Valve Guide Seal: Service and Repair

LEGEND
1 Bearing Cap
2 Bearing Cap Nut
3 Camshafts
4 Camshaft Sprocket
5 Trigger Wheel
6 Camshaft Sprocket Bolt
7 Cylinder Head Deck Height Measurement Point
8 Cylinder Head
9 Valves
10 Valve Guide
11 Valve Stem Seal
12 Valve Springs
13 Valve Spring Plate
14 Valve Keepers
15 Hydraulic Lifter

NOTE:
- During removal and installation procedures, refer to the component location illustration above and component notes below.
- Also refer to Cylinder Head Assembly.

COMPONENT NOTES
Bearing Cap (1)
- Note installed position.
- Note installation and tightening sequence.

Bearing Cap Nut (2)
- Tighten to: 20 Nm (15 ft. lbs.).

Camshafts (3)
- Refer to Testing and Inspection.
- Check axial clearence with lifters removed.
- Axial clearence: 0.15 mm (0.0060 inch)
- Radial clearence: 0.1 mm (0.0039 inch)
- Maximum runout: 0.01 mm (0.0004 inch)

Trigger Wheel (5)
- For Camshaft Position (CMP) Sensor.
- When installing, contact surfaces must be dry.

Camshaft Sprocket Bolt (6)
- Tighten to: 100 Nm (74 ft. lbs.).
- Counter hold with a suitable 22 mm wrench on camshafts when removing or installing.
- Oil contact surface when installing.

Cylinder Head Deck Height (7)
- Dimension a, minimum: 139.5 mm (5.4963 inch).

Valves (9)
- Do not rework, only lapping is permitted.

Valve Guide (10)
- Replacement guides have a collar.

Hydraulic Lifter (15)
- Do not interchange used lifters.
- Store with camshaft contact surfaces down.
- Oil contact surfaces.
- Remove prior to checking camshaft axial clearence

REMOVAL
1. Remove camshaft.
2. Remove valve lifters (do not interchange).
3. Store lifters with camshaft contact surface down.
4. Remove spark plugs.
5. Turn crankshaft to move piston to Bottom Dead Center (BDC) position.





6. Install adapter tool No. 2036, or equivalent, and adjust bar to cylinder stud height.
7. Install pressure hose tool No. VW 653/3, or equivalent, in spark plug hole and apply steady pressure.

- Minimum pressure: at least 6 bar (87 psi).

8. Remove valve springs with valve lever tool No. VW 541/1A and bar tool No. VW 541/5, or equivalent.

NOTE: Tight valve keepers can be loosened with light taps on the tool lever.

9. Pull out valve shaft seals with puller tool No. 3047A, or equivalent.

REPLACEMENT





1. Slide plastic seal protector -A- onto valve stem to prevent damage to new seals.
2. Lubricate seal -B-.
3. Carefully push seal onto valve stem using installer tool No. 10-204, or equivalent.

INSTALLATION
Reverse procedure to install.