Volkswagen Workshop Service and Repair Manuals

Renewing valve stem seals with cylinder head installed Special tools and workshop equipment required

t  Valve stem seal puller -3364-

t  Valve stem seal fitting tool -3365-

t  Removal and installation device for valve cotters -VAS 5161- with guide plate -VAS 5161/23- and sleeve -VAS 5161/23-1- t  2x M6x30 bolts Procedure –  Remove all glow plugs → Chapter. –  Remove camshafts → Chapter. –  Mark allocation of roller rocker fingers and hydraulic compensation elements for reinstallation. –  Remove roller rocker fingers together with hydraulic compensation elements and place down on a clean surface. –  Set piston of respective cylinder to „bottom dead centre“.

–  Place guide plate -VAS 5161/23- onto cylinder head. –  Tighten guide plate on intake manifold side by hand using knurled screw -VAS 5161/12- and 2 M6x30 bolts -item 1- until it makes contact.

–  Screw sealing pins -VAS 5161/10- into guide plate. –  Screw adapter -VAS 5161/11- hand-tight into relevant glow plug thread.

–  Insert drift -VAS 5161/3- into guide plate and use a plastic hammer to knock loose the firmly seated valve cotters.

–  Screw toothed piece -VAS 5161/6- with hooking fork -VAS 5161/5- into guide plate. –  Push sleeve -VAS 5161/23-1- onto assembly cartridge -VAS 5161/8-. –  Connect adapter to compressed air supply using a commercially available union and apply pressure continuously. l  Minimum pressure: 6 bar –  Attach pressure fork -VAS 5161/2- to toothed piece and press assembly cartridge down. –  At the same time, turn knurled screw of assembly cartridge clockwise until tips engage in valve cotters. –  Move knurled screw back and forth to press apart valve cotters and capture them in assembly cartridge. –  Release pressure fork. –  Remove assembly cartridge with knurled spacer ring. –  Remove valve spring and valve spring plate.

–  Pull off valve stem seal using valve stem seal puller -3364-.

Caution Risk of damage when installing valve stem seals. Place plastic sleeve -A-, enclosed with new valve stem seals -B-, onto valve stem. –  Lightly oil sealing lip of valve stem seal. –  Push valve stem oil seal onto plastic sleeve. –  Carefully press valve stem oil seal onto valve guide using valve stem seal fitting tool -3365-. –  Remove plastic sleeve.

If the valve cotters have been removed from the assembly cartridge, they must first be inserted into the valve insertion device -VAS 5161/18-. l  Larger diameter of valve cotters faces upwards. –  Insert valve spring and valve spring plate. –  Press assembly cartridge onto valve cotter insertion device from above and pick up valve cotters.

–  Insert assembly cartridge into guide plate -VAS 5161/23- again. –  Press pressure fork downwards and pull knurled screw upwards, turning it clockwise and anticlockwise. This inserts the valve cotters. –  Reduce pressure on pressure fork whilst pulling on knurled screw. –  Repeat procedure on each valve. Reassembly Installation is carried out in the reverse order; note the following: –  Ensure that all roller rocker fingers contact valve stem ends correctly and are clipped into relevant hydraulic compensation elements. –  Install camshafts → Chapter. –  Install glow plugs → Chapter.