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

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 removed)

Special tools and workshop equipment required

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

Removing and installing valve stem seals (cylinder head removed)

Engine and gearbox support -VAS 6095-

Removing and installing valve stem seals (cylinder head removed)

Cylinder head tensioning device -VAS 6419-

Removing and installing valve stem seals (cylinder head removed)

Valve stem pliers -VAS 6770-

Removing and installing valve stem seals (cylinder head removed)

Valve stem seal fitting tool -3365-

Procedure

Removing and installing valve stem seals (cylinder head removed)

–	Removing cylinder head → Chapter

–	Insert cylinder head tensioning device -VAS 6419- into engine and gearbox support -VAS 6095-.

–	Tension cylinder head on cylinder head tensioning device as shown in illustration.

–	Connect cylinder head tensioning device to compressed air.

–	Use lever -arrow- to slide air cushion under combustion chamber from which valve stem seals are to be removed.

–	Allow compressed air to flow into air cushion until it lies against valve disc.

Removing and installing valve stem seals (cylinder head removed)

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

–	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 removed)

–	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.

–	Remove valve spring and valve spring plate.

Removing and installing valve stem seals (cylinder head removed)

–	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 removed)

–	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 removed)

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 removed)

–	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.

–	Installing cylinder head → Chapter.

Removing and installing valve stem seals (cylinder head removed)

Removing and installing valve stem seals (cylinder head installed)

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