Camshaft, Lifters and Push Rods: Locations
Assembly overview
Note:
^ Cylinder heads with cracks between the valve seats, or between the valve seat and the spark plug threads, can continue to be used without reducing the service life, as long as the cracks have a width of max. 0.3 mm, or only the first 4 threads of the spark plug threads are cracked.
^ After installing new hydraulic valve lifters, do not start engine for about 30 minutes (otherwise valves will strike pistons). Next, turn crankshaft through 2 rotations.
1 - 10 Nm
2 - Intake camshaft
^ Checking axial play
^ Check radial play with Plastigage
- Wear limit: 0.1 mm
^ Runout: max. 0.035 mm
3 - Drive chain
^ Mark direction of rotation before removing (installation position)
4 - 10 Nm
5 - O-ring
^ Replace
6 - Valve 1 for camshaft adjustment N205
7 - 3 Nm
8 - Camshaft adjuster
9 - Seal
^ Rubber/metal seal
^ Replace
10 - Cylinder head
^ Resurfacing sealing surfaces
^ Sealing contact surfaces and
11 - Valves
^ Do not grind valves; only hand-lapping is permitted
^ Valve dimensions
12 - Oil seal
^ For intake camshaft
PTFE seal:
^ Do not oil sealing lip of seal
13 - Hood
^ For Camshaft Position (CMP) sensor.
^ Note position when installing
14 - Washer
^ Conical
15 - 25 Nm
16 - Camshaft Position (CMP) sensor/sensor 2 G40/G163
17 - 10 Nm
18 - 65 Nm
^ Use retainer 3036 to loosen and tighten
19 - Camshaft sprocket
^ Note installed position: Thin rib of camshaft gear points outward and TDC marking cylinder. 1 is visible
20 - Oil seal
^ For exhaust camshaft
PTFE seal:
^ Do not oil sealing lip of seal
21 - Valve guide
22 - Valve stem seal
23 - Valve spring
^ Removing and installing:
- Cylinder head removed: with valve spring compressor 3362
24 - Valve spring retainer
25 - Valve keepers
26 - Valve lifter
^ Do not interchange
^ With hydraulic valve clearance compensation
^ Store loose lifters with camshaft contact surfaces facing down.
^ Before installing, check axial play of camshafts
^ Lubricate contact surface.
27 - Intake camshaft bearing cap
28 - Double bearing cap
^ Coat contact surface lightly with sealant AMV 174 004 01
29 - Exhaust camshaft bearing cap
30 - Exhaust camshaft
^ Checking axial play
^ Check radial play with Plastigage
- Wear limit: 0.1 mm
^ Runout: max. 0.035 mm
Cylinder head - sealing surface, resurfacing
Resurfacing measurement is made via the holes for cylinder head bolts.
- Dimension - a - : at least 139.2 mm
Camshaft, checking axial play
Special tools, testers and auxiliary items required
^ Dial indicator holder VW 387
^ Dial indicator
Measure with valve lifters removed, chain removed and bearing caps 2 and 4 installed.
Wear limit: 0.2 mm
Valve dimensions
Note: Do not grind valves. Only hand-lapping is permitted.
Note:
^ 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.
^ It is not necessary to saw through the entire valve stem. The valve stem will break relatively easily after a shallow cut has been made.
^ The valves must not come into contact with water while being cut.
^ Drop no more than 10 of the prepared valves at a time into a bucket filled with cold water and move away quickly.
^ A brief chemical reaction will occur during which the sodium will be burnt away.
^ The treated parts may then be scrapped.
Seal contact surfaces of double bearing cap/cylinder head
- Using a small screwdriver, carefully apply a thin layer of sealant D 454 300 A2 to both edges of sealing surfaces between double bearing cap and cylinder head - arrows -.
Seal contact surfaces of camshaft adjuster/cylinder head
- Using a small screwdriver, carefully apply a thin layer of sealant D 454 300 A2 to both edges of sealing surfaces between camshaft adjuster and cylinder head - arrows -.