Camshaft, Lifters and Push Rods: Service and Repair
Valvetrain Assembly Overview
• Cylinder heads with cracks between the valve seats can continue to be used without reducing service life, as long as the tears have a width of max. 0.5 mm.
• Do not re-grind valve seats, only hand-lapping the valves is permitted.
1 20 Nm + 90° (1/4 turn) additional turn
• Replace
• Observe sequence for loosening and tightening => [ Camshaft ] Service and Repair.
2 Rocker arm axle
• Do not interchange
3 Cylinder head bolt
• Observe sequence for loosening and tightening => [ Cylinder Head ] Cylinder Head.
• Before installing, insert shims => [ (Item 4) Washer ] into cylinder head
4 Washer
• For cylinder head bolts
• Insert into cylinder head before assembling bearing caps
5 Valve lifter
• Do not interchange
• With hydraulic valve clearance compensation
• Place on running surface when setting down
• Before installing, check axial play of camshafts => [ Camshaft, Checking Axial Play ]
• Lubricate contact surface
• Before removing, remove bearing caps for camshaft
6 Valve keepers
7 Valve spring plate
8 Outer valve spring
• Removing and installing:
• Cylinder head removed: With valve spring compressor (2037)
• Installed: => [ Valve Stem Seals, Replacing ] Service and Repair.
9 Inner valve spring
• Removing and installing:
• Cylinder head removed: With valve spring compressor (2037)
• Installed: => [ Valve Stem Seals, Replacing ] Service and Repair.
10 Valve stem seal
• Replacing => [ Valve Stem Seals, Replacing ] Service and Repair.
11 Valve guide
• Checking => [ Valve Guides, Checking ] Testing and Inspection.
• If the wear limit is exceeded, replace the cylinder head
12 Pump-injector unit
• Removing and installing => [ Pump Injector Unit ] Pump Injector Unit.
13 Cylinder head
• See notes => [ Valvetrain Assembly Overview ] Service and Repair.
14 Seal
• Do not additionally oil or grease sealing lip of oil seal
• Before installing, remove oil remains from camshaft journal with a clean cloth
• To install, tape over the groove on the taper of the camshaft with commercially available adhesive strip (e.g. scotch tape)
• Removing and installing => [ Camshaft Gasket ] Service and Repair.
15 Valves
• If there are signs of wear on the shaft, replace the valve seating surface
• Do not rework, only grinding is permitted
• Valve dimensions => [ Valve Dimensions ] [1][2]Specifications
16 Bearing shell
• Do not interchange used bearing shells (mark)
• Make sure retaining tabs are engaged properly in bearing caps and cylinder head
17 Camshaft
• Checking axial play => [ Camshaft, Checking Axial Play ]
• Removing and installing => [ Camshaft ] Service and Repair.
• Check radial clearance with Plastigage(R)
Wear limit: 0.11 mm run-out: max. 0.04 mm
18 Bearing cap
• Installation sequence => [ Camshaft ] Service and Repair.
• When installing, seal the separating surfaces on the bearing covers 1 and 5 with ( AMV 174 004 01)=> [ Bearing Caps 1 and 5, Sealing Separating Surfaces ]
19 8 Nm + 90° (1/4 turn) additional turn
• Replace
Camshaft, Checking Axial Play
Special tools, testers and auxiliary items required
• Dial gauge holder (VW 387)
• Dial gauge
Test Sequence
Measure with valve lifters removed and with first, third and last bearing cap installed.
Wear limit: max. 0.15 mm
Bearing Caps 1 and 5, Sealing Separating Surfaces
- Apply the sealant (AMV 174 004 01) thinly and evenly on surface - 1 -.
• Make sure that no sealant enters the grooves - arrows -.