Assembly overview

• 1 20 Nm + ¹/4 turn further (90°)
  • Renew
  • Use camshaft lock - T10016- to loosen and tighten ⇒ 2.1 Assembly overview.
• 2 Camshaft sprocket
  • Note position when installing toothed belt ⇒ 1.3 Removing, installing and tensioning toothed belt.
• 3 Sealing ring
  • Renew only with camshaft installed.
  • Lightly oil sealing lip of oil seal
  • Renewing ⇒ 2.3 Renewing camshaft oil seals
• 4 Coupling drive toothed belt
  • Mark direction of rotation before removing
  • Check for wear
  • Do not kink
  • Removing, installing and tensioning ⇒ 1.3 Removing, installing and tensioning toothed belt.
• 5 Camshaft case
  • Removing and installing ⇒ 1.5 Removing and installing camshaft housing
  • Remove sealant residue.
  • Coat with D 154 103 A1 before fitting
  • When installing, fit vertically from above onto studs and dowel pins.
• 6 10 Nm + ¹/4 turn further (90°)
  • Renew
  • Tighten from inside outwards.
• 7 Cap/ignition ignition transformer
• 8 10 Nm
• 9 Roller rocker fingers
  • Check roller bearing.
  • Oil contact surface
  • When installing, secure to supporting element using securing clip.
• 10 Cotters
• 11 Sealing cover
• 12 20 Nm
• 13 Lifting eye
• 14 Non-return valve, 6 Nm
  • Do not overtighten, otherwise the valve can stick.
  • Clean thread. Insert with D 154 102 A1.
• 15 Support element
  • Check oil spray holes.
  • With hydraulic valve clearance compensation.
  • Do not interchange
  • Before installing, check camshaft axial clearance ⇒ 2.1 Assembly overview.
  • Oil contact surface
• 16 Valve spring plate
• 17 Valve springs
  • Cylinder head removed: use valve spring tool - 3362-.
  • Cylinder head installed: ⇒ 2.5 Renewing valve stem seals
• 18 Valve stem seal
  • Renewing ⇒ 2.5 Renewing valve stem seals
• 19 Valve guide
  • Checking ⇒ 2.4 Checking valve guides
• 20 0.3 … 0.7 bar oil pressure switch - F1-, 25 Nm
  • Checking ⇒ 1.5 Checking oil pressure and oil pressure switch
  • If seal is leaking, nip open and renew.
• 21 Valves
  • Do not rework; only lapping-in is permitted.
  • Valve dimensions ⇒ 2.1 Assembly overview
• 22 Cylinder head
  • Reworking valve seats ⇒ 2.2 Reworking valve seats.
  • Reworking sealing surface ⇒ 2.1 Assembly overview.
• 23 20 Nm
• 24 Tensioning pulley
  • Checking ⇒ 1.4 Checking semi-automatic toothed belt tensioner
  • Tensioning toothed belts ⇒ 1.3 Removing, installing and tensioning toothed belt.
• 25 Plug, 45 Nm
  • Insert with D 154 102 A1.
  • Must not be screwed in too far.
  • Maximum permitted insertion depth from top of plug to camshaft housing surface = 2 mm.
• 26 Camshafts
  • Checking axial clearance ⇒ 2.1 Assembly overview.

• Coat with oil before inserting (also axial bearing shoulder).
• After installing, renew oil seal.
• Renewing seals ⇒ 2.3 Renewing camshaft oil seals.

• 27 O-ring
  • Renew
  • Moisten with oil before inserting.

Locking both camshaft pulleys with camshaft locking tool - T10016-.

• Guide both locking pins through camshaft pulley locking pin holes to stop in camshaft housing fitting holes.

• Slide retainer -B- to stop against inlet camshaft pulley -C-.
• When both camshaft pulleys are locked in the fitting holes, the camshaft pulleys can be loosened or tightened.

Reworking cylinder head sealing surface

Cylinder head reworking dimension: a = at least 108.25 mm

Checking camshaft axial clearance

Special tools and workshop equipment required

• Universal dial gauge holder - VW 387-
• Dial gauge

Perform measurements with camshaft housing removed and cap fitted.

Wear limit: max. 0.40 mm

Valve dimensions