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)

• Guide Plate for 3.0 Ltr. TDI Engine (VAS 5161/23)

Removing

- Remove the glow plugs using the hinged socket (3220). Refer to => [ Glow Plugs ] Service and Repair.

- Remove the camshafts. Refer to => [ Camshaft ] Service and Repair.

- Position the guide plate for 3.0 ltr. TDI engine (VAS 5161/23) on the cylinder head.

- Attach the guide plate to the intake manifold side of the head using the knurled thumb screw M6 (VAS 5161/12) and to the stud bolts hand tight with M6 nuts - 1 -.






- Install the compression stud (VAS 5161/10) in the guide plate.

- Install the adapter for compressed air connection (VAS 5161/11) in the glow plug threads and tighten hand tight.






- Insert the punch (VAS 5161/3) into the guide plate and loosen the stuck valve retainers using a plastic mallet.






- Install the guide forks M6/M8 with threaded studs (VAS 5161/5) in the guide plate with the retainer (VAS 5161/6).






- Push the knurled spacer ring (VAS 5161/23-1) onto the assembly cartridge (VAS 5161/8).

- Connect the adapter for compressed air connection (VAS 5161/11) to compressed air with a commercially available connector and apply a constant pressure.

• Minimum pressure: 6 bar positive pressure.

- Engage the pressure fork with lever for assembly cartridge (VAS 5161/2) at the engaging device and press down the assembly cartridge.

- At the same time, turn the knurled thumb screw of the assembly cartridge to the right, until the points engage in the valve retainers.

- Lightly move the knurled thumb screw back and forth, this causes the valve retainers to be pressed apart and captured in the assembly cartridge.

- Release the pressure fork.

- Remove the assembly cartridge with the knurled spacer ring, the spring plate and the valve spring.

- Pull off the valve stem seal using the valve seal removal tool (3364).






Installing

• A plastic sleeve - A - is supplied with the new valve stem seals.






- Place the plastic sleeve - A - on the valve stem to prevent damage to the new valve stem seal - B -.

- Lightly coat the sealing lips of the valve stem seal with oil.

- Push the valve stem seal onto the plastic sleeve.

- Carefully press the valve stem seal onto the valve guide using valve stem seal driver (3365).

- Tap lightly on the driver with a plastic mallet until the valve stem seal is seated.

- Remove the plastic sleeve.

- Insert the valve spring and spring plate on the cylinder head.

- If the valve retainers were removed from the assembly cartridge, they must then be inserted into the valve insertion device (VAS 5161/18).






• The large diameter of the valve retainers point upward.

- Press the assembly cartridge onto the valve insertion device from above and remove the valve retainers.

- Insert the assembly cartridge (VAS 5161/8) in the guide plate.






- Press the pressure fork down and pull the knurled thumb screw upward while turning it left and right to insert the valve retainers.

- Release the pressure fork with the knurled thumb screw still pulled.

Further installation is in the reverse order of removal. Note the following:

- Install the glow plugs. Refer to => [ Glow Plugs ] Service and Repair.

- Install the camshafts. Refer to => [ Camshaft ] Service and Repair.

• After installing the camshafts, do not crank the engine for at least 30 minutes. The hydraulic lash adjusters must seat themselves (otherwise the valves will crash into the pistons).

• After working on the valvetrain and adjusters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that the valves do not strike the pistons.