Attention: This describes the replacement of caps on a gasoline engine. For a diesel engine, compressed air is not required, but the piston of the corresponding cylinder must be at top dead center (TDC). Set the piston of the first cylinder to TDC.
Withdrawal
Remove the camshaft and hydraulic lifters.
Set the piston of the corresponding cylinder to the bottom dead center position (NMT). To do this, turn the crankshaft by the pulley so that the mark on the pulley coincides with the base mark on the toothed belt cover (the piston of the first cylinder is then at TDC) In this case, the pistons of cylinders 2 and 3 are at BDC. Mark crankshaft pulley from below with chalk and turn ½ (180°) turnover until then. until the chalk marking matches the original mark. The pistons of cylinders 1 and 4 are now at BDC.
Remove all spark plugs.
Screw the compressed air adapter VW 653/3 or HAZET 3428 with hose into the appropriate cylinder.
If a special tool is not available, the adapter can be made from an old spark plug. To do this, cut off the earth electrode -1-. Break the ceramic insulator -2- with a screwdriver and break and remove the central electrode -3-. Knock out the remains of the central electrode together with the glass sealant -4- and the contact head -5- with a suitable beard (-3mm). In this case, clamp the candle in a vice or in a cartridge.
Attention: Do not damage the threads of the spark plug, which in turn can damage the threads in the cylinder head.
Screw the spark plug into the appropriate cylinder and connect it to the compressed air hose.
Supply air to the cylinder with a pressure of at least 6 bar.
Install tool VW 2036 on support 1 and 4 and compress valve springs with tool VW541/1. Tool HAZET 2577-2 can also be used. In this case, it is necessary to install a support device on the stud of the camshaft support and compress the valve springs.
Attention: The piston must be at BDC.
Take out the crackers and decompress the springs.
Attention: Loosen the seats of the crackers with soft hammer blows on the tool lever.
Remove the poppet springs and valve springs.
Remove valve stem caps. To remove them, specialized workshops use the VW10-218 or VW 3047, HAZET 791-5 or HAZET 791-2 puller. Seals sit, as a rule, firmly. You have to use a puller to remove them.
Installation
Put on the plastic sleeve -A- (supplied with caps) on the valve stem. Lightly lubricate cap -B- with oil, insert into tool VW 10-204 or HAZET 2577 and carefully insert into valve guide. Remove sleeve and mandrel.
Caution: If the seal is fitted without using the plastic sleeve, the caps may be damaged! After that, the engine will consume an increased amount of oil!
Insert and compress valve springs and spring plates.
Insert crackers, open the springs.
Replace all caps in the same way. Install hydraulic tappets and camshaft.
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