VALVETRAIN Overview

WARNING: This page is about a different car, the 2009 Volkswagen GTI and 2008 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

The cylinder head and the cylinder head cover must be replaced together.

After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic lash adjusters must seat themselves (otherwise the valves will crash into the pistons).

After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.

Always replace gaskets and seals.

Fig 1: Identifying Assembly Overview: Valvetrain

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Exhaust Valve
- Do not grind, only hand lapping is permitted.
- Valve dimensions, refer to Fig 3.
- Checking valve guides, refer to VALVE GUIDE, CHECKING .
Cylinder Head
Valve Guide
- Checking, refer to VALVE GUIDE, CHECKING .
Valve Stem Seal
Valve Spring
Valve Spring Plate
Valve Retainers
Roller Rocker Arm with Hydraulic Lash Adjuster
- Do not interchange.
- Lubricate the contact surfaces.
Exhaust Camshaft
- Check the radial clearance using Plastigage R (roller rocker arm removed).
- Radial play on bearing diameter - 24 mm: 0.024 to 0.066 mm.
- Radial play on bearing diameter - 32 mm: 0.030 to 0.051 mm.
- Run out:
  Max. 0.04 mm.
Cylinder Head Cover
- With integrated camshaft bearings.
- Clean the sealing surface, reworking is not permitted.
- Remove the old sealant residue.
Bolt
- Always replace.
- Tightening sequence, refer to Fig 2.
O-ring
- Always replace.
- Lubricate with engine oil.
Sealing Plug
Intake Camshaft
- Check the radial clearance using Plastigage R (roller rocker arm removed).
- Radial play on bearing diameter - 24 mm: 0.024 to 0.066 mm.
- Run out:
  Max. 0.04 mm.
Cap
- Always replace.
- Removing: With the cylinder head cover installed, pierce through one side of the cover with an awl and pry it out.
- Installing: Without sealant, press in 1 to 2 mm using the thrust piece -3334-.
Intake Valve
- Do not grind, only hand lapping is permitted.
- Valve dimensions, refer to Fig 3.
- Checking the valve guides, refer to VALVE GUIDE, CHECKING .

Fig 2: Identifying Cylinder Head Cover - Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Replace the bolts.

-- Hand tighten the bolts in several passes in sequence -1 through 6-.

-- Tighten the bolts in sequence -1 through 6- to 8 Nm using a torque wrench.

-- Tighten the bolts an additional 90° (1/4) turn using a ratchet in sequence -1 through 6-.

NOTE:

Ensure the cylinder head cover is not tilted.

Fig 3: Identifying Valve Dimensions

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Intake and exhaust valves must not be refaced by grinding. Only hand lapping is permitted.

Dimension		Intake Valve	Exhaust Valve
diameter a	mm	33.85 0.10	28.0 0.1
diameter b	mm	5.98 0.007	5.955 0.007
c	mm	103.97	101.87
α	°	45	45