Arrrghh!...84 4ksq Cam Front Oil Seal Replacement

[gwbutler]

Hello all,

Last weekend I performed my first timing belt (TB) replacement on my 84 4ksq.  I rented the TB tool kit from Blaufernugen, and, for the most part was pleased with what the tools did. However, I found that the cam front oil seal removal (2085) tool didn't really "catch" the inside of the oil seal (what a PITA) and I ended-up having to carefully pry out the semi-removed seal with a small flathead screw driver (although I never touched the metal inside the seal housing I checked for even minor scoring once the seal was removed). 

The plastic oil seal installation sleeve that Blufergnugen sent me instead of tool 10-203 allowed quite a bit of "play" and, regardless of how far I screwed the cam sprocket bolt into the cam, did not seat the seal far enough to meet the chamfered edge of the seal housing. There appeared to be a spacer built into the tool that must stop at the end of the camshaft to avoid (he..he..) pushing the seal too far into the cam and blocking the oil return hole. I found that I had to use the old seal, a deep 30mm socket, and a hammer to seat the seal at the chamfered edge of the seal seat. Needless to say, once everything was buttoned up, the engine started-up like a charm, ran nicely for about a minute (although I do have to replace a previously noisy lifter),... and started leaking oil out of the cam front oil seal.  Obviously I'll be replacing the seal again next weekend. Now I have to have Blaufergnugen send out their damned 2085 and 10-203-like tools again...and tie-up a few hundred dollars.  I can't trust the "new" oil seal integrity. Any listers have BTDT's to relate? What'd I do wrong?  TIA

Regards,

George B.
Massachusetts