Servicing valve gear — VW

EW EX FB FD FH FK FN FP FR FT FV GH HN JB RE GY HM HV AJD BBV
Note:

Cylinder heads which have cracks between the valve seats or between a valve seat insert and the spark plug thread can continue to be used without reducing service life, provided that the cracks do not exceed a max. width of 0.5 mm or when no more than the first spark plug threads are cracked.

Bearing cap
With bearing cap 4 in the case of engines with no hydraulic bucket tappets
Pay attention to centre offset of bore => Fig.
2
Fit cap and determine position before installing camshaft
Installation sequence: removing and installing camshaft => page
15-26

20 Nm
Camshaft
Checking axial clearance => Fig.
1
Removing and installing => page
15-26
Check radial clearance with Plastigage
Wear limit: 0.1 mm
Runout: max. 0.01 mm
Identification and valve timing => Figs.
3
and
4

Woodruff key
Ensure tight fit

80 Nm
Counterhold with 3036 for loosening and tightening

Bucket tappet
Check axial clearance of camshaft before installing => Fig.
1
Oil contact surfaces
Do not interchange

Hydraulic bucket tappet:

Lay aside with contact surface facing downwards
Checking => page
15-30

Bucket tappet with shim:

Checking and adjusting valve clearance => page
15-36

Upper valve spring retainer
Note version => Fig.
6

Upper valve spring
Inner valve spring
Removing and installing
Cylinder head removed: with 2037
Cylinder head in situ:
renewing valve stem oil seals => page
15-31

Valve stem oil seal
Renewing => page
15-31

Lower valve spring retainer
Remove and install with 3047 A

Valve guide
Checking =>page
15-32
Renewing => page
15-33

Valves
Valve dimensions =>Fig.
5
Note version =>Fig.
6
Only grind in; do not rework
Checking and adjusting valve clearance =>page
15-36
( not hydraulic bucket tappets)

Plug
Renew

Oil stop
Hydraulic bucket tappets only (4 bearing caps)

Oil seal
Lightly lubricate sealing lip and outer edge
Renewing =>page
15-34

Cylinder head
Exchange cylinder heads with camshaft bearing shells => Fig.
7
Reworking valve seats => page
15-23
Reworking dimension a = 132.6 mm (min. height)
Cracked cylinder head => note onpage
15-8
1.6 l engine "big valve" cylinder head can be identified by casting number 1GS 103 373D

Fig.1
Checking axial clearance of camshaft

Wear limit: 0.15 mm

Measure with bucket tappets removed and first and last bearing caps installed.

Fig.2
Installation position of camshaft bearing caps

Note centre offset. Before installing camshaft, mount bearing caps and determine installation position.

Fig.3
Camshaft identification, valve timing

Identification with adjustable bucket tappets

Cam base circle: a = dia. 38 mm

Engine codes · Lug on cam · Colour of paint between cams
1 (-A-) · 3 (-B-) · 1 + 2 · 3+4
EW ä07.85, · - · - · yellow · -
HN ä 07.85
EX ä09.83 · x · - · blue · -
EX 10.85 ä 08.85 · x · x · - · white1)
EX2) · x · x · - · -
EM, FN, FP, FR, · x · x · - · -
FV, GH, JB
FB, FD, FH, FK · x · - · - · -
FT3) · - · - · - · -
HM ä01.87 · x · - · white1)

1)
Not all camshafts are painted white

2)
When performing repairs, camshaft with lug at 1st (-A-) and 3rd (-B-) cam and stamped-in code number "049J" (-C-) is to be replaced by a different version for engine code EX

3)
Austria only (no identification)

Valve timing with 1 mm valve stroke

Engine codes · EM, FN, FP, FR, FV, GH, JB · EW ä 07.85, / HN ä 07.85, / GY 04.86 ä
Inlet opens · 4° before TDC · 5° before TDC
Inlet closes · 46° after BDC · 21°after BDC
Exhaust opens · 44° before BDC · 41° before BDC
Exhaust closes · 6° after TDC · 3° before TDC

Engine codes · EX ä 07.85, HM, HV · FB, FD, FH, FK
Inlet opens · 1° before TDC · 7° before TDC
Inlet closes · 37° after BDC · 43° after BDC
Exhaust opens · 42° before BDC · 47° before BDC
Exhaust closes · 2° after TDC · 3° before TDC

