Camshaft, Lifters and Push Rods: Service and Repair

Valve gear, assembly overview

Note: Cylinder heads with cracks between the valve seats may be used without reducing engine life, provided the cracks are short and not more than 0.5 mm wide.





1- 20 Nm plus an additional 1/4 turn (90°)
^ Replace
^ Note sequence when loosening and tightening
2- Rocker arm shaft
^ Do not interchange
3- Cylinder head bolt
^ Note sequence when loosening and tightening
4- Washer
^ For cylinder head bolts
^ Position in cylinder head before installing bearing caps.
5- Hydraulic lifter
^ Do not interchange
^ With hydraulic valve clearance compensation
^ Store with cam contact surface downward
6- Keepers
7- Valve spring plate
8- Outer valve spring
9- Inner valve spring
10- Valve stem seal
11- Valve guide
12- Unit injector
13- Cylinder head
14- Seal
^ Do not additionally oil or grease oil seal sealing lip
^ Before installing, remove oil remains from camshaft journals with a clean cloth
^ To install, tape over (e.g. with cellophane tape) groove in taper of camshaft
15- Valves
16- Bearing shell
^ Do not interchange used bearing shells (mark)
^ Ensure proper seating of retaining lugs in bearing caps and cylinder head
17- Camshaft
^ Check radial clearance with Plastigage(R), wear limit: 0.11 mm
^ Run-out: max. 0.01 mm
18- Bearing cap
^ To install, seal parting surfaces of bearing caps 1 and 5 with AMV 174 004 01
19- 8 Nm plus an additional 1/4 turn (90°)
^ Replace





Checking camshaft axial clearance

Special tools, testers and auxiliary items required
^ Universal dial gauge bracket VW 387
^ Dial gauge

Work sequence
Check with lifters removed and with first, third and last bearing caps installed.
Wear limit: max. 0.15 mm





Sealing parting surfaces of bearing caps 1 and 5
- Apply sealant AMV 74 04 1 thinly and evenly onto surfaces - 1 -.

Note: Ensure that no sealant gets into the grooves - arrows -.





Valve dimensions

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

Valve dimensions:

Camshaft identification, valve timing

Identification
^ Cam base diameter: a = 52.8 mm
^ Identification by stamped numbers and letters on face of No. 4 cylinder exhaust cam:





Valve timing at 1 mm valve lift