Servicing Valve Gear (Volkswagen of South Africa) — VW

1F ADZ AGY AFX AFV
Engine code letters AGY, AFX, AFV

Note:

Cylinder heads which have cracks between the valve seats or between valve seat inserts and the spark plug thread can be used further without reducing service life, provided the cracks do not exceed a maximum of 0.5 mm in width, or when no more than the first spark plug thread is cracked.

Bearing cap
Installation position=> Fig.
2

20 Nm
Camshaft
Checking axial clearance=> Fig.
1
Checking radial clearance with plastigage
Wear limit: 0.1 mm
Run-out: max. 0.01 mm
Identification and valve timing=> Fig.
5

Woodruff key
Ensure tight fit

80 Nm
Counter-hold with 3036 to loosen and tighten

Cylinder head
Exchange cylinder head with camshaft bearing caps

Oil seal
Rework dimension
Minimum heigh: a
1.4 l = 132.60
1.6 l = 130.83
1.8 l = 131.52

Valves
Do not rework only grinding in is permitted
Valve dimensions=> Fig.
4

Valve guide
Valve stem seal
Valve spring
Valve spring plate
Cotters
Bucket tappet
Do not interchange
With hydraulic valve clearance compensation
Store with cam contact surface downwards
Before installing check camshaft axial clearance=> Fig.
1
Oil contact surface

Fig.1
Checking camsaft axial clearance

Wear limit: max. 0.15 mm

Check with bucket tappets removed and with first and last bearing caps fitted.

Fig.2
Fitting position of camshaft bearing caps

Note offset. Before installing camshaft fit bearing caps and determine fitting position.

Fig.3
Exchange cylinder heads with camshaft bearing shells

Exchange cylinder heads/exchange engines are in some cases supplied with camshaft bearing shells.

A -
Cylinder head with standard camshaft.
a = 26.00 mm ø
C -
Cylinder head with undersize camshaft
a = 25.75 mm ø and yellow coloured spot on VW-Audi emblem.

Note:

Undersize camshafts will not be supplied as a replacement part. In cases of repair install camshaft with the corresponding cearing shells.

Fig.4
Valve demensions

Engine code: AGY

Dimension · Inlet valve · Exhaust valve
ø a · mm · 38.0 · 33.0
ø b · mm · 7.97 · 7.97
c · mm · 91.90 - 0.90 · 91.20 - 0.40
font=symbol charset=fontspecific code=181 descr='[prop]' · <° · 45 · 45

Engine code: AFX, AFV

Dimension · Inlet valve · Exhaust valve
ø a · mm · 39.5±0.15 · 32.9+0.15
ø b · mm · 6.92±0.02 · 6.92+0.02
c · mm · 91.85 · 91.15
font=symbol charset=fontspecific code=181 descr='[prop]' · <° · 45 · 45

Note:

Valves must not be reworked. Only grinding-in is permitted.

Fig.5
Camshaft indentification and valve timing

Identification

Cam base diameter: a = 34 mm ø

Identification by numbers and letters stamped between inlet and exhaust cams:

Engine codes · AGY · AFX, AFV
Cylinder 1 arrow I · L · B
Cylinder 2 arrow II · 026 · 037

Valve timing at 1 mm valve lift

Engine codes · AGY · AFX, AFV
Inlet opens after TDC · 8° · 3°
Inlet closes after BDC · 44° · 44°
Exhaust opens before TDC · 34° · 37°
Exhaust closes after TDC · 2° · 4°