Engine codes · FT
Inlet opens · 6° before TDC
Inlet closes · 32° after BDC
Exhaust opens · 42° before BDC
Exhaust closes · TDC

Fig.4
Camshaft identification, valve timing

Identification with hydraulic bucket tappets

Cam base circle: a = dia. 34 mm (with adjustable bucket tappets: a = dia. 38 mm)
Identification by way of stamped-in numbers and letters between inlet and exhaust cams

Engine codes · Cylinder 1 · Cylinder 3
Arrow -A- · Arrow -B-
EW 08.85 ä · B/M · 026
HN 08.85 ä
EX 08.85 ä · H/Q · 026
EW 03.86 ä
HN 03.86 ä · M · 026
RE 03.86 ä
EX 07.87 ä · Q · 026
HM 02.87 ä · L · 026
HV 02.87 ä
AJD 10.98 ä · L or AF · 026
BBV 04.02 ä · L or AF · 026

Valve timing with 1 mm valve stroke

Camshaft · -A- · -B- · -A- · -B-
B · 026 · M · 026
Inlet opens · 3° before TDC · TDC
Inlet closes · 19° after BDC · 22° after BDC
Exhaust opens · 27° before BDC · 28° before BDC
Exhaust closes · 5° after · 6° before TDC

Camshaft · -A- · -B- · -A- · -B-
H · 026 · Q · 026
Inlet opens · 3° before TDC · 5° after TDC
Inlet closes · 33° after BDC · 41° after BDC
Exhaust opens · 41° before BDC · 37° before BDC
Exhaust closes · 5° after · 1° before TDC

Camshaft · -A- · -B-
L or AF · 026
Inlet opens · 8° after TDC
Inlet closes · 44° after BDC
Exhaust opens · 34° after BDC
Exhaust closes · 2° after

Fig.5
Valve dimensions

Note:

Valves are not to be reworked. Only grinding is permitted.

Engine codes · EM, · FB, · FD, · FH, · FK, · FN,
FP, · FR, · FT, · FV, · GH, · JB,
GY, · HM

Inlet valve · Exhaust valve
a · 34.00 mm · 31.00 mm
b · 7.97 mm / 7 mm1) · 7.95 mm / 7 mm1)
c · 98.70 - 0.50 mm · 98.50 - 0.50 mm
alpha · 45° · 45°

1)
Engine codes HM ä 01.97 only

Engine code · AJD · BBV

Inlet valve · Exhaust valve
a · 38.00 mm · 33.00 mm
b · 7.97 mm · 7.97 mm
c · 91.90 - 0.90 mm · 91.20 - 0.40 mm
alpha · 45° · 45°

Engine codes · EW ä 07.85, · EX ä 07.85,
HN ä 07.85

Inlet valve · Exhaust valve
a · 38.00 mm · 33.00 mm
b · 7.97 mm · 7.95 mm
c · 98.70 - 0.50 mm · 98.50 - 0.50 mm
alpha · 45° · 45°

Engine codes · EW 08.85 ä, · EX 08.85 ä,
HN 08.85 ä, · RE

(with hydraulic valve clearance compensation)

Inlet valve · Exhaust valve
a · 38.00 mm · 33.00 mm
b · 7.97 mm · 7.95 mm
c · 91.90 - 0.90 mm · 91.20 - 0.40 mm
alpha · 45° · 45°

Fig.6
Valve types

05.81 ä installation of valves with 3 grooves

Distinguishing features

Valve with 3 grooves on stem (previously one groove)
Valve taper with 3 beads (previously one bead)
Valve spring seat:

Surface copper-plated or yellow chromation (previously steel grey) with approx. 1.5 mm inner chamfer -arrow A- (previously no chamfer) and broad outer chamfer -arrow B-

Note:

When performing repairs, 1 and 3-groove valves can be mixed. It is to be noted that the respective valves are only to be installed with the envisaged valve tapers and valve spring seats.

Fig.7
Exchange cylinder heads with camshaft bearing shells

Exchange cylinder heads/exchange engines are sometimes supplied with bearing shells for camshafts.

Cylinder head with standard size camshaft
a = 26.00 mm dia.
Cylinder head with undersize camshaft
a = 25.75 mm dia. and dot of yellow paint on VW-Audi emblem

Note:

Undersize camshafts are not supplied as replacements. For repairs, install a standard size camshaft with corresponding bearing shells.