CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
3.3
Checking axial clearance of camshafts
Special tools and workshop equipment required
♦ Universal dial gauge holder - VW 387-
♦ Dial gauge - VAS 6079-
Test sequence
– Perform measurement with retaining frame removed.
– Fit camshaft to be tested in retaining frame.
– Attach dial gauge - VAS 6079- with universal dial gauge holder
- VW 387- to cylinder head.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
•
Axial clearance: 0.05 to 0.17 mm
3.4
Renewing valve stem seals
⇒ “3.4.2 Removing and installing valve stem seals (cylinder head
removed)”, page 205
3.4.1
Removing and installing valve stem seals (cylinder head installed)
200
Rep. gr.15 - Cylinder head, valve gear
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Special tools and workshop
equipment required
♦ Spark plug socket - 3122 B-
♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365-
♦ Adapter - T40012-
♦ Torque wrench - V.A.G 1331-
♦ Dismantling and assembling device for valve cotters - VAS
5161-
♦ Guide plate - VAS 5161/19C-
Removing valve stem oil seals
– Remove camshafts ⇒ page 185 .
– Mark allocation of roller rocker fingers and hydraulic compen‐
sation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and place down on a clean surface.
– Unscrew spark plugs using spark plug socket and extension -
3122 B- .
3. Valve gear
201
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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Reworking guide plate
Check if recess -arrow- is present.
– If necessary, rework guide plate - VAS 5161/19C- -arrow-, until
it rests against cylinder head and guide plate -1- is free.
– Bolt guide plate - VAS 5161/19C- to cylinder head using
knurled screws - VAS 5161/12- .
Installation position:
-E- points towards intake side
-A- points towards exhaust side
– Set piston of respective cylinder to “bottom dead centre”.
– Screw adapter - T40012- into spark plug thread.
– Connect compressed air with pressure rating of at least 6 bar.
– Strike tight valve cotters with drift - VAS 5161/3- and a plastic
hammer.
For inlet side
– Screw retainer - VAS 5161/6- with guide fork - VAS 5161/5-
into centre thread of guide plate - VAS 5161/19C- .
– Insert assembly cartridge - VAS 5161/8- into guide plate - VAS
5161/19C- .
– Attach pressure fork - VAS 5161/2- to retainer - VAS 5161/6- .
202
Rep. gr.15 - Cylinder head, valve gear
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
For exhaust side
– Screw retainer - VAS 5161/6- with guide fork - VAS 5161/5-
into outer thread of guide plate - VAS 5161/19C- .
– Press installation cartridge - VAS 5161/8- down and turn
knurled screw of installation cartridge - VAS 5161/8- to right
until tips engage in valve cotters.
– Move knurled screw back and forth slightly to press apart valve
cotters and capture them in the assembly cartridge.
– Release pressure fork - VAS 5161/2- .
– Remove installation cartridge - VAS 5161/8- .
– Pull off valve stem seals using valve stem seal puller - 3364- .
– If valve stem seal puller - 3364- cannot be used on account of
restricted space, drive out roll pin -arrow- with a drift and re‐
move impact extractor attachment.
– Place lower part of valve stem seal puller - 3364- onto valve
stem seal.
– Insert punch -1- into bore in lower part of puller.
– Place installation lever on puller and pull out valve stem seal
-arrow-.
3. Valve gear
203
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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Installing valve stem seals
– Place plastic sleeve -A-, enclosed with new valve stem seals
-B-, onto valve stem.
– Lightly oil sealing lip of valve stem seal.
– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Take out plastic sleeve.
– Insert valve spring and valve spring plate.
– Install removal and installation device for valve cotters - VAS
5161- as shown.
Inlet side
Exhaust side
204
Rep. gr.15 - Cylinder head, valve gear
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Note
♦ If the valve cotters have been removed from the installation
cartridge, they must first be inserted into the insertion device
- VAS 5161/18- .
♦ Press assembly cartridge -VAS 5161/8- onto insertion device
from above and pick up valve cotters.
