Volkswagen Workshop Service and Repair Manuals

Removing and installing valve stem seals

Special tools and workshop equipment required

t	10 mm jointed spanner -3220-

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 knurled spacer ring -VAS 5161/23-1-

Procedure –  Remove all glow plugs using U/J extension and socket -3220- → Chapter. –  Remove camshafts → Chapter. –  Fit guide plate -VAS 5161/23- onto cylinder head.

–  Secure guide plate on intake manifold side with knurled screw -VAS 5161/12- and tighten it hand-tight to studs using M6 collarless nuts -1-. –  Screw sealing pin -VAS 5161/10- into guide plate.

–  Screw adapter -VAS 5161/11- hand-tight into glow plug hole of relevant cylinder.

–  Insert drift -VAS 5161/3- into guide plate and knock valve cotters loose using a plastic hammer.

–  Screw engaging fork -VAS 5161/5- with snap-in device -VAS 5161/6- into guide plate. –  Slide knurled spacer ring -VAS 5161/23-1- onto assembly cartridge -VAS 5161/8-. –  Connect adapter -VAS 5161/11- to compressed air line using a commercially available connection piece, and apply constant air pressure. l  Minimum pressure: 6 bar –  Attach pressure fork -VAS 5161/2- to snap-in device and push 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 lightly to press apart valve cotters and capture them in the assembly piece. –  Release pressure fork. –  Take out assembly cartridge with knurled spacer ring, valve plate and valve spring.

–  Remove valve stem oil seals using valve stem seal puller -3364-.   Note

A plastic sleeve -A- is included with the new valve stem oil seals. –  Fit plastic sleeve -A- onto valve stem to prevent damage to new valve stem oil seal -B-. –  Lightly lubricate sealing lip of valve stem oil seal. –  Slip valve stem oil seal over plastic sleeve. –  Carefully press valve stem oil seal onto valve guide using valve stem seal fitting tool -3365-. –  If necessary, use a plastic head hammer and tap lightly on fitting tool until valve stem oil seal is fitted to stop. –  Remove plastic sleeve. –  Insert valve spring and valve spring plate into cylinder head.

–  If valve cotters have been removed from assembly cartridge, they need to be put into insertion device -VAS 5161/18- first.   Note Larger diameter of valve cotters faces upwards. –  Press assembly cartridge onto insertion device from above and pick up valve cotters.

–  Re-insert assembly cartridge -VAS 5161/8- into guide plate. –  Push pressure fork down and pull knurled screw upwards while turning to left and right - this will insert the valve cotters. –  Release pressure fork with knurled screw still in pulled position. Installation is carried out in the reverse order; note the following: –  Install glow plugs → Chapter. –  Install camshafts → Chapter.   Note t  Engine is not to be rotated for approx. 30 minutes after installing camshafts. The hydraulic compensation elements must settle (otherwise valves will strike pistons). t  After working on the valve gear, turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.