Volkswagen Golf Service & Repair Manual: Removing and installing valve stem seals (cylinder head removed)
| Special tools and workshop equipment
required |
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| Removal and installation device for valve cotters -VAS
5161A- with guide plate -VAS 5161A/32-32-. |
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| Engine and gearbox support -VAS 6095- |
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| Cylinder head tensioning device -VAS 6419- |
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| Valve stem pliers -VAS 6770- |
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| Valve stem seal fitting tool -3365- |
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Removing cylinder head
→ Chapter |
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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. |
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Connect cylinder head tensioning device to compressed air. |
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Use lever -arrow- to slide air
cushion under combustion chamber from which valve stem seals are
to be removed. |
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Allow compressed air to flow into air cushion until it lies
against valve disc. |
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Fit guide plate -VAS 5161A/32-1- onto cylinder head and
secure with knurled screws -VAS 5161/12-. |
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Insert punch -VAS 5161/3A- into guide plate and use a
plastic hammer to knock loose the firmly seated valve cotters. |
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Screw toothed piece -VAS 5161/6- with hooking fork
-VAS 5161/5- into guide plate. |
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Slide sleeve -VAS 5161A/32-2- onto assembly cartridge and
insert cartridge into guide plate -VAS 5161A/32-3-. |
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Attach pressure fork -VAS 5161/2- to toothed piece and press
assembly cartridge down. |
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At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters. |
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Move knurled screw back and forth to press apart valve
cotters and capture them in assembly cartridge. |
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Remove installation cartridge. |
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Unbolt guide plate and move to side. |
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Remove valve spring and valve spring plate. |
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Pull off valve stem seal using valve stem pliers -VAS 6770-. |
 Note
| Risk of damage when installing valve stem seals. |
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Place plastic sleeve -A-,
enclosed with new valve stem seals -B-,
onto valve stem. |
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Lightly oil sealing lip of valve stem seal. |
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Push valve stem seal onto plastic sleeve. |
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Carefully press valve stem seal onto valve guide using valve
stem seal fitting tool -3365-. |
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| 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. |
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Press assembly cartridge onto insertion device from above
and pick up valve cotters. |
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Insert valve spring and valve spring plate. For installation
position of valve spring refer to
→ Fig.. |
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Bolt guide plate -VAS 5161A/32-1- onto cylinder head again. |
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Insert assembly cartridge -VAS 5161A/32-2- with sleeve -VAS
5161A/32-3- into guide plate. |
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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. |
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Repeat procedure on each valve. |
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Installing cylinder head
→ Chapter. |
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Special tools and workshop equipment
required
Spark plug socket and extension -3122 B-
...
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Removing and installing valve stem seals (cylinder head installed)