Valve Guide Seal: Service and Repair

Valve Stem Seals, Cylinder Head Installed

Special tools, testers and auxiliary items required

• Valve Seal Removal Tool (3364)

• Valve Stem Seal Driver (3365)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Valve Cotters Asm/Disasm Device (VAS 5161)

Removing

- Remove the glow plugs. Refer to => [ Glow Plugs ] Description and Operation.

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

- Position the guide plate (VAS 5161/23) on the cylinder head.






- Secure the guide plate (VAS 5161/23) to the intake manifold side using the knurled screw (VAS 5161/12) and on the studs with collarless M6 nuts - 1 - tightened by hand.

- Install the sealing pin (VAS 5161/10) in the guide plate (VAS 5161/23).






- Install the adapter (VAS 5161/11) to the respective glow plug threads and tighten by hand.

- Insert the drift (VAS 5161/3) into the guide plate (VAS 5161/23) and loosen the valve retainers with a plastic mallet.






- Install the installation fork (VAS 5161/5) in the guide plate (VAS 5161/23) with the engaging device (VAS 5161/6).






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

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

• Minimum pressure: 6 bar

- Engage the pressure fork (VAS 5161/2) at the engaging device (VAS 5161/6) and press down the installation cartridge (VAS 5161/8).

- At the same time, turn the knurled bolt of the installation cartridge (VAS 5161/8) clockwise until the points engage in the valve retainers.

- Lightly move the knurled bolt back and forth, this causes the valve retainers to be pressed apart and captured in the installation cartridge (VAS 5161/8).

- Release the pressure fork (VAS 5161/2).

- Remove the installation cartridge (VAS 5161/8) with the knurled spacer ring (VAS 5161/23-1) , the valve 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 seal.






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

- Lightly coat the valve stem seal lips - B - with oil.

- Slide the valve stem steal - B - onto the plastic sleeve - A -.

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

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

- Remove the plastic sleeve again - A -.

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

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






• The large diameter of the valve retainers point upward.

- Press the installation cartridge (VAS 5161/18) onto the insertion device (VAS 5161/8) from above and take up the valve keepers.

- Insert the insertion device (VAS 5161/8) in the guide plate (VAS 5161/23).






- Press the pressure fork (VAS 5161/2) down and pull the knurled bolt upward while turning it left and right to insert the valve retainers.

- Release pressure fork (VAS 5161/2) with the knurled bolt still pulled.

The rest of the installation is performed in reverse order of removal, noting the following:

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

• After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into the pistons).

• After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

- Install the glow plugs. Refer to => [ Glow Plugs ] Description and Operation.