Valve Stem Seals

(With the cylinder head installed)

Special Tools And Workshop Equipment Required 

• Spark Plug Removal Tool 3122 B
• Valve Seal Removal Tool 3364
• Valve Stem Seal Driver 3365
• Adapter T40012
• Torque Wrench (5-50 Nm) V.A.G 1331
• Valve Cotters Asm/Disasm Device VAS 5161
• Guide Plate for FSI Engine VAS 5161/19B

Removing 

-- Remove the camshafts. Refer to CAMSHAFTS .

-- Remove roller rocker arms and place them on a clean surface. Make sure they are not interchanged.

-- Remove the spark plugs using the spark plug removal Tool 3122 B.

-- Install the guide plate for FSI engine VAS 5161/19B to the cylinder head using the knurled thumb screws M6 VAS 5161/12 as shown.

Fig 1: Identifying FSI Engine VAS 5161/19B Guide Plate Tightened On Cylinder Head Using Knurled Bolts VAS 5161/12

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Adjust piston of the respective cylinder to Bottom Dead Center (BDC).

-- Install adapter T40012 into the spark plug threads and connect the compressed air of at least 6 bar positive pressure.

Fig 2: Identifying Drift VAS 5161/3 And Plastic Mallet To Loosen Stuck Valve Keepers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen any stuck valve retainers using the punch VAS 5161/3 and a plastic mallet.

Intake Side: 

Fig 3: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the retainer VAS 5161/6 using guide forks M6/M8 with threaded studs VAS 5161/5 into the center thread in the guide plate for FSI engine VAS 5161/19B.

-- Install the assembly cartridge VAS 5161/8 into the guide plate for FSI engine VAS 5161/19B.

-- Attach the pressure fork with lever for assembly cartridge VAS 5161/2 to the retainer VAS 5161/6.

Exhaust Side: 

Fig 4: Identifying Pressure Forks VAS 5161/2 Engaged

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the retainer VAS 5161/6 using the guide forks M6/M8 with threaded studs VAS 5161/5 into the outer thread in the guide plate for FSI engine VAS 5161/19B.

-- Press the assembly cartridge VAS 5161/8 down. At the same time, turn the knurled thumb screw on the assembly cartridge VAS 5161/8 clockwise until the points engage in the valve retainers.

-- Lightly move the knurled thumb screw back and forth, this causes the valve retainers to be pressed apart and captured in the assembly cartridge.

-- Release the pressure fork with lever for assembly cartridge VAS 5161/2.

-- Take out the assembly cartridge VAS 5161/8.

-- Remove the valve stem seal using the valve seal removal Tool 3364.

Fig 5: Identifying Valve Seal Removal Tool 3364

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- In the event the valve seal removal Tool 3364 cannot be used due to limited space, drive out the roll pin -arrow- using a drift and remove the impact device.

Fig 6: Identifying Valve Seal Removal Tool 3364

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the lower part of the valve seal removal Tool 3364 onto the valve stem seal.

Fig 7: Identifying Placement Of Lower Part Of Valve Seal Removal Tool 3364 On To Valve Stem Oil Seal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert a drift -1- into the hole in the lower part of the valve seal removal Tool 3364.

-- Using the drift -1- as a handle, pull out the valve stem seal in the -direction of the arrow-.

Installing 

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lubricate the sealing lip of valve stem seal -B-, Insert it into the valve stem seal driver 3365, and carefully push it onto the valve guide.

-- Remove the plastic sleeve -A-.

-- Install the valve spring and valve spring retainers.

Fig 9: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the valve cotters asm/disasm device VAS 5161 as shown:

Fig 10: Identifying Pressure Forks VAS 5161/2 Engaged

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the valve cotters asm/disasm device VAS 5161 as shown:

NOTE:

If the valve retainers were removed from the assembly cartridge, they must be Inserted into the valve Insertion device VAS 5161/18 next.

Fig 11: Identifying Installation Cartridge VAS 5161/8

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Press the assembly cartridge VAS 5161/8 onto the Insertion device from above and capture the valve retainers.

-- Press down the assembly cartridge VAS 5161/8 with the pressure fork with lever for assembly cartridge VAS 5161/2 and turn the knurled thumb screw of the assembly cartridge back and forth while pulling it upward at the same time.

-- Release the pressure fork with lever for assembly cartridge VAS 5161/2 with the knurled thumb screw still pulled.

-- Remove the valve cotters asm/disasm device VAS 5161.

-- Install the spark plugs. Refer to IGNITION SYSTEM COMPONENT OVERVIEW .

-- Install the ignition coils with power output stages. Refer to IGNITION COIL WITH POWER OUTPUT STAGE .

Further installation is in the reverse order of removal.