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 small and not more than 0.5 mm wide.
^ Do not rework valve seats. Only lapping-in of valves is permitted.

Valve gear, assembly overview:

1 - 20 Nm plus 1/4 turn (90°)
^ Replace
^ Observe sequence when loosening and tightening

2 - Rocker shaft
^ Do not interchange

3 - Cylinder head bolt
^ Observe sequence when loosening and tightening

4 - Washer
^ For cylinder head bolts
^ Fit into cylinder head before installing bearing caps

5 - 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
^ Before removing remove camshaft bearing shells

6 - Keepers
7 - Valve spring plate
8 - Exterior valve spring
9 - Interior valve spring
10 - Valve stem seal
11 - Valve guide
^ If wear limit exceeded replace cylinder head

12 - Pump/injector unit
^ Valves for pump/injector units, cylinders 1 to 4 -N240- to -N243-

13 - Cylinder head

14 - Oil seal
^ Do not additionally oil or grease oil seal sealing lip
^ Remove oil residues of camshaft pin with a clean cloth before installing
^ Seal groove on camshaft taper when installing with commercially available sticky tape (e.g. Selotape)

15 - Valves
^ Replace valve when scoring can be seen at shaft and contact surfaces
^ Do not rework. Only lapping-in is permitted

16 - Bearing shell
^ Do not interchange used bearing shells (mark)
^ Ensure lugs seating correctly in bearing cap and cylinder head

17 - Camshaft
^ Check radial clearance with Plastigage(R)
- Wear limit: 0.11 mm
- Runout: maximum 0.04 mm

18 - Bearing cap
^ To install seal bearing cap contact surfaces 1 and 5 with AMV 174 004 01

19 - 8 Nm plus 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
Measure with hydraulic lifters removed and with first, third and last bearing caps fitted.

Wear limit: maximum 0.15 mm





Seal bearing caps 1 and 5 contact surfaces
- Apply a thin even coat of sealant AMV 174 004 01 onto surfaces - 1 -.

Note:
^ Observe that no sealant enters the grooves - arrows-.





Valve dimensions

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

Valve dimensions: