All engines
Worn valve stem seals cause high engine oil consumption. The caps are mounted on top of the guides and remove oil from the valve stems. Since the valve springs must be removed to replace the valve stem seals, with the cylinder head installed on the engine, the corresponding valve could fall into the cylinder. Nevertheless, the caps can be removed with the cylinder head installed, if the special tools VW-2036 with VW-541 / 1A or HAZET 2577-2 are used, and for a gasoline engine also compressed air.
Attention:. The diesel engine does not require compressed air. The piston of the corresponding cylinder must first of all be set to the TDC position so that the valves can rest on it.
Removing
Remove camshaft and poppets, see above.
Gas engine
Set the piston of the corresponding cylinder to the BDC position. To do this, use a socket wrench to turn the crankshaft on the belt pulley bolt so that the notch on the belt pulley coincides with the alignment mark on the toothed belt housing (pistons of cylinders 1 and 4 are now at TDC). At the same time, the pistons of cylinders 2 and 3 are at BDC. Mark the crankshaft pulley at the bottom with chalk, then turn the pulley 1/2 turn (180°), until the chalk mark lines up with the alignment mark. The pistons of cylinders 1 and 4 are now 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 earth 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 rest of the central electrode together with fiberglass -4- and the connecting electrode -5- with a suitable drift (about 3 mm). In this case, clamp the spark plug in a vise or insert it into a suitable socket head.
Attention: To avoid damage to the threads in the cylinder head, the threads of the spark plug must not be damaged.
Screw the prepared spark plug into the appropriate cylinder and connect it to the compressed air hose.
Continuously pressurize the cylinder with compressed air 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 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, the pistons of cylinders 2 and 3 are in the BDC position. Mark the crankshaft pulley at the bottom with chalk, then turn the pulley 1/2 turn (180°), until the chalk mark lines up with the alignment mark. The pistons of cylinders 1 and 4 are now at BDC, while the pistons of cylinders 2 and 3 are at TDC.
Screw special tool VW 2036 onto bearing pedestals 1 and 4 and compress valve springs with tool VW 541/1A. You can also use the HAZET 2577-2 tool. In this case, screw the supporting device attached to the tool to the camshaft mounting studs and compress the valve springs with a puller.
Attention: The piston must be at BDC.
Take out the crackers, loosen the springs.
Attention: Loosen firmly seated crackers with light hammer blows on the pry bar.
Remove the valve springs and valve springs.
Take out the oil seal. In workshops, special tools are used for removal (VW 10-218, VW3047A, HAZET791-5 or HAZET791-2 impact puller). As a rule, valve stem seals sit very firmly. Therefore, an impact puller must be used for removal.
Installation
Plastic sleeve -A- (supplied with oil seals) put on the valve stem.
Lubricate the valve stem seal -B- lightly with oil, insert into the puller VW 10-204 or HAZET 2577 and carefully push it onto the valve guide. Remove bushing and upsetting device.
Attention: For motors manufactured from 11/94, a puller VW 3129 is required.
Attention: If the assembly is carried out without using a plastic sleeve, the valve stem 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 the springs.
Replace all valve stem seals in the same manner. Install poppets and camshaft, see above.
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