Valve Guide Seal: Service and Repair

LEGEND
1 Bearing Cap
2 Nut
3 Camshaft
4 Hydraulic Lifter
5 Keepers
6 Upper Valve Spring Plate
7 Outer Valve Spring
8 Inner Valve Spring
9 Valve Stem Seal
10 Lower Valve Spring Plate
11 Valve Guide
12 Camshaft Oil Seal
13 Cylinder Head
14 Valves
15 Swirl Chamber
16 Lower Sealing Cone

NOTE:
- During removal and installation procedures, refer to the component location illustration above and component notes below.
- Cylinder heads with cracks between the valve seats may be used without reducing engine life, provided the cracks are small and not more than 0.5 mm wide.

COMPONENT NOTES
Bearing Cap (1)
- Note installation position, refer to the Installation procedures below.

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


Camshaft (3)
- Check axial clearance, refer to Testing and Inspection.

Hydraulic Lifter (4)
- Do not interchange.
- Has hydraulic valve clearance compensation.
- Checking, refer to Lifter Valve.
- Store with cam contact surface facing downwards.
- Check camshaft axial clearance, before installing.
- Oil the contact surfaces before assembly.

Outer Valve Spring (7)
- Remove or install with Cylinder Head Assembly removed using valve spring compressor tool No 2037, or equivalent.

Inner Valve Spring (8)
- Remove or install with Cylinder Head Assembly removed using valve spring compressor tool No 2037, or equivalent.

Valve Stem Seal (9)
- Refer to Cylinder Head Assembly for procedure.

Valve Guide (11)
- Testing and inspection, refer to Cylinder Head Assembly.
- Replacement, refer to Cylinder Head Assembly.

Camshaft Oil Seal (12)
- Oil but DO NOT grease seal lips.
- To remove and install, remove camshaft bearing cap.
- Refer to Timing Components for toothed timing belt removal.

Cylinder Head (13)

Valves (14)

Swirl Chamber (15)
- Replace if damaged, refer to Cylinder Head Assembly.

Lower Sealing Cone (16)

SPECIAL TOOLS
^ Puller tool No. 3047A, or equivalent.
^ Valve Assembly tool 2036, or equivalent.
^ Valve Lever tool No. VW 541/1A with press piece tool No. VW 541/5 or tool No. US 4481, or equivalents.
Seal Fitting tool tool No. 10-204 or tool No. US 5042, or equivalents.

REMOVAL
1. Remove camshaft, engine.
2. Remove hydraulic lifters (do not interchange) and store with the cam contact surface facing downwards.
3. Bring piston of respective cylinder to Top Dead Center (TDC).






4. Fit assembly tool and adjust mountings to height of studs
5. Remove valve springs with valve lever and press piece.

NOTE: The valves are supported by the piston crown.





6. Remove valve stem seals using puller.

INSTALLATION






1. To prevent damage to the new valve stem seals, place plastic sleeve -A- on the end of the valve stem.
2. Oil valve stem seal -B-, place it in fitting tool and push carefully onto the valve guide.
3. Reverse remaining procedures to install.