Valve: Service and Repair

1. 10 Nm (7 ft. lbs.)
2. Intake camshaft
^ Axial clearance, checking refer to Fig. 2
^ Removing and installing refer to Camshaft, Lifters and Push Rods; Camshaft, Engine.
^ Radial clearance, checking with Plastigage Wear limit: 0.1 mm
^ Run-out: max. 0.01 mm
3. Drive chain
^ Before removing, mark direction of engine rotation
4. Chain tensioner
5. Seal
^ Rubber/metal seal
^ Replace
6. Seal
7. Cylinder head
^ Reworking valve seats
^ Reworking sealing surface refer to Fig. 1
^ Sealing transition points refer to Fig. 4 and Fig. 5
8. Exhaust valves
^ Do not rework, only lapping-in is permitted
^ Valve dimensions refer to Fig. 3
9. Intake valves
^ Do not rework, only lapping-in is permitted
^ Valve dimensions refer to Fig. 3
10. Oil seal
^ Lightly oil sealing lip of oil seal
^ Replacing refer to Camshaft, Lifters and Push Rods; Camshaft Oil Seal.
11. Hood
^ for Camshaft Position sensor
^ When installing, note component relationships
12. Washer
^ Conical
13. 25 Nm (18 ft. lbs.)
14. Camshaft Position sensor G40
15. 10 Nm (7 ft. lbs.)
16. 100 Nm (74 ft. lbs.)
^ Use 3036 counter-hold to loosen and tighten
17. Camshaft sprocket
^ Note installed position: Small web of camshaft sprocket points outwards and No. 1 Cyl. TDC marking is visible
18. Oil seal
^ Replacing
19. Valve guide
^ Checking
^ Replacing
^ Servicing version has a collar
20. Valve stem seal
^ Replacing
21. Valve spring
^ Removing and installing: with cyl head removed and 3362 installed:
22. Upper valve spring plate
23. Valve keepers
24. Hydraulic lifter
^ Do not interchange
^ With hydraulic valve clearance compensation
^ Checking refer to Camshaft, Lifters and Push Rods; Lifter, Valve.
^ Store with cam contact surfaces facing downwards
^ Before installing, check camshaft axial clearance refer to Fig. 2
^ Oil contact surfaces
25. intake camshaft bearing cap
^ Installation position and installation sequence
26. Double bearing cap
^ Lightly coat bearing cap contact surface with sealant: AMV 174 004 01
27. Exhaust cam bearing cap
^ Installed position and installation sequence
^ Lightly coat last (outer) bearing cap contact surface with sealant: AMV 174 004 01
28. Exhaust camshaft
^ Axial clearance, checking refer to Fig. 2
^ Removing and installing
^ Radial clearance, checking with plastigage: Wear limit: 0.1 mm
^ Run-out: 0.01 mm maximum





Fig. 1 Cylinder head sealing surface, reworking

Note: The dimension for reworking is measured through the holes for the cylinder head bolts
^ a = minimum 139.2 mm





Fig. 2 Camshaft axial clearance, checking
Special tools, testers, measuring instruments and auxiliary items required
^ VW 387 Universal dial gauge bracket
^ Dial gauge
- Check with hydraulic lifters and chain removed and No. 2 and 4 bearing caps fitted. Wear limit: max. 0.2 mm








Fig. 3 Valve dimensions

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

WARNING: Use extreme care when disposing of sodium filled valves. They must first be cut through the center of the stem using a sharp hacksaw. When doing this, the valves, tools, hands etc. must be completely dry. Valves prepared this way can then be thrown in multiples into a bucket of water a maximum of ten at a time. After tossing the sawn valve pieces into the bucket, step back quickly because a violent chemical reaction will result as the sodium reacts with the water. After they have been neutralized by this treatment, the valves can be disposed of with normal metal scrap.





Fig. 4 Sealing transition points between double bearing cap and cylinder head
- Carefully apply a thin coat of sealant "D 454 300 A2" to both edges of sealing surfaces between double bearing cap and cyl. head -arrows- using a small screwdriver.





Fig. 5 Sealing transition points between camshaft adjuster and cylinder head
- Carefully apply a thin coat of sealant "D 454 300 A2" to both edges of sealing surfaces between camshaft adjuster and cyl. head -arrows- using a small screwdriver.