Valve Stem Seals, Cylinder Head Installed

Valve Stem Seals, Cylinder Head Installed

Special tools, testers and auxiliary items required

• 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)

• M6 x 30 Bolt (Qty: 2)

Removing

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

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

- Mark the allocation of the roller rocker arms and the hydraulic lash adjusters so they can be reinstalled again.

- If necessary, remove the roller rocker arm with the hydraulic lash adjusters and place them on a clean surface.

- Move the piston for the respective cylinder to the Bottom Dead Center (BDC) position.

- Install the guide plate for 3.0L TDI engine (VAS 5161/23) to the cylinder head.






- Secure the guide plate on the intake manifold side with the knurled thumb screws M6 (VAS 5161/12) and the 2 M6 x 30 bolts - 1 - all the way by hand.

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






- Install the adapter for compressed air connection (VAS 5161/11) by hand into the glow plug threads.

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






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






- Install the sleeve (VAS 5161/23-1) on the assembly cartridge (VAS 5161/8).

- Connect the adapter to the compressed air using a commercially available intermediate piece and apply steady pressure.

• Minimum pressure: 6 bar positive pressure.

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

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

- Move the knurled thumb screw left and right slightly. This presses the valve retainers apart and captures them in the assembly cartridge.

- Release the pressure fork with lever for assembly cartridge.

- Remove the assembly cartridge with the knurled sleeve.

- Remove the valve spring and the spring plate.

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






Installing






Risk of damage when installing valve stem seals.

• Place the plastic sleeve - A - that is attached to the valve stem seals - B - on the valve stem.

- Lightly oil the valve stem seal.

- Slide the valve stem seal onto the plastic sleeve.

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

- Remove the plastic sleeve.

When the valve retainers were removed from the assembly cartridge, they must be inserted in the valve insertion device (VAS 5161/18) next.






• The large diameter of the valve retainers point upward.

- Insert the valve spring and spring plate.

- Press the assembly cartridge onto the valve insertion device for the valve retainers from above and take up the valve retainers.

- Insert the assembly cartridge in the guide plate for 3.0L TDI engine (VAS 5161/23).






- Press the pressure fork down and pull the knurled thumb screw up while turning left and right. This inserts the valve retainers.

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

- Repeat the procedure on each valve.

Further installation is performed in the reverse order of removal. When doing this note the following:

- Make sure all the roller rocker arms align on the ends of the valve stems correctly and are clipped onto the respective hydraulic lash adjusters.

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

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