Valve Stem Seals, Removing And Installing: Procedure

Vehicles with Ceramic Glow Plugs:

Vehicles with Metal Glow Plugs: 

-- Remove the glow plugs with the Glow Plug Socket:3220  .

Continuation for All Vehicles:

Fig 1: Identifying Punch VAS 5161/3, Knurled Thumb Screws VAS 5161/12 And Guide Plate For 3.0 Liter TDI Engine VAS 5161/23

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the camshafts. Refer to CAMSHAFTS, REMOVING AND INSTALLING .

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

-- Secure guide plate with Valve Keeper Tool Kit - Knurled Thumb Screws 12:VAS5161A/12  .

-- Insert the Valve Cotter Tool Update Kit Punch 3A:VAS5161/30  into the guide plate and loosen the valve retainers with a plastic mallet.

-- Install the Valve Keeper Tool Kit Compression Stud:VAS5161/10  in the Guide Plate.

Fig 2: Identifying Compression Stud VAS 5161/10 And Compressed Air Connection VAS 5161/11

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the Valve Keeper Tool Kit Adapter for Compressed Air Connection:VAS5161/11  in the glow plug threads and tighten by hand.

-- Screw engaging device Valve Cotter Tool Kit - Retainer:VAS5161/6  with installation fork Valve Cotter Tool Kit - Guide Forks M6/M8 Threaded:VAS5161/5  into Guide Plate.

Fig 3: Identifying Valve Insertion Device VAS 5161/8 Inserted In Guide Plate For 3.0 Liter TDI Engine VAS 5161/23

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Slide the Valve Cotter Tool Kit - Guide Plate 23 Sleeve:VAS5161/23-1  on the Valve Cotter Tool Update Kit assembly cartridge VAS5161/8A:VAS5161/30  .

-- Connect the Adapter to compressed air with a commercially available connector and apply constant pressure.

• Minimum pressure: 6 bar (87 psi)

-- Engage Pressure Fork:VAS5161/2  at Engaging Device and press down Installation Cartridge.

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

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

-- Release pressure fork.

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

-- Pull off valve stem seals using the Puller - Valve Seal:3364  .

Fig 4: Identifying Valve Seal Removal Tool 3364

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

If the Puller - Valve Seal:3364  cannot be used on some valve stem seals due to restricted clearance, proceed as follows.

Fig 5: Driving Out Roll Pin

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Drive the tensioning pin -arrow- on the Valve Seal Removal Tool:3364  out with a drift and remove the impact puller attachment.

-- Place the lower section of the Valve Seal Removal Tool:3364  on the valve stem seal.

Fig 6: Identifying Lower Section Of Valve Seal Removal Tool 3364 On Valve Stem Seal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the valve stem seal puller with a drift or cotter pin driver -1- as illustrated.

-- Position a puller on the valve stem seal puller and remove the seal in direction of -arrow-.

NOTE:

A plastic sleeve -A- is supplied with the new valve shaft seals.

Fig 7: Identifying Plastic Sleeve, New Valve Stem Oil Seals & Valve Stem Seal Driver 3365

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place plastic sleeve -A- on valve stem to prevent damage to new valve stem seals -B-.

-- Lightly coat sealing lips of valve stem seal with oil.

-- Push valve stem seal onto plastic sleeve.

-- Carefully press valve stem seal onto valve guide using Seal Installer - Valve Stem:3365  .

-- Remove plastic sleeve again.

-- If the valve retainers were removed from the installation cartridge, they must then be inserted into the Valve Keeper Tool Kit Valve Insertion Device:VAS5161/18  .

Fig 8: Identifying Installation Cartridge VAS 5161/8

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Press the installation cartridge onto the insertion tool from above and remove the valve retainers.

-- Insert the Valve Keeper Tool Kit Assembly Cartridge:VAS5161/8  in the Guide Plate.

Fig 9: Identifying Valve Insertion Device VAS 5161/8 Inserted In Guide Plate For 3.0 Liter TDI Engine VAS 5161/23

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Release Pressure Fork with the knurled bolt still pulled.

Assemble in reverse order of disassembling. Note the following:

-- Install the glow plugs. Refer to GLOW PLUG SYSTEM .

-- Install camshafts. Refer to CAMSHAFTS, REMOVING AND INSTALLING .