Valve gear, repairing: Notes

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2002 Volkswagen Jetta, 2002 Volkswagen GTI, 2001 Volkswagen Jetta, 2001 Volkswagen GTI, and 2000 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

If cracks are small, and no more than 0.5 mm wide, cylinder heads with cracks between the valve seats or between the valve seat ring and the spark plug thread can continue to be used without a reduction in life.

Fig 1: Exploded View Of Valve gear

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Bearing cover

Installation position Installation position camshaft bearing cover
Order of installation, refer to Camshafts, removing and installing

2 - 20 Nm

3 - Camshafts

Checking axial clearance Valve gear, repairing
Installing and removing, refer to Camshafts, removing and installing
Check radial clearance using Plastigage. Max. wear: 0.10 mm
Runout: max. 0.01 mm

4 - Camshaft sprocket

Removing and installing, refer to Camshafts, removing and installing

5 - Pickup wheel

For Camshaft Position (CMP) sensor G40
Contact area at camshaft sprocket and pickup wheel must be dry during installation
Removing and installing, refer to Camshafts, removing and installing

6 - 100 Nm

Place against camshaft using fork wrench SW 24 for removal and installation, refer to Camshafts, removing and installing
Oil bolt head contact area during installation

7 - Cylinder head height

Min. height: a = 139.5

8 - Cylinder head

Observe Note, refer to Valve gear, repairing
Reworking valve seats, refer to Valve seats, reworking

9 - Valves

Do not rework, only lapping is allowable
Valve measurements. Refer to Valve measurements

10 - Valve guide

Checking, refer to Valve guides, checking
Replacing, refer to Valve guides, replacing
Repair guide with collar

11 - Valve stem seal

Replacing, refer to Valve stem seals, replacing

12 - Valve springs

Removing and installing:

With cylinder head removed: use 2037
With cylinder head installed: Refer to Valve stem seals, replacing

13 - Valve spring retainer

14 - Valve keepers

15 - Valve lifters

Do not interchange
With hydraulic valve clearance balancing
Checking, refer to Hydraulic lifters, checking
For storage, lay down with running face downward

Prior to installation, check camshaft axial clearance Camshafts, checking axial clearance under Valve gear, repairing
Oil running face