Warning: This is a removal description for a gasoline engine. The diesel engine does not require compressed air. The piston of the respective cylinder must first be set to TDC.
Sectional Spark Plug
Withdrawal
1. Remove the camshaft and poppets.
2. Set the piston of the corresponding cylinder to the BDC position. To do this, turn the crankshaft with a socket wrench on the belt pulley bolt so that the notch on the belt pulley coincides with the alignment mark on the toothed belt housing (piston of cylinder 1 is now at TDC). At the same time, the pistons of cylinders 2 and 3 are at BDC. Mark the crankshaft pulley at the bottom with chalk, then turn the pulley 1/2 turn (180 degrees), until the chalk mark lines up with the alignment mark. Pistons 1 and 4 are now at BDC.
3. Remove all spark plugs.
4. Screw the compressed air hose adapter VAG-653/3 or HAZET 3428 into the spark plug hole of the respective cylinder.
5. If there is no adapter, it can be made from an old spark plug. To do this, remove ground electrode 1 (see fig. Sectional Spark Plug). Use a screwdriver to destroy the ceramic insulator 2, then, swinging the central electrode in different directions, break it off and pull it out. Knock out the rest of the central electrode together with fiberglass 4 and connecting electrode 5 with a suitable punch (about 3 mm).
At the same time, clamp the spark plug in a vise or insert it into the appropriate socket head. Attention: To avoid damage to the threads in the cylinder head, the threads of the spark plug must not be damaged.
6. Screw the prepared spark plug into the appropriate cylinder and connect it to the compressed air hose.
7. Continuously pressurize the cylinder with compressed air at a pressure of at least 6 bar.
8. Screw the VAG 2036 special tool on the bearing pedestals 1 and 4 and compress the valve springs with the VAG 541/1 tool. You can also use the HAZET 2577 tool. In this case, screw the support device attached to the tool to the camshaft mounting studs and compress the valve springs with a puller.
Warning: The piston must be at BDC when doing this.
9. Take out the crackers, loosen the springs.
Warning: Loosen firmly seated crackers with light hammer blows on the pry bar.
10. Remove the valve springs and valve springs.
11. Remove the oil seal. In workshops, special tools are used for removal (VAG 10-218, VAG 3047, HAZET 791-5 or HAZET 791-2 impact puller). As a rule, valve stem seals sit very firmly. Therefore, an impact puller must be used for removal.
Installation
1. Plastic sleeve - A - (supplied with oil seals) put on the valve stem. Oil cap - B - lightly lubricate with oil, insert into the upsetting device VAG 10-204 or HAZET 2577 and carefully slide onto the valve guide. Remove the sleeve and upsetting device.
Warning: If the assembly is carried out without using a plastic sleeve, the valve stem seals will be damaged! As a result, the engine consumes too much oil.
2. Install the valve springs and valve spring plate, compress the springs.
3. Insert crackers, loosen the springs.
4. Replace all valve stem seals in the same manner. Install poppets and camshaft.
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