Removing and Installing Valves

Removing and installing valves

Tools





Preliminary work
1. Remove cylinder head.
2. Remove camshafts.
3. Take hydro-tappets and roller-type cam followers out of the cylinder head and lay them on a clean surface, arranged according to cylinders and valves. Do not confuse components.

Information

Component overview








Removing valves





Note:
^ Secure the cylinder head on a level surface, which allows easy access to the valves from underneath.
^ No valves should be hidden by the surface under the cylinder head.
^ The cylinder head fastening must not tip over when tools are used.

1. Attach the lever tool 2036-1, 2 and 4- to the cylinder head and adjust it. The installation position of the tool must be adjusted for each valve.
2. Attach additional tool VW 541/1A-5- under the pipe of the lever tool 2036 and press the concave washer on the valve down using the pressure piece. Keep pressing the washer down.
3. Remove the two valve keys from the valve using pointed-nose pliers or a fine magnet.
4. Relax the concave washer and valve spring and remove loose components.
5. Press the valve down and pull it out of the valve guide.

Installing valves

Note:
^ Inlet and exhaust valves have different valve stem diameters. Do not confuse them.
^ The valves cannot be touched up afterwards.
^ The valves can be grinded using commercially available valve grinding paste.

1. Check the valve guide (valve tilt clearance).
2. Apply a small amount of valve grinding paste to the valve seat.
3. Oil the valve stem of a new valve and insert it into the valve guide from the combustion chamber. Push the valve in until it is seated securely in the valve seat of the cylinder head.





4. Grind the valve with a commercially available valve grinder (with rubber suction head) using rotating movements. To do this, hold the valve grinder between the palms of both hands and press against the valve seat with rotating movements.

ATTENTION Valve grinding paste residues can cause mechanical damage!
^ Remove all valve grinding paste fully after grinding.

5. Carry out the grinding procedure for each valve.
6. Valve stem seals must be replaced if the mileage is high.
7. Fit the valve springs, concave washers and valve keys using the additional tool VW 541/1A and lever tool 2036.

Subsequent work

1. Fit hydro-tappets and roller-type cam followers.
2. Install camshafts.
3. Fit cylinder head.

Information

Valve dimensions