Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 682
– Install the Valve Cotter Tool Kit - Adapter - T40012- in the
spark plug threads.
– Connect compressed air with at least 6 bar (87 psi) pressure.
– Loosen stuck valve retainers using a Punch - VAS5161/3A-
and a plastic hammer.
For Intake Side
– Install the Valve Cotter Tool Kit - Retainer - VAS5161/6- with
Valve Cotter Tool Kit - Guide Forks M6/M8 Threaded -
VAS5161/5- in the center thread of the Valve Cotter Tool Kit -
Guide Plate 19B - VAS5161/19B- .
– Place the Valve Cotter Tool Kit - Assembly Cartridge -
VAS5161/8- in the Valve Cotter Tool Kit - Guide Plate 19B -
VAS5161/19B- .
– Engage the Pressure Fork With Lever for Assembly Cartridge
- VAS5161/2- on the Retainer - VAS5161/6- .
For Exhaust Side
– Install the Valve Cotter Tool Kit - Retainer - VAS5161/6- with
Valve Cotter Tool Kit - Guide Forks M6/M8 Threaded -
VAS5161/5- in the outer thread of the Valve Cotter Tool Kit -
Guide Plate 19B - VAS5161/19B- .
– Press down the Assembly Cartridge - VAS5161/8A- and at the
same time turn the knurled thumb screw on the Assembly
Cartridge - VAS5161/8A- to the right until the points engage
in the valve retainers.
– Move the knurled thumb screw back and forth slightly. This
presses the valve retainers apart and captures them in the in‐
stallation cartridge.
– Release the Pressure Fork With Lever For Assembly Car‐
tridge - VAS5161/2- .
– Remove the Assembly Cartridge - VAS5161/8A- .
– Remove the valve stem seals using Puller - Valve Seal -
3364- .
– If the Puller - Valve Seal - 3364- cannot be used because there
is not enough space, drive the roll pin -arrow- out using a drift
and remove the impact attachment.
– Position the lower part of the Puller - Valve Seal - 3364- on the
valve stem seal.
– Place the drift -1- in the hole in the lower section of the removal
tool.
– Position the lever on the removal tool and remove the valve
stem seal in direction of -arrow-.
Install Valve Stem Seals
– Place the plastic sleeve -A- that is attached to valve stem seals
-B- on valve stem.
– Lightly oil the valve stem seal.
– Slide the valve stem seal onto the plastic sleeve.
– Carefully press the valve stem seal onto the valve guide with
the Seal Installer - Valve Stem - 3365- .
– Remove plastic sleeve.
– Insert the valve spring and valve spring plate.
– Connect the Valve Keeper Tool Kit - VAS5161A- as illustrated.
Intake Side
Exhaust Side
Note
♦
If the valve retainers were removed from the assembly car‐
tridge, they must then be inserted into the Valve Insertion
Device - VAS5161/18- .
♦
Press the Assembly Cartridge -VAS5161/8A- onto the inser‐
tion device from above and capture the valve retainers.
– Press the Valve Keeper Tool Kit Assembly Cartridge -
VAS5161/8- down with the Valve Keeper Tool Kit Pressure
Fork with Lever for Assembly Cartridge - VAS5161/2- and ro‐
tate the cartridge knurled thumb screw back and forth while
pulling up.
– Release the Pressure Fork with Lever for Assembly Cartridge
- VAS5161/2- with the knurled thumb screw pulled.
– Remove the Valve Keeper Tool Kit - VAS5161A- .
Further assembly is performed in the reverse order of removal,
thereby observing the following:
– Install the camshafts. Refer to
⇒ “4.2 Camshaft, Removing and Installing”, page 136
.
4.6.2
Valve Shaft Seals, Removing and In‐
stalling, Cylinder Removed
Special tools and workshop equipment required
♦ Puller - Valve Seal - 3364-
♦ Seal Installer - Valve Stem - 3365-
♦ Valve Keeper Tool Kit - VAS5161A-
♦ Valve Cotter Tool Kit - Guide Plate 19B - VAS5161/19B-
♦ Engine And Transmission Holder - VAS6095-
♦ Cylinder Head Tensioning Device - VAS6419-
Remove Valve Stem Seals
– Remove the camshafts. Refer to
⇒ “4.2 Camshaft, Removing and Installing”, page 136
– Mark the allocation of the roller rocker lever and the hydraulic
adjusting elements so they can be installed again.
– If necessary, remove the roller rocker levers with the hydraulic
adjusting elements and place them on a clean surface.
– Insert the Cylinder Head Tensioning Device - VAS6419- in the
Engine And Transmission Holder - VAS6095- .
– Tension the cylinder head on the cylinder head tensioning de‐
vice, as illustrated.
– Connect the cylinder head tensioning device to the com‐
pressed air.
– Slide the air cushion with the lever -arrow- under the combus‐
tion chamber onto the valve stem seal that will be removed.
– Let enough compressed air flow into the air cushion until it
contacts the valve plate.
– Install the Valve Cotter Tool Kit - Guide Plate 19B -
VAS5161/19C- with the Valve Cotter Tool Kit Knurled Thumb
Screws M6 - VAS5161/12- as shown on the cylinder head.
– Insert the Punch - VAS5161/3- in the guide plate and loosen
the stuck valve retainers with a plastic mallet.
For Intake Side
– Install the Valve Cotter Tool Kit - Retainer - VAS5161/6- with
Valve Cotter Tool Kit - Guide Forks M6/M8 Threaded -
VAS5161/5- in the center thread of the Valve Cotter Tool Kit -
Guide Plate 19B - VAS5161/19B- .
– Place the Valve Cotter Tool Kit - Assembly Cartridge -
VAS5161/8- in the Valve Cotter Tool Kit - Guide Plate 19B -
VAS5161/19B- .
– Engage the Pressure Fork With Lever for Assembly Cartridge
- VAS5161/2- on the Retainer - VAS5161/6- .
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