Overhaul
Disassembling and assembling cylinder headTools
Preliminary work for disassembling cylinder head
1. Remove engine.
2. Remove transmission.
3. Remove cylinder head.
Disassembling cylinder head
ATTENTION: Risk of damage due to particles of dirt.
^ Oil bores/oil ducts can become blocked up.
^ When working on the engine, absolute cleanliness is essential.
^ Lay removed engine parts on a clean base and cover them without fail.
^ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
The following tool is used and recommended for the described work: commercially available tool Valve keys assembly-disassembly tool for Boxster + Carrera NR.54 (Sauer Co., Art. No. for standard case 600 50 00).
Component overview of cylinder head
Note: Reusable inner parts of the cylinder head must always be cleaned thoroughly and assigned to their original installation location.
1. Remove spark plugs, if not already done.
2. Screw in the three valve locating screws -arrows- in the spark plug threads.
Note: Put the screw clamps for fixing the cylinder head only on the aluminium supports, under no circumstances on the sealing surface.
3. Align aluminium supports on the cylinder head with fastening screws. Fix cylinder head to the workbench with screw clamps. Slide on assembly shaft with the joint to the aluminium supports and fasten them.
4. Screw lever arm on joint and the disassembly head on the lever arm.
5. Place disassembly head on upper valve-spring plate and press together the valve springs with the lever arm. The valve keys and the concave washer stick due to the magnetic insert on the disassembly head. Repeat this process by moving the joint at the required valves.
6. Using the VW special tool puller 3364 pull off the valve-stem seal.
7. Check valve springs, valves, valve guides, and valve seats for damage.
8. Thoroughly clean cylinder head and all parts before assembling. Carry out repairs approved by PAG, if necessary.
Assembling cylinder head
Note: Reusable inner parts of the cylinder head must always be cleaned thoroughly and assigned to their original installation location.
Note: Replace valve-stem seal.
1. Insert lower valve-spring plate, oil valve stem lightly and position assembly sleeve (shim set for valve-stem seals). Either set new valve-stem seal on the assembly sleeve or insert in the assembly driver 9606.
2. Press valve-stem seal with the assembly driver 9606 up to the stop on the valve stem. Take off tool and assembly sleeve.
3. Insert corresponding valve spring(s) and upper valve-spring plate.
4. Fasten assembly head to lever arm. Push sliding sleeve downward to the stop and insert the valve keys. In order to ensure correct assembly, the wedges should be centered. Then push the sliding sleeve back again (valve keys fixed).
5. Position assembly head with the pressure piece over the valve stem and align the assembly head so that it is aligned with the valve. Slowly press the assembly head downwards and guide it with your hand until a clicking sound can be heard. The valve keys are then automatically pressed into the correct installation position.
6. Swivel out the lever with the assembly head and check the seat of the valve keys. Repeat the process if necessary.
Assembling cylinder head, touching up
1. Install cylinder head.
2. Mount transmission.
3. Install engine.