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 a knurled screw (VAS 5161/12) and on the studs using collarless M6 nuts - 1 - tightened by hand.
- Install the compression stud (VAS 5161/10) in the guide plate (VAS 5161/23).
- Install the adapter for compressed air connection (VAS 5161/11) into the respective glow plug threads and tighten by hand.
- Insert the punch (VAS 5161/3) into the guide plate (VAS 5161/23) and loosen the valve retainers using a plastic mallet.
- Install the guide forks M6/M8 with threaded studs (VAS 5161/5) in the guide plate (VAS 5161/23) 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
- Engage the pressure fork with lever for assembly cartridge (VAS 5161/2) at the retainer (VAS 5161/6) and press down the assembly cartridge (VAS 5161/8).
- At the same time, turn the knurled thumb screw on the assembly cartridge (VAS 5161/8) clockwise 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 (VAS 5161/8).
- Release the pressure fork with lever for assembly cartridge (VAS 5161/2).
- Remove the assembly 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 assembly cartridge (VAS 5161/8) , 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 (VAS 5161/18) onto the valve insertion device (VAS 5161/8) from above and take up the valve retainers.
- Insert the valve insertion device (VAS 5161/8) into the guide plate (VAS 5161/23).
- Press the pressure fork with lever for assembly cartridge (VAS 5161/2) down and pull the knurled thumb screw upward while turning it left and right to insert the valve retainers.
- Release the pressure fork with lever for assembly cartridge (VAS 5161/2) with the knurled thumb screw 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 lash adjusters must seat themselves (otherwise the valves will crash into the pistons).
• After working on the valvetrain, carefully rotate the engine by hand at least 2 full revolutions to ensure that the valves do not strike the pistons when starting.
- Install the glow plugs. Refer to => [ Glow Plugs ] Description and Operation.