Table of contents: Removal ↓ Installation ↓
Increased oil consumption may be due to wear of the valve stem caps. They can be removed without dismantling the cylinder head. However, this requires a special tool VW 2036 and VW 541/1 or HAZET 2577-2, and for petrol engines also compressed air.
Note: This describes replacing the caps on a gasoline engine. For a diesel engine, the use of 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.
Removal
Remove the camshaft and hydraulic lifters.
Set the piston of the corresponding cylinder to the bottom dead center (BDC) position. 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, pistons of cylinders 2 and 3 are at BDC. Mark the bottom of the crankshaft pulley with chalk and turn it ½ (180°) of a turn until the chalk mark coincides with the original mark. Now pistons of cylinders 1 and 4 are at BDC.
Remove all spark plugs.
Screw the compressed air adapter VW 653/3 or HAZET 3428 with hose into the corresponding cylinder.
If there is no special tool available, an adapter can be made from an old spark plug. To do this, cut off the ground 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 punch (-3 mm). In this case, clamp the spark plug in a vice or in a chuck.
Caution: Do not damage the spark plug threads, which in turn may cause damage to 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.
Mount the VW 2036 tool on brackets 1 and 4 and compress the valve springs with the VW541/1 tool. The HAZET 2577-2 tool can also be used. In this case, it is necessary to mount the support device on the camshaft support mounting stud and compress the valve springs.
Note: The piston must be at BDC.
Remove the crackers and release the springs.
Caution: Loosen the seats of the crackers by gently striking the lever of the tool with a hammer.
Remove the plate springs and valve springs.
Remove the valve stem caps. To remove them, specialized workshops use the VW10-218 or VW 3047 tool, HAZET 791-5 or the HAZET 791-2 puller. The seals are usually firmly seated. To remove them, you have to use a puller.
Installation
Put on the plastic sleeve "A" (comes with caps) on the valve stem. Lightly lubricate the cap "B" with oil, insert it into the VW 10-204 or HAZET 2577 mandrel and carefully insert it into the valve guide sleeve. Remove the sleeve and mandrel.
Caution: If the seal is installed without using a plastic bushing, the caps may be damaged! After this, the engine will consume an increased amount of oil!
Insert and compress the valve springs and spring retainers.
Insert crackers, release springs.
Replace all caps in a similar manner. Install hydraulic tappets and camshaft.