic valve clearance compensation
^ Checking
^ Store with cam contact surface downwards
^ Before installing check camshaft axial clearance see Fig. 2
^ Oil contact surface
27-Inlet camshaft bearing cap
^ Installation position and installation sequence.
28-Double bearing cap
^ Must be located on dowel sleeves
^ Lightly coat contact surfaces with sealant "AMV 1 74 004 01" and observe installation position and installation sequence
^ Seal transition points between double bearing cap and cylinder head see Fig. 4
29-Exhaust camshaft bearing cap
^ Installation position and installation sequence
30-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





Fig. 1 Refacing cylinder head sealing surface
The dimension for refacing is measured through the holes for the cylinder head bolts
a = minimum 139.2 mm





Fig. 2 Checking camshaft axial clearance
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
^ Universal dial gauge bracket VW 387
^ Dial gauge
Check with valve 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 refaced. 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 burn. After this treatment, the valves can be put in with the normal 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 chain tensioner/cylinder head as well as camshaft adjuster/cylinder head
- Carefully apply a thin coat of sealant "D 454 300 A2" to both edges of sealing surfaces between chain tensioner/cylinder head as well as camshaft adjuster/cylinder head-arrows-using a small screwdriver.