Valve Guide Seal: Service and Repair

LEGEND
1 Bearing Cap
2 Nut
3 Camshaft
4 Valve Stem Seal
5 Cylinder Head
6 Oil Seal
7 Exhaust Valve
8 Hydraulic Valve Lifter
9 Intake Valve

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

COMPONENT NOTES
Bearing Cap (1)
- Note installation position..

Nut (2)
- Tighten to: 17 Nm (13 ft. lbs.)..

Camshaft (3)
- Maximum runout: 0.01 mm (0.0004 inch).

Valve Stem Seal (4)
- Always replace..

Oil Seal (6)
- Always replace.

Hydraulic Valve Lifter (8)
- Oil contact surfaces before installing.
- Store with cam lobe contact surface facing downward.

REMOVAL

NOTE: Cylinder head installed

1. Remove toothed timing belt, refer to Timing Components.
2. Remove camshafts and hydraulic lifters.
3. Remove spark plugs.
4. Rotate crankshaft by hand to set piston of appropriate cylinder to Bottom Dead Center (BDC).
5. Thread hose tool No. VW 653/3 hose and cylinder leakdown tester tool No. US 1106, or equivalents, with seal into spark plug hole by hand and apply a continuous pressure of at least 6 bar (87 psi).





6. Install compressor tool No. 2036 and adjust to height of studs.
7. Remove valve spring with valve spring tensioner tool No. VW 541/1 and thrust pad tool No. VW 541/5, or equivalents.

NOTE: Tight valve keepers can be loosened by tapping lightly on lever vVV541/1 with a hammer.

8. Remove valve springs.





9. Remove valve stem oil seal with slide hammer tool No. 3047 A, or equivalent.

INSTALLATION





1. Fit protective sleeve over valve stem.
2. Slide seal carefully onto valve guide.

NOTE: Always use the enclosed plastic sleeve for installation of valve stem oil seals to protect the seal from being damaged by the valve keeper grooves.

3. Reverse remaining procedures to install.