Disassembling and Assembling Cylinder Head
WM 157037 Disassembling and assembling cylinder head
Preliminary work for disassembling cylinder head
Preliminary work for disassembling cylinder head
1. Remove engine.
2. Remove transmission.
3. Remove cylinder head.
Disassembling cylinder head
Disassembling cylinder head
Caution:
Risk of damage due to particles of dirt.
Danger of material damage due to blocked oil bores/oil ducts.
- Absolute cleanliness is essential when working on the engine.
- Lay removed engine parts on a clean base and make sure to cover them.
- Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
The following tool is used and recommended for the described work: commercially available tool Valve keys assembly disassembly tool for Boxster + Carrera NR.54 (Sauer Co., Art. No. for standard case 600 50 00).
Disassembling and assembling cylinder head tools
Component overview of cylinder head
Cylinder head components
Information:
Reusable inner parts of the cylinder head must always be cleaned thoroughly and assigned to their original installation location.
1. Remove spark plugs, if not already done.
2. Screw in the three valve locating screws -arrows- in the spark plug threads.
Valve locating screws
Information:
Put the screw clamps for fixing the cylinder head only on the aluminum supports, under no circumstances on the sealing surface.
3. Align aluminum supports on the cylinder head with fastening screws. Fix cylinder head to the workbench with screw clamps. Slide on assembly shaft with the joint to the aluminum supports and fasten them.
Mounting aluminum supports
4. Screw lever arm on joint and the disassembly head on the lever arm.
5. Place disassembly head on upper valve-spring plate and press together the valve springs with the lever arm. The valve keys and the concave washer stick due to the magnetic insert on the disassembly head. Repeat this process by moving the joint at the required valves.
6. Using the VW special tool puller 3364 pull off the valve-stem seal.
Pulling off the valve-stem seal (VW-special tool 3364)
7. Check valve springs, valves, valve guides, and valve seats for damage.
8. Thoroughly clean cylinder head and all parts before assembling. Carry out repairs approved by PAG, if necessary.
Assembling cylinder head
Assembling cylinder head
Information:
Reusable inner parts of the cylinder head must always be cleaned thoroughly and assigned to their original installation location.
Information:
Replace valve-stem seal.
1. Insert lower valve-spring plate, oil valve stem lightly and position assembly sleeve (shim set for valve-stem seals). Either set new valve-stem seal on the assembly sleeve or insert in the assembly driver 9606.
Valve stem seal
2. Press valve-stem seal with the assembly driver 9606 up to the stop on the valve stem. Take off tool and assembly sleeve.
Valve-stem seal on valve stem
Pressing in valve-stem seal
3. Insert corresponding valve spring(s) and upper valve-spring plate.
4. Fasten assembly head to lever arm. Push sliding sleeve downward to the stop and insert the valve keys. In order to ensure correct assembly, the wedges should be centered. Then push the sliding sleeve back again (valve keys fixed).
Assembly head for valve keys
5. Position assembly head with the pressure piece over the valve stem and align the assembly head so that it is aligned with the valve. Slowly press the assembly head downwards and guide it with your hand until a clicking sound can be heard. The valve keys are then automatically pressed into the correct installation position.
Mounting the valve keys
6. Swivel out the lever with the assembly head and check the seat of the valve keys. Repeat the process if necessary.
Assembling cylinder head, touching up
Assembling cylinder head, touching up
1. Install cylinder head.
2. Mount transmission.
3. Install engine.