Contents: Removal ↓ Installation ↓
All engines
Worn valve stem seals are the cause of high oil consumption by the engine. The seals are installed on the top of the guides and remove oil from the valve stems. Since the valve springs must be removed to replace the valve stem seals, the corresponding valve could fall into the cylinder when the cylinder head is installed on the engine. However, the seals can be removed with the cylinder head installed if special tools VW-2036 with VW-541 /1A or HAZET 2577-2 are used, and for a gasoline engine also compressed air.
Note: The diesel engine does not require compressed air. The piston of the corresponding cylinder must first be set to the TDC position so that the valves can rest on it.
Removal
Remove the camshaft and tappets, see above.
Gasoline engine
Set the piston of the corresponding cylinder to the BDC position. To do this, use a socket wrench to turn the crankshaft by the belt pulley mounting bolt so that the notch on the belt pulley coincides with the installation mark on the toothed belt cover (pistons of cylinders 1 and 4 are now at TDC). At the same time, pistons of cylinders 2 and 3 are at BDC. Mark the crankshaft belt pulley at the bottom with chalk, then turn the belt pulley 1/2 turn (180°) until the chalk mark coincides with the installation mark. Now pistons of cylinders 1 and 4 are at BDC.
Remove all spark plugs.
Screw the compressed air hose adapter VW 653/3 or HAZET 3428 into the spark plug hole of the corresponding cylinder.
If there is no adapter, it can be made from an old spark plug. To do this, remove the ground electrode "1". Use a screwdriver to destroy the ceramic insulator "2", then, swinging the central electrode in different directions, break it off and pull it out. Knock out the remainder of the central electrode together with the fiberglass "4" and the connecting electrode "5" with a suitable punch (approximately 3 mm). In this case, clamp the spark plug in a vice or insert it into the appropriate socket head.
Caution: To avoid damaging the threads in the cylinder head, the spark plug threads must not be damaged.
Screw the prepared spark plug into the appropriate cylinder and connect it to the compressed air hose.
Continuously pump compressed air into the cylinder at a pressure of at least 6 bar.
Diesel engine
Set the piston of the corresponding cylinder to the TDC position. To do this, use a socket wrench to turn the crankshaft by the belt pulley mounting bolt so that the mark on the flywheel coincides with the mark in the inspection hole of the gearbox housing (pistons of cylinders 1 and 4 are now at TDC), see chapter "Diesel engine".
When the pistons of cylinders 1 and 4 are at TDC, pistons of cylinders 2 and 3 are at BDC. Mark the bottom of the crankshaft pulley with chalk, then turn the pulley 1/2 turn (180°) until the chalk mark coincides with the timing mark. Now pistons of cylinders 1 and 4 are at BDC, while pistons of cylinders 2 and 3 are at TDC.
Screw the special tool VW 2036 onto bearing stands 1 and 4 and compress the valve springs with the VW 541/1A tool. You can also use the HAZET 2577-2 tool. In this case, screw the support device supplied with the tool onto the camshaft mounting studs and compress the valve springs with a puller.
Note: The piston must be at BDC.
Remove the crackers and loosen the springs.
Note: Loosen tightly seated crackers by lightly hitting the pry bar with a hammer.
Remove the valve spring plates and valve springs.
Remove the oil seal. Workshops use special tools for removal (VW 10-218, VW3047A, HAZET791-5 or impact puller HAZET791-2). As a rule, valve stem seals are very tightly seated. Therefore, an impact puller must be used to remove them.
Installation
Plastic bushing "A" (comes with valve stem seals) put on the valve stem.
Lightly lubricate the valve stem seal "B" with oil, insert it into the VW 10-204 or HAZET 2577 retaining device and carefully push it onto the valve guide. Remove the bushing and retaining device.
Please note: Engines built from 11/94 onwards require the VW 3129 pre-tensioner.
Caution: If assembly is carried out without using a plastic bushing, the oil seals will be damaged! As a result, the engine consumes too much oil.
Install the valve springs and valve spring plate, compress the springs.
Insert crackers, loosen springs.
Replace all valve stem seals in the same manner. Install the tappets and camshaft, see above.
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