Page 3 of 58
15-39
4 -
Cylinder head
See note Page 15
-37
Checking valve guides Page 15
-86
Reworking valve seats Page 15
-88
Dowel sleeves for bearing caps must be
located in cylinder head. Seal joints Fig. 3
and Fig. 4
,
Page 15
-8
5 -
Valve guide
Checking Page 15
-86
6 -
Valve stem seal
Replacing Page 15
-77
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Page 4 of 58
15-40
7 -
Valve springs
Removing and installing Page 15
-77
8 -
Valve spring plate
9 -
Valve keepers
10 -
Hydraulic valve lifter
Checking Page 15
-74
Removing and installing Page 15
-77
Do not interchangeStore with cam contact surface downwardBefore installing check camshaft axial
clearance Page 15
-48
Oil contact surface
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Page 5 of 58
15-41
11 -
Intake camshaft
Check radial clearance with Plastigage
(hydraulic lifters not installed). Wear limit:
0.1 mm Run-out: no more than 0.035 mmChecking axial clearance Page 15
-48
Removing and installing camshafts
Page 15
-62
12 -
Bearing cap for intake camshaft
Must be located on dowel sleevesDowel sleeves must be located in cylinder
head. Note installation positionInstallation sequence Page 15
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Page 6 of 58
15-42
13 -
Double bearing cap
Must be located on dowel sleevesDowel sleeves must be located in cylinder
head Coat sealing surface lightly with AMV 188
001 02 before installation Page 15
-71
Seal connections between double bearing
cap and cylinder head Fig. 3
, Page
15
-8
14 -
Exhaust camshaft
Check radial clearance with Plastigage
(hydraulic lifters not installed). Wear limit:
0.1 mm Run-out: no more than 0.035 mmChecking axial clearance Page 15
-48
Removing and installing camshafts
Page 15
-62
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Page 8 of 58
15-44
19 -
Camshaft adjuster
With solenoid valve for camshaft
adjustment -N205- Checking Page 15
-92
Hold in position with retainer for chain
tensioner 3366 before removing Removing and installing Page 15
-62
Seal sides of joints between camshaft
adjuster and cylinder head Fig. 4
,
Page 15
-8
20 -
Metal/rubber gasket
Before installation coat sealing surface
lightly with AMV 188 001 02 Page 15
-67
21 -
Gasket
Always replace
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Page 9 of 58
15-45
22 -
Exhaust valve
With sodium fillingNote instructions on scrapping valves with
a sodium filling Page 15
-47
Do not rework, only lapping in is permittedValve dimensions Fig. 1
, Page 15
-
47
Checking valve guides Page 15
-86
Reworking valve seats Page 15
-88
23 -
Intake valve
Do not rework, only lapping in is permittedValve dimensions Fig. 1
, Page 15
-
47
Checking valve guides Page 15
-86
Reworking valve seats Page 15
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Page 12 of 58
15-48
Camshaft axial clearance, checking
Special tools and equipment
Universal dial indicator bracket VW 387Dial indicator
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Page 39 of 58
15-74
Hydraulic valve lifters, checking
Special tools and equipment
Feeler gauge
Wood or plastic wedge
Note:
Hydraulic valve lifters cannot be adjusted or
repaired.
Irregular valve noise during starting is normal.
Test sequence
- Start engine and let run until coolant
temperature has reached approx. 80 C.
- Increase engine speed to about 2500 rpm for 2
minutes (perform road test if necessary).
Note:
If the irregular valve noises stop but recur
repeatedly during short journeys, a new oil
retention valve must be fitted. Oil retention valve
location: In oil filter bracket -Item 6 -, Page
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