Valve Gear, Assembly Overview
Valve gear, assembly overview
1 - Double bearing cap
^ Sealing contact surfaces
^ Lightly coat contact surfaces using sealant AMV 174 004 01 and note installed position and installation sequence
2 - 10 Nm
3 - Exhaust camshaft bearing cap
^ Observe installation position and installation sequence
^ Coat contact surface of last, outer bearing cap lightly with sealant AMV 174 004 01
4 - Exhaust camshaft
^ Check radial play with Plastigage,
- Wear limit: 0.1 mm
^ Run-out: max. 0.035 mm
^ Checking axial play
5 - Cap
^ Replace
^ To remove, remove bearing cap
^ With bearing cap installed, carefully drive in using retractor 3202 and plastic mallet.
6 - Intake camshaft bearing cap
^ Installation position and installation sequence
7 - Intake camshaft
^ Check radial play with Plastigage,
- Wear limit: 0.1 mm
^ Run-out: max. 0.035 mm
^ Checking axial play
8 - Camshaft adjuster
^ Secure using bracket for chain adjustment 3366 before removing
9 - Drive chain
^ Mark direction of rotation (installation position) before removing
10 - O-ring
^ Replace
11 - Camshaft Adjustment Valve 1 -N205- / Camshaft Adjustment Valve 2 -N208-
12 - 3 Nm
13 - Rubber/metal seal
14 - Seal
^ Replace
15 - Valve lifter
^ Do not interchange
^ With hydraulic valve clearance compensation
^ Place with running surface down when storing
^ Lubricate contact surface
^ Before installing, check axial play of camshafts
16 - Valve keepers
17 - Valve spring plate
18 - Valve spring
19 - Valve stem seal
20 - Valve guide
21 - Cylinder head
^ Resurfacing sealing surfaces
^ Sealing contact surfaces
22 - Valves
^ Do not rework, only lapping is permitted
^ Valve dimensions
^ Exhaust valves with sodium filling: Observe note for disposal
23 - Oil seal
24 - Hood
^ For Hall sender
^ Observe installed location
25 - Washer
^ Conical
26 - 25 Nm
27 - Camshaft Position (CMP) sensor -G40- / Camshaft Position (CMP) sensor 2 -G163-
28 - Guide sleeve
^ Ensure seated tightly
^ Replace if damaged
Cylinder head sealing surface, resurfacing
Resurfacing measurement is made via holes for cylinder head bolts.
- Dimension - 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: 0.2 mm
Valve dimensions
Note: Valves must not be reworked. Only lapping is permitted.
Note: Dispose of sodium-filled exhaust valves only after they have been treated.
CAUTION! To prevent eye damage and skin abrasion, wear protective glasses and clothing!
- Cut valves at middle of shaft using a metal saw. Do not let valves come into contact with water during this process.
- Throw no more than 10 cut valves at a time into a bucket filled with water and then step away swiftly!
Note: A sudden chemical reaction occurs, during which the sodium filling burns. The treated parts may then be discarded through conventional disposal channels.
Sealing contact surfaces of bearing cap/cylinder head
Special tools, testers and auxiliary items required
^ Sealant D 454 300 A2.
- Using a small screwdriver, carefully apply a thin layer of sealant D 454 300 A2 to both edges of sealing surfaces between bearing cap and cylinder head - arrows -.