Pro
te
cte
d b
y c
op
yri
gh
t. C
op
yi
ng
fo
r p
riv
at
e
o
r c
o
m
m
e
rc
ia
l p
u
rp
o
s
e
s
, i
n
p
a
rt
o
r i
n
w
h
o
le
, i
s
n
o
t p
e
rm
itt
ed
u
nl
es
s a
ut
ho
ris
ed
by
Vo
lksw
agen
AG. Volkswagen AG doe
s not
gua
ran
tee
or a
cc
ep
t a
ny
lia
b
ilit
y w
ith
re
s
p
e
c
t t
o
th
e
c
o
rr
e
c
tn
e
s
s
o
f
in
fo
rm
a
tio
n
in
th
is
d
oc
um
en
t.
C
op
yrig
ht b
y V
olk
sw
age
n A
G.
9 - Valve internal spring
❑ Removing and installing: Cylinder head removed: with Compressor device -2037- mounted:
⇒ page 56
.
❑ Install in the cylinder head before putting the bearing caps.
10 - Valve stem seal
❑ Replace
⇒ page 56
.
11 - Valve guide
❑ Check
⇒ page 55
.
12 - Injection unit
❑ Remove and install
⇒ page 112
.
13 - Cylinder head
❑ See note
⇒ page 51
.
❑ Rework valve seats
⇒ page 53
14 - Oil seal
❑ Do not apply additional lubricant or grease to the seal lip.
❑ Before installation, remove oil residues from crankshaft trunnion with clean cloth.
❑ For installation, cover the groove in the camshaft tapered section with adhesive tape.
❑ Remove and install.
15 - Valves
❑ Valve dimensions
⇒ page 53
16 - Bearing shell
❑ Do not interchange used bearing shells (mark)
❑ Ensure proper seating of retaining clips in bearing caps and cylinder head.
17 - Camshaft
❑ Check axial clearance
⇒ page 52
❑ Remove and install
⇒ page 58
.
❑ Check radial clearance with Plastigage. Wear limit: 0.11 mm.
❑ Excentricity: max. 0.01 mm.
❑ Valve identification and synchronization
⇒ page 53
18 - Bearing cap
❑ Installation sequence
⇒ page 58
.
❑ Bearing cap 4 is identified as bearing cap 5.
❑ When installing, use Sealant -AMV 17400401- to seal surfaces of bearing caps 1 and 4, which contact
cylinder head
19 - 8 Nm + 90°
❑ Replace after each removal .
Check camshaft axial clearance
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
52
Rep. Gr.15 - Cylinder head, valve control mechanism