Disassembly and assembly of the cylinder head (VW Passat B2)

Disassembly

Loosen the valve drive clearance adjusting bolts as much as possible so that the valve drive levers can be removed.

Remove the lever retaining springs and the levers themselves (see photo).



Remove the oil line.

Remove the camshaft from the cylinder head supports.

Compress the valve springs with a special device, release the valves from the crackers and remove the valves.

Remove the springs with plates.

Remove the valve stem oil seals and spring support washers using pliers 10 218.

If the removed parts do not need to be replaced, arrange them in order so that they can be installed in their original place during assembly.

Wash all removed parts.

Check the degree of wear of the valve guide bushings (for dimensions, see subsection "Design and technical characteristics").

Measure the clearance between the valve stem and the guide bushing using a stand with an indicator. To do this, insert a new valve into the guide bushing so that its stem is level with the edge of the bushing. Place the indicator leg on the valve head and measure the clearance.



Replace the guide bushings if the clearance exceeds the maximum allowable limit, which is 1.0 mm for intake valves and 1.3 mm for exhaust valves.

Using a ruler, check the non-flatness of the mating surface of the cylinder head and, if necessary, grind it.

Check the condition of the valve springs and valves.

Check the condition of the valve seats and grind them if necessary. Grinding should be carried out only with the help of special equipment and in compliance with the dimensions specified in the subsection "Design and technical characteristics".

If necessary, grind the working chamfers of the inlet valves. The working chamfers of the exhaust valves are not subject to grinding. Grinding of the exhaust valves is allowed, in other cases they are subject to replacement.

Before assembly, thoroughly clean the cylinder head.

Assembly

Install the valve spring support washers in place and insert the valves into the guide bushings.

Using the VW 10 204 mandrel, press new valve stem seals onto the guide bushings, then place the valve stem seal protective bushings onto the valve stems.

Install the valve springs and spring retainers. Install the crackers using a valve spring compressor.

Lubricate the bearing journals and cams of the camshaft with engine oil and install it together with the oil seal.

Install the levers onto the adjusting bolts.

Install the retaining levers by inserting them into the grooves of the adjusting bolts so that the springs rest on the levers.

Note: If the threads on the adjuster bolt bushing are damaged, a Heli-Coil or SEDC type threaded insert bushing can be used.

Using mandrel 10 203, press in the camshaft oil seal.

Install the camshaft toothed pulley and tighten its mounting bolt to a torque of 8 kgf.m.