Valvetrain, Assembly Overview

Valvetrain, assembly overview





1- 10 Nm
2- Intake camshaft
^ Checking radial clearance using Plastigage(R), Wear limit: 0.1 mm
^ Run-out: max. 0.01 mm
3- Drive chain
^ Mark direction of rotation before removing
4- 10 Nm
5- O-ring
^ Replace
^ Only vehicles with engine code: AWP, AWW
6- Camshaft Adjustment Valve 1 N205
^ Only vehicles with engine code: AWP, AWW
7- 3 Nm
^ Only vehicles with engine code: AWP, AWW
8- Camshaft adjuster
^ Only vehicles with engine code: AWP, AWW
^ For vehicles with engine code AWD: Chain tensioner
9- Gasket
^ Rubber/metal seal
^ Replace
10- Cylinder head
11- Valves
^ Exhaust valves with sodium filling: Observe note for disposal
12- Seal
13- Hood
^ For Camshaft Position (CMP) sensor G40
^ Observe installed location
14- Washer
^ Conical
15- 25 Nm
16- Camshaft Position (CMP) sensor G40
17- 10 Nm
18- 65 Nm
19- Camshaft sprocket
^ Thin rib of camshaft gear points outward and cylinder 1 TDC marking is visible
^ Note position when installing toothed belt
20- Seal
21- Valve guide
22- Valve stem seal
23- Valve spring
24- Valve spring plate
25- Valve keepers
26- Valve lifter
^ Do not interchange
^ With hydraulic valve clearance compensation
27- Bearing cap for intake camshaft
28- Double bearing cap
^ Must be located on alignment sleeves
^ Lightly coat contact surface with Sealant AMV 174 004 01 and follow installation position and sequence
^ Seal contact surfaces of double bearing cap/cylinder head
29- Exhaust camshaft bearing cap
30- Exhaust camshaft
^ Radial clearance using Plastigage(R), Wear limit: 0.1 mm
^ Run-out: max. 0.01 mm





Refacing cylinder head sealing surface
Refacing measurement is made via holes for cylinder head bolts.

a = at least 139.2 mm





Camshaft, checking axial play

Special tools, testers and auxiliary items required
^ Dial gauge holder VW 387
^ Dial gauge

Measure with valve lifters removed, chain removed and bearing caps 2 and 4 installed.
Wear limit: max. 0.2 mm





Valve dimensions

Note: Valves must not be refaced. Only lapping is permitted.

Valve dimensions:

Note: Worn sodium-filled exhaust valves must not be scrapped without first being properly treated. The valves must be cut at the middle of the shaft using a metal saw. While doing this, do not come into contact with water. At the very most, throw 10 of the prepared valves into a bucket filled with water. Then, move quickly away, because a sudden chemical reaction will occur during which the sodium is burnt away. The treated parts may then be discarded through conventional disposal channels.





Double bearing cap contact surfaces, sealing
- Apply a small amount of Sealant AMV 174 004 01 to contact surfaces - arrows - on double bearing cap.





Chain tensioner or camshaft adjuster/cylinder head contact surfaces, sealing
- Apply a small amount of Sealant AMV 174 004 01 to chain tensioner/cylinder head or camshaft adjuster/cylinder head sealing surfaces - arrows -. (Part numbers are for reference only. Always check with your Parts Department for the latest part number information).