Camshaft - assembly overview — VW

VW
Gol
2009
Saveiro
2010
Voyage
2009
Power unit
4 - Cyl. injection engine (1.6 l)
Edition
09.2015
Camshaft - assembly overview
Note
Cylinder heads with cracks between the valve seats or between a valve seat and
Spark plug
Q
threads can still be used without reducing the useful life, provided that such cracks are small, maximum 0,5 mm wide or when only the first
Spark plug
Q
threads have cracks.
Lubricate all supporting and sliding surfaces prior assembly.
With the cylinder head removed, use a
Plate
VW 5541/3
to fasten the cylinder head and valve support.
WARNING
Always replace self-locking nuts and screws subject to angular torque
Camshaft
Check axial clearance
Chapter
.
Removal and installation
Chapter
.
Check radial clearance with Plastigage, Wear limit of 0.1 mm.
Eccentricity: max. 0.05 mm.
Code
Fig.
6 Nm 90°
Replace after each removal.
Observe installation and sequence instructions when loosening and tightening
Chapter
.
Cylinder head cover
The thrust surface cannot be serviced with the engine cylinder head.
With integrated camshaft bearings.
Cover and head form a pair; therefore, the pair engraving is on the exhaust manifold side, close to
Hall Sensor
G40
.
Remove any residue of
Sealing compound for engines
AMV 188 001 02
or
Sealing compound for engines
D 154 103 A1
.
Apply
Sealant compound for engines
AMV 188 001 02
or
Sealant compound for engines
D 154 103 A1
before positioning.
For installation, place it vertically on the holes of the cylinder head with guide pins.
Removal and installation
Chapter
.
Camshaft seal
Seal with spring
Quickly lubricate with oil the sealing ring lip.
Seal without spring
The sealing ring lip does not require lubrication.
Replace
Chapter
.
Roller rockers
Check free operation of the roller.
Lubricate the surface of the roller bearing with oil.
For installation, loosen the safety clamp on the support element.
Supplier
“INA”
with
“030”
engraving on the side near the spherical region.
Supplier
“GTT”
with
“S3011”
engraving on the side near the spherical region.
Do not mix, as in a single head only parts from the same supplier may be installed.
Support element
Do not change the working position.
With valve clearance hydraulic offsetting.
Lubricate sliding surface.
Supplier
“INA”
with
“I”
engraving on the bottom of the support element.
Supplier
“GTT”
with
“GT”
engraving on the bottom of the support element.
Do not mix, as in a single head only parts from the same supplier may be installed.
25 Nm
Replace after each removal.
Lifting tackle/anchoring for engine
Numbers of spare parts:
Support
030 103 390 F
(pulley side)
Support
030 103 390 G
(flywheel side).
Engine cylinder head
The thrust surface cannot be serviced with the cover.
The head and the cover form a pair; therefore, the engraving for the pair is on the exhaust tube side, close to
Hall Sensor
G40
.
Grind valve seat
Chapter
.
Grind sealing surface on the engine block side
Fig.
Valves
Do not grind, may be seated only.
Valve dimensions
Fig.
Remove with the
Device
2036
and the
Plate
VW 5541/3
.
Valve guide
Check
Chapter
.
Valve stem sealant
Replace
Chapter
.
Valve spring
Remove and install: Engine head removed with
Compression device
2037
and
Plate
VW 5541/3
Chapter
.
Spring dish
Keys
Note
With cylinder head removed, use the
Plate
VW 5541/3
.
Sealing surface on the cylinder block side - grinding
Engine cylinder head grinding measurement:
a
= minimum of 135.6 mm.
Note
When grinding the surface, valve seats must be ground with the same measure; otherwise, the valves would hit the pistons. Observe the minimum elevation permitted.