Replacing the valve stem seals (VW Transporter T4)

Spark plug

Increased oil consumption may be caused by worn out oil seals. Oil seals can be removed even on the installed cylinder head, but this requires a special tool VW-2036 with VW541/1 or HAZET 2577-2, and for petrol engines – compressed air.

Attention! The removal is described on a gasoline engine. In the case of a diesel engine, compressed air is not needed, but then the piston of the corresponding cylinder must be at TDC. Set the engine to the TDC position for cylinder 1 (see Fig. subsection 2.5.2.1).

Removal

1. Remove the camshaft and tappets (see subsection 2.7).

2. Set the piston of the corresponding cylinder to BDC (bottom dead center). To do this, turn the crankshaft with a socket wrench on the belt pulley so that the notch on the belt pulley coincides with the corresponding mark on the toothed belt guard (1 cylinder is now at TDC). At this time, cylinders 2 and 3 are at BDC. Mark the crankshaft belt pulley from below with chalk, then turn the belt pulley another 1/2 turn (180°) until the chalk mark matches the corresponding mark. Now cylinders 1 and 4 are at BDC.



3. Remove all spark plugs.

4. Screw the VW 653/3 or HAZET 3428 adapter into the desired cylinder instead of the spark plug and connect a hose with compressed air.

5. If you don't have a special tool at hand, make an adapter from an old spark plug. To do this, bite off the ground electrode (1), break the ceramic insulator (2) with a screwdriver, swing it from side to side, break the central electrode (3) and remove it. Knock out the remains of the middle electrode together with the glass mass (4) and the connecting pin (5) with a suitable punch (about 3 mm) (see fig. Spark plug). At the same time, clamp the spark plug in a vice.

Attention! Do not damage the spark plug thread, so as not to damage the thread in the cylinder head hole, where the manufactured adapter will be screwed.

6. The adapter prepared in this way is screwed into the required cylinder and a hose with compressed air is connected to it.

7. Maintain a constant pressure of at least 6 bar in the cylinder using compressed air.



8. Screw the VW-2036 device to 1 and 4 bearing stands and compress the valve springs with the VW541/1 device. You can also use the HAZET 2577-2 device. In this case, screw the counterstop on the device to the camshaft mounting stud and compress the springs with the spring compressor.

Attention! In this case, the piston must be at BDC.

9. Remove the housing crackers and loosen the valve springs.

Attention! Firmly seated conical crackers should be knocked out with light blows of a hammer through a crowbar.

10. Remove the spring plates and valve springs.

11. Remove the oil-deflecting caps. For this purpose, factories use a special tool (VW 10-218 or VW 3047, HAZET 791-5 or impact puller HAZET 791-2). Old oil deflector caps are usually very tightly seated, so an impact puller is often used to remove them.

Installation

1. Plastic sleeve (A) (supplied with oil-reflecting caps) place it on the valve stem. Lubricate the valve stem seal (B) with a thin layer of oil, install it in the pressing tool VW 10-214 or HAZET 2577 and carefully press it onto the stem guide. Remove the sleeve and pressing tool.

Warning! If the installation is carried out without using a plastic sleeve, the oil deflector cap will be damaged! As a result, the engine will consume too much oil!

2. Install the springs, valve plates and compress the springs.

3. Install cone crackers, loosen springs.

4. Replace the remaining oil seals in the same manner. Install the plate tappets and camshaft.