Volkswagen Workshop Service and Repair Manuals

(with cylinder head fitted)

Special tools, testers and auxiliary items

• ◆ Torque wrench V.A.G 1331 (5...50 Nm)
• ◆ Torque wrench V.A.G 1332 (40...200 Nm)
• ◆ Spark plug spanner 3122B
• ◆ Puller 3047A
• ◆ Assembly tool 2036
• ◆ Pressure hose VW 653/3
• ◆ Lever VW 541/1A with press piece VW 541/5
• ◆ Fitting tool 3129

Removing

• ‒ First remove camshafts .
• ‒ Remove the bucket tappets and place them with the contact surface downwards. When doing this ensure that the tappets are not interchanged.
• ‒ Remove spark plugs with spark plug spanner 3122B.
• ‒ Set piston of appropriate cylinder to "bottom dead centre".
• ‒ Screw pressure hose VW 653/3 into the spark plug thread.
• ‒ Connect pressure hose to compressed air system supplying
       at least 6 bar
  and remove valve springs.
• ‒ Fit assembly tool 2063 and adjust to height of studs.
• ‒ Remove valve springs with lever VW 541/1A and press piece VW 541/5.

Note:

Tight cotters can be loosened by tapping lightly on the lever.

→ Inlet side

Note:

If necessary, to prevent the lever from slipping on the tool, a notch should be made on the lever as shown a = 50 mm.

→ Exhaust side

• ‒ Pull off valve stem seals with 3047A.

Installing

• ‒ → To prevent damage to the new valve stem seals, place plastic sleeve -A- on valve shaft.
• ‒ Oil valve stem seal -B-, place it in the tool 3129 and push carefully onto the valve guide.