Cylinder Head Disassembly

PROCEDURE

Cylinder Head, Camshaft and Valve Train 1 – exhaust valve; 2 – intake valve; 3 – gasket; 4 – valve spring, inner; 5 – valve spring, outer; 6 – valve spring retainer; 7 – valve tappet; 8 – adjusting shim; 9 – camshaft; 10 – camshaft bearing cap; 11 – key; 12 – camshaft sprocket; 13 – washer; 14 – sprocket mounting bolt; 15 – valve keepers; 16 – valve stem seal; 17 – valve spring seat washer; 18 – valve guide; 19 – cylinder head; 20 – camshaft oil seal

PROCEDURE 1. Remove the intake manifold and exhaust manifold, if they were not removed earlier when removing the cylinder head from the engine. 2. Remove bolt 14 (see illustration Cylinder Head, Camshaft and Valve Train), remove sprocket 12 and remove key 11. 3. Remove the nuts securing bearing caps 10 Nos. 5, 1 and 3, counting from the camshaft drive belt. The bearing caps are numbered, but marks can be made on them if the numbers are not visible. Remove the bearing caps. 4. Loosen and evenly remove, in diagonal sequence, the nuts of bearing caps Nos. 2 and 4. Remove the bearing caps. 5. Remove camshaft 9. 6. Remove oil seal 20. 7. Remove valve tappets 7, marking them beforehand so that they can be installed in their original positions during assembly. Engines EZ and GU built from January 1985 use hydraulic valve lifters. A shim 8 is installed in the recess of tappet 7 from above. Shims must not be swapped; each shim must remain in its original position. 8. Using the special tool, compress valve springs 5 and 4 and remove valve keepers 15. 9. Slowly release the lever of the special tool to relieve spring pressure. Remove the tool. 10. Remove spring retainer 6 and remove springs 4 and 5. 11. Remove valve stem seal 16 and spring seat 17, placing something in the combustion chamber beforehand to prevent the valve from falling in. 12. Remove the valve from the combustion chamber side, marking it so that it can be installed in the same position. Remove the remaining valves in the same way. Inspection and Repair of Cylinder Head and Components Inspection and repair of the cylinder head and its components are similar to inspection and repair of the cylinder head of engines with displacement 1.1 and 1.3 L. Differing data is given below.

Cylinder Head Height Cylinder head height – 132.6 mm.

Distance between valve stem end and cylinder head upper surface Dimension "a": intake valves – 33.8 mm; exhaust valves – 34.1 mm.

Valve Seat Dimensions a – outside diameter of valve seat; b – distance from cylinder head surface to outside diameter of seat; c – width of valve seat contact face; z – lower plane of cylinder head

Engines EZ and GU Intake valve Exhaust valve a = 37.2 a = 32.4 c = 2.0 c = 2.4 b = 9.2 b = 9.2 Engines with output of 112 L hp. Intake valve Exhaust valve a = 39.2 a = 32.4 c = 2.0 c = 2.4 b = 9.2 b = 9.6 Engines with hydraulic valve lifters Intake valve Exhaust valve a = 34.8 a = 27.8 c = 2.2 c = 2.2 b = 9.2 b = 9.6

Valve Dimensions a – valve head diameter; b – stem diameter; c – valve length

Engines EZ and GU Intake valve Exhaust valve a = 38.0 a = 33.0 c = 7.97 c = 7.95 b = 98.7 b = 98.5 Engines with output of 112 L hp. Intake valve Exhaust valve a = 40.0 a = 33.0 c = 7.97 c = 7.95 b = 98.7 b = 98.5 Engines with hydraulic valve lifters Intake valve Exhaust valve a = 38.0 a = 33.0 c = 7.97 c = 7.95 b = 91.0 b = 90.8

Camshaft journal diameter 26 mm. Maximum permissible journal wear 0.25 mm. Camshafts are marked as follows: – engine with displacement 1.6 L – yellow paint mark between the cams of cylinder 1; – engine with displacement 1.8 L – cast boss on the first cam and blue paint mark between the cams of cylinder 1; – EZ engine with hydraulic valve lifters – stamped marking between the cams of cylinder 1, I-BII-026; – GU engine with hydraulic valve lifters – stamped marking between the cams of cylinder 1, I-AII-026. Undersize camshaft with 25.75 mm journal diameter is marked with yellow paint on the "VW–Audi" inscription. Maximum permissible camshaft runout, measured at the center journal – 0.1 mm.