Valve Guide Seal: Service and Repair
Valve Stem Seals
Special tools, testers and auxiliary items required
• Hinged Socket (3220)
• Valve Seal Removal Tool (3364)
• Valve Stem Seal Driver (3365)
• Valve Cotters Asm/Disasm Device (VAS 5161) with
• Guide Plate for 3.0 Liter TDI Engine (VAS 5161/23)
Removing
With Ceramic Glow Plugs
CAUTION!
• Ceramic glow plugs are very sensitive because of the materials they are made with. They require special handling when assembling and disassembling. Always follow the procedures described when removing and installing. Refer to one of the following:
• => [ Ceramic Glow Plugs ] Ceramic Glow Plugs
• => [ Metal Glow Plugs ] Metal Glow Plugs
With Metal Glow Plugs
- Remove the glow plugs using (3220).
Continuation for All
- Remove the camshafts. Refer to => [ Camshafts ] Camshafts.
- Install the (VAS 5161/23) on the cylinder head.
- Secure the guide plate using (VAS 5161/12).
- Insert the (VAS 5161/3) into the guide plate and loosen any stuck valve retainers using a plastic mallet.
- Install the (VAS 5161/10) in the guide plate.
- Install the (VAS 5161/11) in the glow plug threads and tighten by hand.
- Install the (VAS 5161/6) with (VAS 5161/5) into the (VAS 5161/23).
- Push the (VAS 5161/23-1) onto the (VAS 5161/8).
- Connect compressed air to the (VAS 5161/11) with a commercially available connector and apply constant pressure.
• Minimum pressure: 6 bar
- Engage the (VAS 5161/2) at (VAS 5161/23-1) and press down (VAS 5161/8).
- At the same time, turn the knurled bolt on the (VAS 5161/8) to the right, until the points engage in the valve retainers.
- Lightly move the knurled bolt back and forth, causing the valve retainers to be pressed apart and be captured in the (VAS 5161/8).
- Release the pressure fork.
- Remove the (VAS 5161/8) with the spacer ring, the valve plate and the valve spring.
- Pull off valve stem seals using (3364).
If the (3364) cannot be used on some valve stem seals due to restricted clearance, proceed as follows:
- Drive the tensioning pin - arrow - on the (3364) out with a drift and remove the impact puller attachment.
- Place the lower section of the (3364) on the valve stem seal.
- Using a drift or punch - 1 - insert it into the (3364) as illustrated.
- Using the drift or punch - 1 - and the (3364), remove the seal - arrow -.
• A plastic sleeve - A - is supplied with the new valve shaft seals.
- Place the plastic sleeve - A - on the valve stem to prevent damage to new valve stem seals - B -.
- Lightly lubricate the sealing lips of the valve stem seal with oil.
- Push the valve stem seal onto plastic sleeve.
- Carefully press the valve stem oil seal onto valve guide using (3365).
- Remove the plastic sleeve again.
- If the valve retainers were removed from the (VAS 5161/18), they must then be inserted into the (VAS 5161/18).
• The large diameter of the valve retainers point upward.
- Press the (VAS 5161/18) onto the insertion tool from above and install the valve retainers.
- Insert the (VAS 5161/8) in the (VAS 5161/23).
- Press the pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve retainers.
- Release pressure fork with the knurled bolt still pulled.
Installation is performed in reverse order of removal, noting the following:
- Install the glow plugs. Refer to one of the following:
=> [ Ceramic Glow Plugs ] Ceramic Glow Plugs.
=> [ Metal Glow Plugs ] Metal Glow Plugs.
- Install the camshafts. Refer to => [ Camshafts ] Camshafts.
• After installing the camshafts, do not crank the engine for at least 30 minutes. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on the pistons).
• After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.