Volkswagen Golf Variant / Jetta. Manual - part 389

 

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Volkswagen Golf Variant / Jetta. Manual - part 389

 

 

VAS5161/23- on the cylinder head.

– Secure the Guide Plate on the intake manifold side using the

Valve Cotter Tool Kit - Knurled Bolt - VAS5161/12- and to the

stud bolts hand-tight with threadless M6 nuts -1-.

– Install the Valve Keeper Tool Kit - Compression Stud -

VAS5161/10- in the Guide Plate .

– Install the Valve Keeper Tool Kit - Adapter for Compressed Air

Connection - VAS5161/11- hand-tight in the respective glow

plug threads.

– Insert the Valve Cotter Tool Update Kit - Punch - VAS5161/3-

into the Guide Plate and loosen the stuck valve retainers with

a plastic mallet.

2. Valvetrain    

139

Threaded Studs - VAS5161/5- using the Valve Cotter Tool Kit

- Retainer - VAS5161/6- into the Guide Plate .

– Slide the Valve Cotter Tool Kit - Guide Plate Sleeve -

VAS5161/23-1- onto the Valve Cotter Tool Kit - Assembly

Cartridge - VAS5161/8A- .

– Connect the Valve Cotter Tool Kit - Adapter - VAS5161/11- to

compressed air with a commercially available connector and

apply constant pressure.

• Minimum pressure: 6 bar (87.02 psi)
– Engage the Valve Cotter Tool Kit - Pressure Fork with Lever

for Assembly Cartridge - VAS5161/2- on the Valve Cotter Tool

Kit - Retainer and press the Assembly Cartridge downward.

– At the same time, turn the Assembly Cartridge knurled bolt to

the right until the points engage in the valve retainers.

– Move the knurled bolt gently back and forth, causing the valve

retainers to be pressed apart and gripped in the Assembly

Cartridge .

– Release the Pressure Fork .
– Remove the Assembly Cartridge with the Knurled Spacer

Ring , the valve plate and the valve spring.

Note

The Valve Seal Removal Tool - 3064- is shown, the Puller - Valve

Seal - 3364- is used for removing the valve stem seals.

– Pull off valve stem seals using the Puller - Valve Seal - 3364- .
Installing:

140

A plastic sleeve -A- is supplied with the new valve stem seals.

– Place the plastic sleeve -A- on valve stem to prevent damage

to new valve stem seals -B-.

– Lightly oil the sealing lips of the valve stem seal -B-.
– Push the valve stem seal -B- on the plastic sleeve -A-.
– Carefully press valve stem seal onto valve guide using Seal

Installer - Valve Stem - 3365- .

– Tap lightly on the driver with a plastic mallet until the valve

stem seal is at the stop.

– Remove the plastic sleeve -A- again.
– Insert the valve spring and valve plate in the cylinder head.

– If the valve retainers were removed from the Assembly Car‐

tridge , they must first be inserted into the Valve Keeper Tool

Kit - Valve Insertion Device - VAS5161/18- .

Note

The large diameter of the valve retainers point upward.

– Press the Assembly Cartridge onto the Insertion Tool from

above and remove the valve retainers.

– Insert the Valve Keeper Tool Kit - Assembly Cartridge -

VAS5161/8A- in the Guide Plate .

– Press the Pressure Fork down and pull the knurled bolt upward

while turning it left and right to insert the valve retainers.

– Release the Pressure Fork with the knurled bolt still tightened.
The rest of the installation is performed in reverse order of re‐

moval, while doing so pay attention to the following:
– Install the camshafts. Refer to

⇒ “2.2 Camshafts, Removing and Installing”, page 131

 .

Note

Do not start the engine for approximately 30 minutes after in‐

stalling the camshafts. The hydraulic lifters must seat them‐

selves (otherwise the valves will crash into the pistons).

After working on the valvetrain, carefully rotate engine by hand

at least two full revolutions to ensure that valves do not strike

the pistons when starting.

– Install all the glow plugs. Refer to

⇒ “1 Glow Plugs”, page 408

 .

2.5

Valve Guides, Checking

Special tools and workshop equipment required
♦ Dial Gauge Holder - VW387-

2. Valvetrain    

141

must be flush with the guide. Use only the intake valve in the

intake guide or the exhaust valve in the exhaust guide.

– Determine the tilting clearance.
• Wear limit: 1.30 mm
– If the tilting clearance exceeds the wear limit, the cylinder head

must be replaced.

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