Valve Stem Seals, Cylinder Head Installed, Removing And Installing

Special tools and workshop equipment required 

• Glow Plug Socket 3220
• Puller - Valve Seal 3364
• Seal Installer - Valve Stem 3365
• Valve Cotter Tool Kit VAS5161 with Knurled Spacer Ring VAS 5161/23-1 and Valve Cotter Tool Kit - Guide Plate 23 VAS5161/23

Procedure

Fig 1: Identifying Socket 3320 To Remove Glow Plugs

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-- Remove all glow plugs. Refer to GLOW PLUGS, REMOVING AND INSTALLING .

-- Install the camshafts: left cylinder head, refer to LEFT CYLINDER HEAD CAMSHAFT, REMOVING AND INSTALLING , right cylinder head, refer to RIGHT CYLINDER HEAD CAMSHAFT, REMOVING AND INSTALLING .

-- Mark the allocation of the roller rocker lever and the hydraulic adjusting elements so they can be installed again.

-- If necessary, remove the roller rocker levers with the hydraulic adjusting elements and place them on a clean surface.

-- Move piston for that cylinder to "bottom dead center position".

-- Mount the Valve Cotter Tool Kit - Guide Plate 23 VAS5161/23 on the cylinder head.

Fig 2: Identifying Punch VAS 5161/3, Knurled Thumb Screws VAS 5161/12 And Guide Plate For 3.0 Liter TDI Engine VAS 5161/23

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-- Secure the guide plate with the Knurled Screws VAS 5161/12.

-- Insert the Drift VAS 5161/3 in the guide plate and loosen the stuck valve retainers with a plastic mallet.

-- Install the Sealing Bolt VAS 5161/10 into the guide plate.

Fig 3: Identifying Compression Stud VAS 5161/10 And Compressed Air Connection VAS 5161/11

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-- Install the Adapter VAS 5161/11 by hand into the glow plug thread.

-- Install Engaging Device VAS 5161/6 with installation fork Valve Cotter Tool Kit - Guide Forks M6/M8 Threaded VAS5161/5 in guide plate.

Fig 4: Identifying Valve Insertion Device VAS 5161/8 Inserted In Guide Plate For 3.0 Liter TDI Engine VAS 5161/23

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-- Slide the Knurled Spacer Ring VAS 5161/23-1 onto the Valve Cotter Tool Kit - Assembly Cartridge VAS5161/8.

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

• Minimum pressure: 6 bar

-- Engage Pressure Fork VAS 5161/2 on engaging device and press installation cartridge down.

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

-- Move the knurled wheel left and right slightly. This presses the valve retainers apart and captures them in the installation cartridge.

-- Release the pressure fork.

-- Remove the installation cartridge with the knurled spacer ring.

-- Remove the valve spring and the valve spring plate.

-- Remove the valve stem seal with the Puller - Valve Seal 3364.

Fig 5: Identifying Valve Seal Removal Tool 3364

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If puller cannot be used on several valve stem seals due to restricted clearance, proceed as follows:

Fig 6: Driving Out Roll Pin

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-- Remove the roll pin -arrow- on the puller with a drift and remove the impact puller attachment.

-- Position the lower part of the Puller - Valve Seal 3364 on the valve stem seal.

Fig 7: Identifying Lower Section Of Valve Seal Removal Tool 3364 On Valve Stem Seal

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-- Secure the puller with a drift or cotter pin drive -1- as shown in the illustration.

-- Position the valve lever on the puller and remove the valve stem seal -arrow-.

Fig 8: Identifying Plastic Sleeve, New Valve Stem Oil Seals & Valve Stem Seal Driver 3365

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-- Lightly oil valve stem seal.

-- Slide valve shaft seal onto plastic sleeve.

-- Carefully press the valve stem seal onto the valve guide with the Seal Installer - Valve Stem 3365.

-- Remove plastic sleeve.

If the valve retainers were removed from the installation cartridge, they must be inserted in the next Valve Retainer Inserting Tool VAS 5161/18.

Fig 9: Identifying Installation Cartridge VAS 5161/8

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• The large diameter of the valve retainers point upward.

-- Insert valve spring and valve spring plate.

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

-- Insert the installation cartridge in the Valve Cotter Tool Kit - Guide Plate 23 VAS5161/23.

Fig 10: Identifying Valve Insertion Device VAS 5161/8 Inserted In Guide Plate For 3.0 Liter TDI Engine VAS 5161/23

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

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

-- Repeat the procedure on each valve.

Assembling

Assemble in reverse order of disassembling. Note the following:

-- Install the camshafts: left cylinder head, refer to LEFT CYLINDER HEAD CAMSHAFT, REMOVING AND INSTALLING , right cylinder head, refer to RIGHT CYLINDER HEAD CAMSHAFT, REMOVING AND INSTALLING .

-- Install the glow plugs. Refer to GLOW PLUGS, REMOVING AND INSTALLING .