Valve Guide Seal: Service and Repair

LEGEND
1 Camshaft Bearing Cap
2 Camshaft Bearing Cap Nut
3 Camshaft
4 Woodruff Key
5 Camshaft Sprocket Bolt
6 Cylinder Head
7 Camshaft Seal
8 Cylinder Head Reworking Dimension
9 Valves
10 Valve Guide
11 Lower Valve Spring Seat
12 Valve Seal
13 Valve Springs
14 Upper Valve Spring Seat
15 Valve Keepers
16 Valve Lifters

NOTE: During removal and installation procedures, refer to the component location illustration above and component notes below.

COMPONENT NOTES
Camshaft Bearing Cap (1)
- Note installed position.
- Refer to installation sequence below.

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

Camshaft (3)
- For Axial play, radial clearance and runout checking, refer to Testing and Inspection.
- For installation sequence refer to procedure below.

Woodruff Key (4)
- Check for tight fit.

Camshaft Sprocket Bolt (5)
- Tighten to: 80 Nm (60 ft. lbs.).

Cylinder Head (6)
- Some remanufactured cylinder heads my be supplied with undersized camshafts and bearing shells.

Cylinder Head Reworking Dimension (8)
- Dimension -a-:
- Minimum: 132.6 mm (5.2200 inch).

Valves (9)
- Do not reface, only lapping of valves is allowable.
- Refer to Valve, Intake/Exhaust.

Valve Guides (10)
- Replacement guides are supplied with a shoulder.
- Refer to Valve Guide for procedures.

Valve Lifter (16)
- Do not interchange.
- Checking, refer to Lifter, Valve.
- When removed keep camshaft contact surface pointing downward.
- When installing, oil contact surfaces.

REMOVAL
1. Remove camshaft, refer to Camshaft, Lifters and Pushrods.
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.





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

INSTALLATION
Reverse procedure to install.