– Press installation cartridge - VAS 5161/8- down with pressure
fork - VAS 5161/2- , and turn installation cartridge knurled
screw back and forth whilst pulling upwards.
– Relieve pressure fork - VAS 5161/2- whilst pulling on knurled
screw.
– Remove removal and installation device - VAS 5161- .
The remaining assembly steps are basically a reverse of the dis‐
mantling procedure, when doing this note as follows:
– Install camshafts ⇒ page 185 .
3.4.2
Removing and installing valve stem seals (cylinder head removed)
Special tools and workshop
equipment required
3. Valve gear
205
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365-
♦ Dismantling and assembling device for valve cotters - VAS
5161-
♦ Guide plate - VAS 5161/19C-
♦ Engine and gearbox support - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-
Removing valve stem oil seals
– Remove camshafts ⇒ page 185 .
– Mark allocation of roller rocker fingers and hydraulic compen‐
sation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and place down on a clean surface.
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Tension cylinder head on cylinder head tensioning device as
shown in illustration.
– Connect cylinder head tensioning device to compressed air.
– Use lever -arrow- to slide air cushion under combustion cham‐
ber from which valve stem seal is to be removed.
– Allow compressed air to flow into air cushion until it lies against
valve disc.
Reworking guide plate
Check if recess -arrow- is present.
– If necessary, rework guide plate - VAS 5161/19C- -arrow-, until
it rests against cylinder head and guide plate -1- is free.
– Bolt guide plate - VAS 5161/19C- to cylinder head using
knurled screws - VAS 5161/12- .
Installation position:
-E- points towards intake side
-A- points towards exhaust side
– Insert drift -VAS 5161/3- into guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
206
Rep. gr.15 - Cylinder head, valve gear
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
For inlet side
– Screw retainer - VAS 5161/6- with guide fork - VAS 5161/5-
into centre thread of guide plate - VAS 5161/19C- .
– Insert assembly cartridge - VAS 5161/8- into guide plate - VAS
5161/19C- .
– Attach pressure fork - VAS 5161/2- to retainer - VAS 5161/6- .
For exhaust side
– Screw retainer - VAS 5161/6- with guide fork - VAS 5161/5-
into outer thread of guide plate - VAS 5161/19C- .
– Press installation cartridge - VAS 5161/8- down and turn
knurled screw of installation cartridge - VAS 5161/8- to right
until tips engage in valve cotters.
– Move knurled screw back and forth slightly to press apart valve
cotters and capture them in the assembly cartridge.
– Release pressure fork - VAS 5161/2- .
– Remove installation cartridge - VAS 5161/8- .
– Pull off valve stem seals using valve stem seal puller - 3364- .
Installing valve stem seals
– Place plastic sleeve -A-, enclosed with new valve stem seals
-B-, onto valve stem.
– Lightly oil sealing lip of valve stem seal.
– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.
– Insert valve spring and valve spring plate.
– Remove removal and installation device for valve cotters -
VAS 5161- as shown.
3. Valve gear
207
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Inlet side
Exhaust side
Note
♦ If the valve cotters have been removed from the installation
cartridge, they must first be inserted into the insertion device
- VAS 5161/18- .
♦ Press assembly cartridge -VAS 5161/8- onto insertion device
from above and pick up valve cotters.
– Press installation cartridge - VAS 5161/8- down with pressure
fork - VAS 5161/2- , and turn installation cartridge knurled
screw back and forth whilst pulling upwards.
– Relieve pressure fork - VAS 5161/2- whilst pulling on knurled
screw.
– Remove removal and installation device for valve cotters -
VAS 5161- .
Further assembly is basically a reverse of the dismantling se‐
quence. During this procedure, observe the following:
– Install camshafts ⇒ page 185 .
3.5
Checking valve guides
Special tools and workshop equipment required
208
Rep. gr.15 - Cylinder head, valve gear
2024 VW Passat Owner's Manual
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