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
^ Valve seal removal tool 3364
^ Valve stem seal driver 3365
^ Valve keeper assembly/disassembly device VAS 5161

Removing
^ Cylinder head installed.
- Remove camshafts and camshaft adjuster.

Note:
^ 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 remove 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 jammed valve keepers 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.
^ Installed 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.
- Simultaneously, turn knurled screw of cartridge clockwise until ends engage in valve keepers.
- Move knurled screw back and forth slightly so that valve keepers 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.
^ Installed 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.
- Simultaneously, turn knurled screw of cartridge clockwise until ends engage in valve keepers.
- Move knurled screw back and forth slightly so that valve keepers are pressed apart and taken up into cartridge.





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

All





- 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 seal driver 3365.
- Remove plastic sleeve.





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

Note: Larger diameter of valve keepers must face upward.





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





- 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 valve keepers.
- Release pressure fork with knurled screw still pulled upward.
- Insert valve lifters.
- Install camshafts and camshaft adjuster.

Note:
^ 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.