Valve Guide Seal: Service and Repair
Valve Stem Seals
Special tools, testers and auxiliary items required
• Pressure hose (VW 653/3)
• Spark Plug Removal Tool (3122 B)
• Valve Seal Removal Tool (3364)
• Valve Stem Seal Driver (3365)
• Valve Cotter Disassembly and Assembly Device (VAS 5161)
Procedure
- Remove camshafts and the camshaft adjuster. Refer to => [ Camshafts and Camshaft Adjuster ] Camshafts and Camshaft Adjuster.
• Ensure valve lifters are not exchanged.
• Mark allocation of valve lifter to rear side with waterproof felt-tip pen.
- Remove valve lifter from guides and lay aside with contact surface facing down.
- Using Spark Plug Removal Tool (3122 B), remove spark plugs.
- Adjust piston of the respective cylinder to "Bottom Dead Center position".
- Install the Pressure Hose (VW 653/3) into the spark plug thread and connect the hose to compressed air.
• Pressure: Min. 6 bar positive pressure.
- Insert Drift (VAS 5161/3) into the valve lifter guide.
- Loosen tight valve keepers at all five valves with plastic hammer.
Exhaust side:
- Attach the Engaging Device (VAS 5161/6) and Installation Fork (VAS 5161/4) to a threaded bolt on the cylinder head.
- Slide Guide Socket (VAS 5161/14) up to stop into valve lifter guide on valve to be removed.
• Installation position: Corrugated surfaces face at right angles to direction of travel.
- Push the Knurled Spacer Ring (VAS 5161/17 ) onto the Installation Cartridge (VAS 5161/8 ).
- Push installation cartridge into guide socket.
- Engage Pressure Fork (VAS 5161/2) at Engaging Device (VAS 5161/6) and press down installation cartridge.
- At the same time, turn knurled bolt of installation cartridge to the right, until the points engage in the valve keepers.
- Lightly move knurled bolt back and forth, causing the valve keepers to be pressed apart and be captured in the installation cartridge.
- Release pressure fork.
- Remove the installation cartridge and spacer ring, the valve plate and valve spring.
Intake side
- Attach the Engaging Device (VAS 5161/6) and Installation Fork (VAS 5161/4) to a threaded bolt on the cylinder head.
- Slide Guide Socket (VAS 5161/13) up to stop into valve lifter guide on valve to be removed.
• Installation position: Corrugated surfaces face at right angles to direction of travel.
- Push the Knurled Spacer Ring (VAS 5161/17 ) onto the Installation Cartridge (VAS 5161/8 ).
- Push installation cartridge into guide socket.
- Engage Pressure Fork (VAS 5161/2) at Engaging Device (VAS 5161/6) and press down installation cartridge.
- At the same time, turn knurled bolt of installation cartridge to the right, until the points engage in the valve keepers.
- Lightly move knurled bolt back and forth, causing the valve keepers to be pressed apart and be captured in the installation cartridge.
- Release pressure fork.
- Remove the installation cartridge and spacer ring, the valve plate and the valve spring.
Continued for both sides:
- Pull off valve stem oil seals using Valve Seal Removal Tool (3364).
• A plastic sleeve - A - is supplied with the new valve shaft seals.
- Place plastic sleeve - A - on valve stem to prevent damage to new valve stem seals - B -.
- Lightly coat sealing lips of valve stem seal with oil.
- Push valve stem seal onto plastic sleeve.
- Carefully press valve stem oil seal onto valve guide using Valve Stem Seal Driver (3365).
- Remove plastic sleeve again.
- If the valve keys were removed from the installation cartridge, they must be inserted into Insertion Device (VAS 5161/18 ) next.
• The large diameter of the valve keepers point upward.
- Press Installation Cartridge (VAS 5161/8 ) onto insertion device from above and take up valve keepers.
- Install the installation cartridge into the Guide Socket (VAS 5161/13) or (VAS 5161/14).
- Press the pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve keepers.
- Release pressure fork with the knurled bolt still pulled.
- Insert valve lifter.
- Install camshafts and the camshaft adjuster. Refer to => [ Camshafts and Camshaft Adjuster ] Camshafts and Camshaft Adjuster.
• After installing the camshafts, the engine may not be started for approximately 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.