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 (V.A.G 1331)

• Valve cotter disassembly and assembly device (VAS 5161)

Removing

- Remove all glow plugs. Refer to --> [ Glow Plugs ] Glow Plugs.

- Remove camshafts. Refer to --> [ Camshafts ] Camshafts.

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





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

- Install sealing pins (VAS 5161/10) in guide plate.





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

- Insert drift (VAS 5161/3) in guide plate and loosen stuck valve keepers with a plastic mallet.





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





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

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

• Minimum pressure: 6 bar positive pressure.

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

- At the same time, turn knurled bolt of installation cartridge toward the right, until the points engage in the valve keepers.

- Lightly move knurled bolt back and forth, this causes the valve keys to be pressed apart and captured in the installation cartridge.

- Release pressure fork.

- Remove installation cartridge with knurled spacer ring, the valve plate and the valve spring.

- Pull off valve stem oil seals using valve seal removal tool (3364).





Installing

• 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 the valve stem seal lips - B - with oil.

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

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

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

- Remove plastic sleeve again - A -.

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

- If valve keepers were removed from the installation cartridge , they must then be inserted in the insertion device (VAS 5161/18).





• The large diameter of the valve keepers point upward.

- Press installation cartridge onto insertion device from above and take up the valve keepers.

- Insert installation cartridge (VAS 5161/8) in guide plate.





- Press pressure fork down and pull knurled bolt upward while turning it left and right to insert the valve keepers.

- Release pressure fork with the knurled bolt still pulled.

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

- Install camshafts. Refer to --> [ Camshafts ] Camshafts.

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

- Install all the glow plugs. Refer to --> [ Glow Plugs ] Glow Plugs.