Volkswagen Golf / Golf Plus. Manual - part 309

 

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Volkswagen Golf / Golf Plus. Manual - part 309

 

 

Note

Cylinder heads with cracks between the valve seats may be used

without reducing engine life, provided the cracks are small and

not more than 0.5 mm wide.

Assembly overview - valve gear 

⇒ page 74

 .

Checking valve guides 

⇒ page 76

 .

Renewing valve stem seals 

⇒ page 78

 .

Removing and installing camshaft 

⇒ page 80

Removing and installing camshaft seal 

⇒ page 84

2.1

Assembly overview - valve gear

1 - 20 Nm + 

1

/4 turn (90°) fur‐

ther

❑ Renew
❑ Note sequence when

loosening and tighten‐

ing 

⇒ page 80

 , Re‐

moving and installing

camshaft.

2 - Rocker arm shaft

❑ Do not interchange.

3 - Cylinder head bolt

❑ Renew
❑ Note sequence when

loosening and tighten‐

ing 

⇒ page 67

 , Remov‐

ing and installing cylin‐

der head.

❑ Before installing, insert

washers

⇒ Item 4 (page 74)

 in

cylinder head.

4 - Washer

❑ For cylinder head bolts.
❑ Insert in cylinder head

before installing bearing

caps

5 - Bucket tappet

❑ Do not interchange.
❑ With hydraulic valve

clearance compensa‐

tion.

❑ Store with cam contact

surface downwards

❑ Before installing, check camshaft axial clearance 

⇒ page 76

 .

❑ Oil contact surfaces.
❑ Before removing, remove camshaft bearing caps

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

74

     Rep. Gr.15 - Cylinder head, valve gear

 

head installed 

⇒ page 78

 , Renewing valve stem seals.

9 - Inner valve spring

❑ Removing and installing: with cylinder head removed, use valve spring compressor -2037- ; with cylinder

head installed 

⇒ page 78

 , Renewing valve stem seals.

10 - Valve stem seal

❑ Renewing 

⇒ page 78

11 - Valve guide

❑ Checking 

⇒ page 76

 .

12 - Unit injector

❑ Removing and installing 

⇒ page 169

 .

13 - Cylinder head

❑ See note 

⇒ page 74

 .

14 - Seal

❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove residual oil from camshaft journal using a clean cloth.
❑ To install, tape over groove in taper of camshaft (e.g. using Sellotape).
❑ Removing and installing 

⇒ page 84

 .

15 - Valves

❑ Valve dimensions 

⇒ page 76

16 - Bearing shell

❑ Do not interchange used bearing shells (mark).
❑ Ensure that retaining lugs are correctly seated in bearing caps and cylinder head

17 - Camshaft

❑ Checking axial clearance 

⇒ page 76

 .

❑ Removing and installing 

⇒ page 80

 .

❑ Check radial clearance with Plastigage, wear limit: 0.11 mm.
❑ Runout: max. 0.01 mm.

18 - Bearing cap

❑ Installation sequence 

⇒ page 80

 , removing and installing camshaft

❑ To install, seal parting surfaces of bearing caps 1 and 5 with sealant -AMV 174 004 01- 

⇒ page 76

19 - 8 Nm + 

1

/4 turn (90°) further

❑ Renew

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

2. Valve gear    

75

 

bearing caps fitted.
Wear limit: max. 0.15 mm
Seal parting surfaces of bearing caps 1 and 5 with sealant -AMV

174 004 01-
– Apply sealant -AMV 174 004 01- thinly and evenly on the sur‐

faces -1-.

Note

Be careful that no sealant gets into grooves -arrows-.

Valve dimensions

Note

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

Dimension

Inlet valve

Exhaust valve

∅ a

mm

35.95

31.45

∅ b

mm

6.980

6.956

c

mm

89.95

89.95

α

∠ °

45

45

2.2

Checking valve guides

Special tools and workshop equipment required

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

76

     Rep. Gr.15 - Cylinder head, valve gear

 

be flush with the guide. Due to slight differences in stem di‐

ameters, use only an inlet valve in inlet guide and an exhaust

valve in exhaust guide.

– Determine rock. Wear limit: max. 1.3 mm
– Cylinder head must be renewed if the rock is greater than the

wear limit.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

2. Valve gear    

77

 

 

 

 

 

 

 

 

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