Camshaft, Lifters and Push Rods: Locations

Valvetrain, assembly overview

Valvetrain, assembly overview:

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

2 - Rocker arm axle
^ Do not interchange

3 - Bearing cap
^ To install, seal joint surfaces of outer bearing cap with sealant AMV 176 501

4 - Valve lifter
^ Do not interchange
^ With hydraulic valve clearance compensation
^ Place on running surface when setting down
^ Before installing, check axial play of camshafts
^ Lubricate contact surface
^ Before removing, remove bearing caps for camshaft

5 - Valve keepers
6 - Valve spring plate
7 - Outer valve spring

8 - Inner valve spring

9 - Valve stem seal
^ Replace

10 - Diamond disc
^ Replace

11 - Sleeve
^ For linkage mounting components

12 - Cylinder head
13 - Valves

14 - Pump-injector Unit
15 - Washer
^ For cylinder head bolts
^ Insert into cylinder head before assembling bearing caps
^ Observe "Precautions"

16 - Bearing shell
^ Do not interchange used bearings (mark)
^ Make sure retaining tabs are engaged properly in bearing caps and cylinder head

17 - Camshaft
^ Checking radial clearance with Plastigage(R), Wear limit- 0.11 mm
^ Run-out: max. 0.01 mm

18 - Bearing shell
^ Do not interchange used bearings (mark)
^ Make sure retaining tabs are engaged properly in bearing caps and cylinder head

19 - Cylinder head bolt
^ Replace
^ Observe sequence for loosening and tightening

20 - 8 Nm plus an additional 1/4 turn (90°)
^ Replace





Camshaft, checking axial play

Special tools, testers and auxiliary items required
^ Dial gauge holder VW 387
^ Dial gauge

Test sequence
Measurement with valve lifters removed and bearing caps installed:

Cylinder bank 1 -.
^ Bearing caps 2, 4 and 6 installed

Cylinder bank 2:
^ Bearing caps 9, 11 and 13 installed

Wear limit: max. 0.15 mm





Seal joint surfaces of outer bearing caps

Special tools, testers and auxiliary items required
^ Sealant AMV 176 501

Work procedure
- Apply sealant AMV 176 501 thinly and evenly on surface - 1 -

Cylinder bank - 1 -.
^ Seal bearing caps 1 and 7 with sealant AMV 176 501

Cylinder bank -2-.
^ Seal bearing caps 8 and 14 with sealant AMV 176 501





Valve dimensions

Note:
^ Valves must not be refaced. Only lapping is permitted.

Valve dimensions:

Camshaft identification, valve timing

Identification
^ Base circle of valve cams- a = diameter 52.8 mm
^ Identification by numbers and letters stamped on face surface of camshaft drive side.





Valve timing at 1 mm valve lift

Valve timing at 1 mm valve lift: