Rack for valve drive parts
Removing
1. Remove the cylinder head.
Attention! If valve drive parts are to be installed again, they must be installed in their original locations. In order not to confuse the parts, it is recommended to make a special foam rack (see fig. Rack for valve drive parts).
2. Remove distributor.
3. Mark poppets and remove.
Attention! Store bucket tappets with working surface downwards (side facing the camshaft).
4. Remove valve springs. For this, factories use a special tool VW-2037. You can also remove the cone cotters, valves and springs using commercially available valve spring pliers. But then additional removal of the intake and exhaust manifolds is required.
5. Compress the valve springs and remove the cone crackers. Remove the upper valve spring plate and springs. Take out the valve.
6. Take out the oil seal.
7. Lower valve spring plate (arrow) remove using tool VW-3047 or HAZET 791-5/791-2.
Installation
1. Before installing the valves, check the valve guides and, if necessary, finish or grind the valve seats (see subsection 2.10.3).
Attention! New valve spring plates on the bottom edge of the holes for the cone crackers in some places have very sharp edges that can damage the valve stems (risks, etc.). Replace damaged valves. If necessary, deburr the valve springs before installation.
2. Install the lower valve spring seat.
3. Clean the burrs on the valve stem at the contact points of the cone crackers.
4. For safety reasons, always replace oil seals after dismantling.
5. Lubricate the valve stem with a thin layer of oil and install the valve.
6. Fit a new oil seal.
Attention! If installation is carried out without the use of a plastic sleeve, the seals will be damaged! In this case, an excessive consumption of oil will be observed!
7. Install springs. If the valve springs are to be replaced, replace the springs in pairs (both at once).
8. Install the upper valve spring seat. Valve spring plates have a wide chamfer on the outside (A) and chamfer inside (arrow B).
9. Compress the springs with spring compression pliers and install the cone cotters so that they fit into the valve grooves. Loosen the pliers and install the next valve.
10. Check camshaft end play (see subsection 2.7).
11. Lubricate all poppet tappets with engine oil and install in the holes according to the marks.
12. Install camshaft (see subsection 2.7).
13. Replace cylinder head gasket. Install cylinder head (see subsection 2.6.1.1).
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