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 3.0L TDI Engine (VAS 5161/23)
Removing
with Ceramic Glow Plugs
• 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 => [ Glow Plugs ] Service and Repair.
with Metal Glow Plugs
- Remove the glow plugs using the hinged socket (3220).
Continuation for All
- Remove the camshafts. Refer to => [ Camshafts ] Camshafts.
- Install the guide plate for 3.0L TDI engine (VAS 5161/23) to the cylinder head.
- Secure the guide plate using the knurled thumb screws (VAS 5161/12).
- Insert the punch (VAS 5161/3) into the guide plate and loosen any stuck valve retainers using a plastic hammer.
- Install the compression stud (VAS 5161/10) in the guide plate.
- Install the adapter for compressed air connection (VAS 5161/11) into the respective glow plug threads and tighten hand tight.
- Install the retainer (VAS 5161/6) with the guide forks M6/M8 with threaded studs (VAS 5161/5) into the guide plate.
- Push the knurled sleeve (VAS 5161/23-1) onto the assembly cartridge (VAS 5161/8).
- Connect the compressed air hose to the adapter for compressed air connection (VAS 5161/11) 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) to the engaging device and press down the assembly cartridge.
- At the same time, turn the knurled thumb screw on the assembly cartridge to the right, until the points engage in the valve retainers.
- Lightly move the knurled thumb screw back and forth, causing the valve retainers to be pressed apart and be captured in the assembly cartridge.
- Release the pressure fork with lever for assembly cartridge.
- Remove the assembly cartridge with the spacer sleeve, the upper spring seat and the valve spring.
- Pull off valve stem seal using the valve seal removal tool (3364).
If the valve seal removal tool (3364) cannot be used on some valve stem seals due to restricted clearance, proceed as follows:
- Drive the roll pin - arrow - on the valve seal removal tool (3364) out using a drift and remove the impact attachment.
- Place the lower section of the valve seal removal tool (3364) on the valve stem seal.
- Install a drift - 1 - into the valve seal removal tool (3364) as illustrated.
- Using the drift - 1 - as a lever, pull the valve seal removal tool (3364) up in the - direction of the arrow - and remove the seal.
• 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 new valve stem seals - B -.
- Lightly coat the sealing lips of the valve stem seal with oil.
- Push the valve stem seal the onto plastic sleeve.
- Carefully press the valve stem seal onto the valve guide using the valve stem seal driver (3365).
- Remove the plastic sleeve again.
- 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 => [ Camshafts ] Camshafts.
• 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 seat themselves on 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.