Camshaft, Lifters and Push Rods: Locations
Valve gear, assembly overview
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 4 threads of the spark plug threads are cracked.
^ When new lifters have been installed the engine must not be started for about 30 minutes. (Valves will otherwise contact piston). Additionally, first turn the crankshaft two full turns.
1 - 10 Nm
2 - Intake camshaft
^ Check radial clearance with Plastigage.
^ Wear limit: 0.1 mm
^ Run-out: max. 0.035 mm
3 - Drive chain
^ Mark direction of rotation before removing (installed position)
4 - 10 Nm
5 - O-ring
^ Engines with camshaft timing adjustment only
^ Replace
6 - Valve 1 for camshaft adjustment -N205-
^ Engines with camshaft timing adjustment only
7 - 3 Nm
^ Engines with camshaft timing adjustment only
8 - Camshaft adjuster
^ Engines with camshaft timing adjustment only
^ Engines without camshaft timing adjustment chain tensioner installed
^ Secure with 3366 before removing
9 - Seal
^ Rubber metal gasket
^ Replace
10 - Cylinder head
11 - Valves
^ Do not rework. Only lapping-in is permitted
12 - Oil seal
^ For intake camshaft
^ Do not oil sealing lip of PTFE seal
13 - Hood
^ For camshaft position sensor
^ When installing note fixing arrangement
14 - Washer
^ Conical
15 - 25 Nm
16 - Camshaft Position (CMP) sensor -G40-
17 - 10 Nm
18 - 65 Nm
^ Use retainer 3036 to loosen and tighten
19 - Camshaft pulley
^ Note installed position: Narrow web of camshaft sprocket shows outward and TDC mark No. 1 cylinder is visible
20 - Oil seal
^ For exhaust camshaft
^ Replacing
^ Do not oil sealing lip of PTFE seal
21 - Valve guide
22 - Valve stem seal
23 - Valve spring
24 - Valve spring plate
25 - Keepers
26 - Hydraulic lifter
^ Do not interchange
^ With hydraulic valve clearance compensation
^ Store with cam contact surface downward
^ Before installing check camshaft axial clearance
^ Oil contact surfaces
27 - Bearing cap intake camshaft
28 - Double bearing cap
^ Must fit on dowel sleeves
^ Coat contact surface slightly with sealant D 454 300 A2 before installing
^ Seal transition points of double bearing cap-cylinder head
29 - Exhaust camshaft bearing cap
30 - Exhaust camshaft
^ Check radial clearance with Plastigage: Wear limit: 0.1 mm
^ Run-out: max. 0.035 mm
Reworking cylinder head sealing surface
The reworking dimension is measured through the holes for the cylinder head bolts.
- Dimension - a - = 139.2 mm min.
Checking camshaft axial clearance
Special tools, testers and auxiliary items required
^ Universal dial gauge bracket VW 387
^ Dial gauge
Perform measurement when hydraulic lifters and chain are removed and bearing caps 2 and 4 are installed.
Wear limit: max. 0.2 mm
Valve dimensions
Note:
^ Valves must not be reworked. Only lapping-in is permitted.
^ Worn exhaust valves with sodium filling must not be scrapped without observing the following: The valves must be cut in the shaft center with a metal cutting saw. When doing this they must not contact water. Afterwards, throw a maximum of ten of the prepared valves in a pail filled with water. Then step back as a sudden chemical reaction occurs which makes the sodium filling burn. The parts treated this way can then be disposed of as normal scrap.
Sealing transition points double bearing cap-cylinder head
- Seal both edges on contact surfaces of double bearing cap-cylinder head - arrows - by carefully applying a thin coat of sealant D 454 300 A2 with a small screwdriver.
Sealing chain tensioner-cylinder head or camshaft adjuster-cylinder head transition points
- Seal both edges on contact surfaces of chain tensioner-cylinder head or camshaft adjuster-cylinder head - arrows - by carefully applying a thin coat of sealant D 454 300 A2 with a small screwdriver.