Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 682

– Install the Valve Cotter Tool Kit - Adapter - T40012- in the

spark plug threads.

– Connect compressed air with at least 6 bar (87 psi) pressure.
– Loosen stuck valve retainers using a Punch - VAS5161/3A-

and a plastic hammer.

For Intake Side
– Install the Valve Cotter Tool Kit - Retainer - VAS5161/6- with

Valve Cotter Tool Kit - Guide Forks M6/M8 Threaded -

VAS5161/5- in the center thread of the Valve Cotter Tool Kit -

Guide Plate 19B - VAS5161/19B- .

– Place the Valve Cotter Tool Kit - Assembly Cartridge -

VAS5161/8- in the Valve Cotter Tool Kit - Guide Plate 19B -

VAS5161/19B- .

– Engage the Pressure Fork With Lever for Assembly Cartridge

- VAS5161/2- on the Retainer - VAS5161/6- .

For Exhaust Side
– Install the Valve Cotter Tool Kit - Retainer - VAS5161/6- with

Valve Cotter Tool Kit - Guide Forks M6/M8 Threaded -

VAS5161/5- in the outer thread of the Valve Cotter Tool Kit -

Guide Plate 19B - VAS5161/19B- .

– Press down the Assembly Cartridge - VAS5161/8A- and at the

same time turn the knurled thumb screw on the Assembly

Cartridge - VAS5161/8A- to the right until the points engage

in the valve retainers.

– Move the knurled thumb screw back and forth slightly. This

presses the valve retainers apart and captures them in the in‐

stallation cartridge.

– Release the Pressure Fork With Lever For Assembly Car‐

tridge - VAS5161/2- .

– Remove the Assembly Cartridge - VAS5161/8A- .

– Remove the valve stem seals using Puller - Valve Seal -

3364- .

– If the Puller - Valve Seal - 3364- cannot be used because there

is not enough space, drive the roll pin -arrow- out using a drift

and remove the impact attachment.

– Position the lower part of the Puller - Valve Seal - 3364- on the

valve stem seal.

– Place the drift -1- in the hole in the lower section of the removal

tool.

– Position the lever on the removal tool and remove the valve

stem seal in direction of -arrow-.

Install Valve Stem Seals
– Place the plastic sleeve -A- that is attached to valve stem seals

-B- on valve stem.

– Lightly oil the valve stem seal.
– Slide the valve stem seal onto the plastic sleeve.
– Carefully press the valve stem seal onto the valve guide with

the Seal Installer - Valve Stem - 3365- .

– Remove plastic sleeve.
– Insert the valve spring and valve spring plate.
– Connect the Valve Keeper Tool Kit - VAS5161A- as illustrated.

Intake Side

Exhaust Side

Note

♦

If the valve retainers were removed from the assembly car‐

tridge, they must then be inserted into the Valve Insertion

Device - VAS5161/18- .

♦

Press the Assembly Cartridge -VAS5161/8A- onto the inser‐

tion device from above and capture the valve retainers.

– Press the Valve Keeper Tool Kit Assembly Cartridge -

VAS5161/8- down with the Valve Keeper Tool Kit Pressure

Fork with Lever for Assembly Cartridge - VAS5161/2- and ro‐

tate the cartridge knurled thumb screw back and forth while

pulling up.

– Release the Pressure Fork with Lever for Assembly Cartridge

- VAS5161/2- with the knurled thumb screw pulled.

– Remove the Valve Keeper Tool Kit - VAS5161A- .
Further assembly is performed in the reverse order of removal,

thereby observing the following:
– Install the camshafts. Refer to

⇒ “4.2 Camshaft, Removing and Installing”, page 136

 .

4.6.2

Valve Shaft Seals, Removing and In‐

stalling, Cylinder Removed

Special tools and workshop equipment required
♦ Puller - Valve Seal - 3364-
♦ Seal Installer - Valve Stem - 3365-
♦ Valve Keeper Tool Kit - VAS5161A-
♦ Valve Cotter Tool Kit - Guide Plate 19B - VAS5161/19B-

♦ Engine And Transmission Holder - VAS6095-
♦ Cylinder Head Tensioning Device - VAS6419-
Remove Valve Stem Seals
– Remove the camshafts. Refer to

⇒ “4.2 Camshaft, Removing and Installing”, page 136

 .

– Mark the allocation of the roller rocker lever and the hydraulic

adjusting elements so they can be installed again.

– If necessary, remove the roller rocker levers with the hydraulic

adjusting elements and place them on a clean surface.

– Insert the Cylinder Head Tensioning Device - VAS6419- in the

Engine And Transmission Holder - VAS6095- .

– Tension the cylinder head on the cylinder head tensioning de‐

vice, as illustrated.

– Connect the cylinder head tensioning device to the com‐

pressed air.

– Slide the air cushion with the lever -arrow- under the combus‐

tion chamber onto the valve stem seal that will be removed.

– Let enough compressed air flow into the air cushion until it

contacts the valve plate.

– Install the Valve Cotter Tool Kit - Guide Plate 19B -

VAS5161/19C- with the Valve Cotter Tool Kit Knurled Thumb

Screws M6 - VAS5161/12- as shown on the cylinder head.

– Insert the Punch - VAS5161/3- in the guide plate and loosen

the stuck valve retainers with a plastic mallet.

For Intake Side
– Install the Valve Cotter Tool Kit - Retainer - VAS5161/6- with

Valve Cotter Tool Kit - Guide Forks M6/M8 Threaded -

VAS5161/5- in the center thread of the Valve Cotter Tool Kit -

Guide Plate 19B - VAS5161/19B- .

– Place the Valve Cotter Tool Kit - Assembly Cartridge -

VAS5161/8- in the Valve Cotter Tool Kit - Guide Plate 19B -

VAS5161/19B- .

– Engage the Pressure Fork With Lever for Assembly Cartridge

- VAS5161/2- on the Retainer - VAS5161/6- .