Valve stem seals, replacing

(with cylinder head installed)

Fig 1: Identifying Special Tools - Valve Stem Seals, Replacing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Spark plug removal tool 3122 B
Valve seal removal tool 3364
Valve stem seal driver 3365
Adapter T40012

Torque wrench V.A.G 1331
Valve cotters assembly/disassembly device VAS 5161
Guide Plate F/2.0 Ltr FSI Engine VAS 5161/19A

Valve stem seals, removing

Remove camshafts → Camshafts, removing and installing

NOTE:

To replace the valve stem seals of the exhaust valves for cylinder 3 and 4, the EGR Vacuum Regulator Solenoid Valve N18 must also be removed.

Remove roller rocker levers and place them on a clean surface. Make sure that roller cam followers are not interchanged.
Using spark plug removal tool 3122 B , remove spark plugs.

Fig 2: Tightening Install Guide Plate VAS 5161/19 With Knurled Bolts VAS 5161/12 On Cylinder Head

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fasten Guide Plate F/2.0 Ltr FSI Engine VAS 5161/19A to cylinder as shown using Knurled Screws VAS 5161/12.
Adjust piston of respective cylinder to "Bottom Dead Center position".
Install adapter T40012 into spark plug thread and connect compressed air of at least 6 bar positive pressure.

Fig 3: Using Drift VAS 5161/3 And A Plastic Mallet To Loosen Stuck Valve Keepers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using drift VAS 5161/3 and a plastic mallet, tap to loosen stuck valve keepers.

Fig 4: Installing Valve Cotter Disassembly And Assembly Device VAS 5161 - Intake Side

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install Engaging Device VAS 5161/6 with Installation Fork VAS 5161/5 in Guide Plate F/2.0 Ltr FSI Engine VAS 5161/19A.
Insert Installation Cartridge VAS 5161/8 in Guide Plate F/2.0 Ltr FSI Engine VAS 5161/19A.
Engage pressure fork VAS 5161/2 on engaging device VAS 5161/6.

Fig 5: Installing Valve Cotter Disassembly And Assembly Device VAS 5161 - Exhaust Side

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

On the exhaust side, the pressure fork VAS 5161/2 must be hooked in, as shown.

Press down installation cartridge VAS 5161/8. At the same time, turn knurled bolt of installation cartridge VAS 5161/8 clockwise until points engage in valve keepers.
Lightly move knurled bolt back and forth, this causes the valve keepers to be pressed apart and captured in the installation cartridge.
Release pressure fork VAS 5161/2.
Remove installation cartridge VAS 5161/8.

Fig 6: Identifying Valve Stem Seals Using Valve Seal Removal Tool 3364

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove valve stem seals using Valve Seal Removal Tool 3364.

Fig 7: Identifying Valve Seal Removal Tool 3364

Courtesy of VOLKSWAGEN UNITED STATES, INC.

In the event valve stem seal driver 3364 cannot be used due to constrained spatial arrangements, drive out spring dowel sleeve - arrow - using a drift and remove impact device.

Fig 8: Placing Lower Part Of Valve Seal Removal Tool 3364 On To Valve Stem Oil Seal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place lower part of valve seal removal tool 3364 onto valve stem seal.
Insert a drift - 1 - into bore in lower part of extractor device.
Place a lever at removal tool and pull out valve stem seal - arrow -.

Valve stem seals, installing

Fig 9: Identifying Plastic Sleeve, Valve Stem Oil Seal & Valve Stem Seal Driver 3365

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place plastic sleeve - A - on valve stem to prevent damage to new valve stem oil seals - B -.
Oil sealing lip of valve stem oil seal - B - , insert into valve stem seal driver 3365 and carefully slide onto valve guide.
Remove plastic sleeve - A -.
Insert valve spring and valve spring retainer.

Install valve cotter disassembly and assembly device VAS 5161 as shown.

Fig 10: Installing Valve Cotter Disassembly And Assembly Device VAS 5161 - Intake Side

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Intake side

Fig 11: Installing Valve Cotter Disassembly And Assembly Device VAS 5161 - Exhaust Side

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Exhaust side

Fig 12: Identifying Installation Cartridge VAS 5161/8

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

If the valve keepers were removed from the installation cartridge, they must then be inserted into the insertion device VAS 5161/18.
Press installation cartridge VAS 5161/8 onto insertion device from above and capture the valve keepers.

Press down installation cartridge VAS 5161/8 with pressure fork VAS 5161/2 and turn knurled screw of installation cartridge back and forth while pulling it upward at the same time.
Release pressure fork VAS 5161/2 with knurled bolt pulled.
Remove valve cotter assembly/disassembly device VAS 5161.

The rest of assembly is basically a reverse of disassembling sequence.

How to install camshafts → Camshafts, removing and installing