Valve Guide Seal: Service and Repair

Valve stem seals, replacing
Special tools and repair equipment required





^ Pressure hose VW 653/3
^ Spark plug wrench 3122 B
^ Puller 3364
^ Fitting tool 3365
^ Insertion device VAS 5161

Removing
^ Cylinder head installed.
^ Remove camshafts and camshaft adjuster, Refer to Camshaft, Engine, Service and Repair.

Notes:
^ Ensure that valve lifters are not interchanged.
^ Mark installation position on back of valve lifters with water-proof felt-tip pen.

^ Remove valve lifters from guides and set them down with contact surface facing downward.
^ Use spark plug wrench 3122B to screw out spark plugs.
^ Set piston of appropriate cylinder to "bottom dead center".





^ Screw pressure hose VW 653/3 into spark plug thread and apply constant pressure of at least 6 bar.





^ Place drift VAS 5161/3 in valve lifter guide.
^ Hammer the jammed valve coffers on all five valves loose using a plastic hammer.





Exhaust side
^ Screw snap-in device VAS 5161/6 with attaching fork VAS 5161/4 onto stud on cylinder head.
^ Push guide bushing VAS 5161/14 as far as it will go into valve lifter guide on valve to be removed.

Installation position:
^ Checkered areas must be at right angle to direction of travel
^ Push knurled spacer ring VAS 5161/17 onto cartridge VAS 5161/8.





^ Push cartridge into guide bushing.
^ Attach pressure fork VAS 5161/2 to snap-in device VAS 5161/6 and press cartridge downward.
^ At the same time, turn knurled screw of cartridge clockwise until ends engage in valve cotters.
^ Move knurled screw back and forth slightly so that valve cotters are pressed apart and taken up into cartridge.
^ Release pressure fork.
^ Remove cartridge with spacer ring, guide bushing, valve head and valve spring.





Intake side
^ Screw snap-in device VAS 5161/6 with attaching fork VAS 5161/4 onto stud on cylinder head.
^ Push guide bushing VAS 5161/13 as far as it will go into valve lifter guide on valve to be removed.

Installation position:
Checkered areas must be at right angle to direction of travel
^ Push knurled spacer ring VAS 5161/17 onto cartridge VAS 5161/8.
^ Push cartridge into guide bushing.
^ Attach pressure fork VAS 5161/2 to snap-in device VAS 5161/6 and press cartridge downward.
^ At the same time, turn knurled screw of cartridge clockwise until ends engage in valve cotters.
^ Move knurled screw back and forth slightly so that valve coffers are pressed apart and taken up into cartridge.





^ Release pressure fork.
^ Remove cartridge with spacer ring, guide bushing, valve head and valve spring.





All models:
^ Pull off valve stem seals with 3364.

Installing

Note: A plastic sleeve -A- is included with new valve stem seals.





^ To prevent damage to new valve stem seals -B-, place plastic sleeve -A- on valve stem.
^ Lightly oil sealing lip of valve stem seal.
^ Push valve stem seal onto plastic sleeve.
^ Carefully press valve stem seal onto valve guide using fitting tool 3365.
^ Remove plastic sleeve.





^ If valve coffers were taken out of cartridge, they must first be placed into insertion device VAS 5161/18.

Note: Larger diameter of valve coffers must face upward.





^ Press cartridge VAS 5161/8 onto insertion device from above and take up valve cotters.





^ Insert cartridge VAS 5161/8 back into guide bushing VAS 5161/13 or VAS 5161/14.
^ Push down pressure fork and pull knurled screw up turning left and right - this inserts the valve cotters.
^ Release pressure fork with knurled screw still pulled upward.
^ Insert valve lifters.
^ Install camshafts and camshaft adjuster 1 5-58.

Notes:
^ After installing camshafts, engine must not be started for approximately 30 minutes. Hydraulic valve compensation elements have to settle (otherwise valves will strike pistons).
^ After working on valve gear, turn engine carefully at least 2 rotations to ensure that none of the valves make contact when starter is operated.