Camshaft, Lifters and Push Rods: Service and Repair

Valve gear, servicing

Note:
^ Cylinder heads which have cracks between the valve seats or between valve seat inserts and the spark plug thread can be used further without reducing service life, provided the cracks do not exceed a maximum of 0.3 mm in width, or when no more than the first four spark plug threads are cracked.
^ When new lifters have been installed the engine must not be started for about 30 minutes (otherwise valves will contact pistons). Also, first rotate the crankshaft two complete revolutions.

1- 100 Nm
^ Use counter support tool 3415 to loosen and tighten
2- Camshaft pulley
3- Seal
4- Woodruff key
^ Check if seated securely
5- 20 Nm
6- Bearing cap
^ Installation position, Refer to Fig 3.
7- Camshaft
^ Checking axial clearance, Refer to Fig. 2
^ Check radial clearance with Plastigage.
Wear limit: 0.1 mm
Run-out: max. 0.05 mm
8- Hydraulic lifter
^ Before installing check camshaft axial clearance, Refer to Fig 2
^ Oil contact surface
9- Keepers
10- Valve spring upper plate
11- Valve spring
12- Valve stem seal
13- Valve guide
14- Cylinder head
^ Reworking sealing surface, Refer to Fig. 1
15- Valves
^ Valve dimensions, Refer to Fig 4





Fig. 1 Reworking cylinder head sealing surface
Cylinder head reworking dimension: a = at least 132.6 mm

Note: When the sealing surface has been reworked, the valves must be set deeper by the same amount.





Fig. 2 Checking camshaft axial clearance
Special tools, testers, measuring instruments and auxiliary items required
^ Universal dial gauge bracket VW 387
^ Dial gauge
Check with hydraulic lifters removed and with first and last bearing caps installed.
Wear limit: max. 0.15 mm





Fig. 3 Installation position of camshaft bearing caps
Note offset. Before installing camshaft fit bearing caps and determine fitting position.





Fig. 4 Valve dimensions





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