Valve Stem Seals, Cylinder Head Installed, Replacing

Special tools, testers and auxiliary items required 

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Spark plug removal tool 3122 B
• Valve seal removal tool 3364
• Valve stem seal driver 3365
• Valve cotter disassembly and assembly device VAS 5161

• Adapter T40012

Removing 

• Remove engine → Engine, Removing .
• Leave engine with transmission installed on scissor lift platform VAS 6131 A.
• Remove camshaft timing chains from camshafts → Camshaft Timing Chain, Removing from Camshaft .
• Remove camshafts → Camshafts, Removing and Installing .

• Using spark plug removal tool 3122 B , remove spark plugs.

Fig 2: Placing Drift VAS 5161/3 On Valve Spring Plate And Loosening Stuck Valve Keepers Using Plastic Hammer

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• Place drift VAS 5161/3 on valve spring plate and loosen stuck valve keepers using a plastic hammer.

Fig 3: Placing Guide Plate VAS 5161/19 A From Valve Cotter Disassembly And Assembly Device VAS 5161 On Cylinder Head

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• Place guide plate VAS 5161/19 A from valve cotter disassembly and assembly device VAS 5161 on cylinder head.
• Secure guide plate with knurled screws VAS 5161/12.
• Install adapter T40012 with gasket by hand into respective spark plug thread and apply constant pressure.

• Minimum pressure: 6 bar positive pressure.

Fig 4: Installing Engaging Device VAS 5161/6 With Installation Fork VAS 5161/5 Into Guide Plate

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• Install engaging device VAS 5161/6 with installation fork VAS 5161/5 into guide plate.
• Push installation cartridge VAS 5161/8 into guide plate.
• Hook in pressure fork VAS 5161/2 at engaging device and press down installation cartridge.
• At the same time, turn knurled bolt of installation cartridge to the right, until points engage in the valve keepers.

• Lightly move knurled bolt back and forth, causing the valve keepers to be pressed apart and be captured in the installation cartridge.
• Release pressure fork.
• Take out installation cartridge.
• Unfasten guide plate and turn it aside.

• Pressurized air hose remains connected.

• Remove valve spring with valve spring plate.

Fig 5: Pulling Off Valve Stem Oil Seals Using Valve Seal Removal Tool 3364

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• Pull off valve stem oil seals using Valve Seal Removal Tool 3364.

Fig 6: Identifying Plastic Sleeve, Valve Stem Oil Seal & Valve Stem Seal Driver 3365

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• 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 oil seal onto valve guide using Valve Stem Seal Driver 3365.

• Remove plastic sleeve again.

Fig 7: Identifying Installation Cartridge VAS 5161/8

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If valve keys were removed from the installation cartridge, they must be inserted into insertion device VAS 5161/18 next.

• The large diameter of the valve keepers point upward.

Fig 8: Identifying Tight Spring Coils Face Toward Cylinder Head

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• Install valve spring and valve spring plate.

• The tight spring coils - arrow  - face toward cylinder head.

Fig 9: Installing Engaging Device VAS 5161/6 With Installation Fork VAS 5161/5 Into Guide Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install guide plate onto cylinder head again.
• Insert installation cartridge into guide plate.
• Press pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve keepers.
• Release pressure fork with knurled bolt still pulled.

• Make sure all roller rocker levers seat properly on the valve stem ends and are clipped onto the respective hydraulic adjusting elements.
• Install camshafts → Camshafts, Removing and Installing .
• Position camshaft timing chains on camshafts → Installing  under Camshaft Timing Chain, Removing from Camshaft  .
• Install left and right timing chain covers → Installing  under Left and Right Timing Chain Covers, Removing and Installing  .

• Install cylinder head cover: Left → Left Cylinder Head Cover, Removing and Installing  , right → Right Cylinder Head Cover, Removing and Installing .
• Install engine → Engine, Installing .