Remove bearing caps #1 and #3 (the reading is taken from the side of the camshaft drive), then alternately unscrew the nuts of the studs securing the bearing caps No. 2 and 4 in a crosswise pattern.
Remove the camshaft from the cylinder head bearings and remove the valve lifters.
Dismantling the valves using a valve spring compressor
Install a valve spring compressor on the cylinder head and, using pointed pliers, release the crackers from the valves.
Remove the plate springs.
Remove the valve stem seals using an inertial puller.
Removing and installing valve stem seals Top: Removing the cap. Bottom: Installing the cap
Take out the valves.
Remove the valve spring washers.
Mark the position of parts to be removed so that parts that cannot be replaced can be returned to their original position during assembly.
Clear the details.
Check the degree of wear of the seats of the valve guides and the clearance between the bushings and the valve stems.
Insert the new valve into the guide bush and determine the gap between the end of the stem and the edge of the guide bush using tool VW 387 with an indicator.
Replace guide bushings if clearance exceeds 0.10 mm for intake valve bushings and 0.13 mm for exhaust valve bushings.
Check the flatness of the mating surface of the cylinder head with a metal ruler and a set of feeler gauges.
Grind, if necessary, the mating surface of the cylinder head within acceptable limits (see subsection «Detailed Specifications»).
Check the condition of the valves and valve springs.
Check the condition of the valve seats and, if necessary, grind them. Grinding is carried out with a special tool and within acceptable limits (cm. «Detailed Specifications»).
On engine models «KU» And «NF» in the case of grinding valve seats, a minimum distance must be maintained to ensure the normal operation of the hydraulic valve lifters «A» (see figure in section «Four cylinder engine») between the end of the valve stem and the upper plane of the cylinder head, which for intake valves should be 33.80 mm, for exhaust valves - 34.10 mm.
The shrinkage of the working chamfer of the valve seat must not exceed a value equal to the difference between the value «A» before grinding the valve seat and the minimum value «A» after grinding.
Grind, if necessary, the working chamfers of the inlet valves. The working chamfers of the exhaust valves are not subject to grinding, grinding of the exhaust valves is allowed, and in other cases they must be replaced.
Thoroughly clean the cylinder head before assembly, and after grinding the valve seats and lapping the valves.
Grind, if necessary, the mating surface of the cylinder head within acceptable limits (see subsection «Detailed Specifications»).
Check the condition of the valves and valve springs.
Check the condition of the valve seats and, if necessary, grind them. Grinding is carried out with a special tool and within acceptable limits (cm. «Detailed Specifications»).
On engine models «KU» And «NF» in the case of grinding valve seats, a minimum distance must be maintained to ensure the normal operation of the hydraulic valve lifters «A» (see figure in section «Four cylinder engine») between the end of the valve stem and the upper plane of the cylinder head, which for intake valves should be 33.80 mm, for exhaust valves - 34.10 mm.
The shrinkage of the working chamfer of the valve seat must not exceed a value equal to the difference between the value «A» before grinding the valve seat and the minimum value «A» after grinding.
Grind, if necessary, the working chamfers of the inlet valves. The working chamfers of the exhaust valves are not subject to grinding, grinding of the exhaust valves is allowed, and in other cases they must be replaced.
Thoroughly clean the cylinder head before assembly, and after grinding the valve seats and lapping the valves.
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