Volkswagen Golf Service & Repair Manual: Removing and installing valve stem seals (cylinder head installed)

Volkswagen Golf Service & Repair Manual / 4- cylinder injection engine(1.4 1 direct inction. turbocharger) / Engine cylinder head, valve gear / Valve gear / Removing and installing valve stem seals (cylinder head installed)

Special tools and workshop equipment required

Spark plug socket and extension -3122 B-

Removing and installing valve stem seals (cylinder head installed)

Removal and installation device for valve cotters -VAS 5161A- with guide plate -VAS 5161A/32-32-.

Compressed air adapter -VAS 5161 A/35- (not illustrated)

Removing and installing valve stem seals (cylinder head installed)

Valve stem seal fitting tool -3365-

Removing and installing valve stem seals (cylinder head installed)

Valve stem pliers -VAS 6770-

Procedure

Golf SV

–	Remove plenum chamber cover → Rep. gr.50.

Removing and installing valve stem seals (cylinder head installed)

–	Remove plenum chamber bulkhead → Rep. gr.50.

Removing and installing valve stem seals (cylinder head installed)

–	Remove bolts -arrows-. Remove heat shield from right drive shaft.

–	Unscrew bolts -arrows-, and remove oil supply line -1-.

Continuation for all vehicles

–	Remove camshaft housing → Chapter.

–	Unscrew spark plugs with spark plug spanner -3122 B-.

Removing and installing valve stem seals (cylinder head installed)

–	Unscrew locking pin -T10340-.

–	Set piston of respective cylinder to “bottom dead centre”.

Removing and installing valve stem seals (cylinder head installed)

–	Fit guide plate -VAS 5161A/32-1- onto cylinder head and secure with knurled screws -VAS 5161/12-.

–	Screw compressed air adapter -VAS 5161 A/35- into the respective park plug thread hand-tight.

–	Connect adapter to compressed air supply using a commercially available union and apply pressure continuously.

Minimum pressure: 6 bar

–	Insert punch -VAS 5161/3A- into guide plate and use a plastic hammer to knock loose the firmly seated valve cotters.

Removing and installing valve stem seals (cylinder head installed)

–	Screw toothed piece -VAS 5161/6- with hooking fork -VAS 5161/5- into guide plate.

–	Slide sleeve -VAS 5161A/32-2- onto assembly cartridge and insert cartridge into guide plate -VAS 5161A/32-3-.

–	Attach pressure fork -VAS 5161/2- to toothed piece and press assembly cartridge down.

–	At the same time, turn knurled screw of assembly cartridge clockwise until tips engage in valve cotters.

–	Move knurled screw back and forth to press apart valve cotters and capture them in assembly cartridge.

–	Release pressure fork.

–	Remove installation cartridge.

–	Unbolt guide plate and move to side.

The compressed air hose remains connected.

–	Remove valve spring and valve spring plate.

Removing and installing valve stem seals (cylinder head installed)

–	Pull off valve stem seal using valve stem pliers -VAS 6770-.

Note

Risk of damage when installing valve stem seals.

Removing and installing valve stem seals (cylinder head installed)

–	Place plastic sleeve -A-, enclosed with new valve stem seals -B-, onto valve stem.

–	Lightly oil sealing lip of valve stem seal.

–	Push valve stem seal onto plastic sleeve.

–	Carefully press valve stem seal onto valve guide using valve stem seal fitting tool -3365-.

–	Remove plastic sleeve.

Removing and installing valve stem seals (cylinder head installed)

If the valve cotters have been removed from the assembly cartridge, they must first be inserted into the insertion device.

Larger diameter of valve cotters faces upwards.

–	Press assembly cartridge onto insertion device from above and pick up valve cotters.

–	Insert valve spring and valve spring plate. For installation position of valve spring refer to → Fig..

Removing and installing valve stem seals (cylinder head installed)

–	Bolt guide plate -VAS 5161A/32-1- onto cylinder head again.

–	Insert assembly cartridge -VAS 5161A/32-2- with sleeve -VAS 5161A/32-3- into guide plate.

–	Press pressure fork downwards and pull knurled screw upwards, turning it clockwise and anticlockwise. This inserts the valve cotters.

–	Reduce pressure on pressure fork whilst pulling on knurled screw.

–	Repeat procedure on each valve.

Reassembly

Installation is carried out in the reverse order; note the following:

Golf SV

Removing and installing valve stem seals (cylinder head installed)

–	Install oil supply line -1-, and tighten bolts -arrows- to 9 Nm.

–	Install plenum chamber bulkhead → Rep. gr.50.

–	Install plenum chamber cover → Rep. gr.50.

Continuation for all vehicles

–	Install spark plugs → Booklet.

–	Install camshaft housing → Chapter.

Removing and installing valve stem seals (cylinder head installed)

Specified torques

Removing and installing valve stem seals (cylinder head installed)

Component	Specified torque
Bolts -1-	25 Nm

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