Valve Stem Seals

(With the cylinder head installed)

Special tools and workshop equipment required 

• Spark Plug Removal Tool3122 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 

To remove the valve stem seals, the following components must be removed as follows:

• Intake valves cylinder 1: Transport strap
• Intake valves cylinder 5: Camshaft adjustment valve 1 -N205-
• Exhaust valves cylinder 5: Secondary air injection solenoid valve -N112-

-- Remove the camshafts. Refer to CAMSHAFTS .

-- Remove the roller rocker arm and lay them on a clean surface. Make sure that the rocker arms 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 using the knurled thumb screws M6 VAS 5161/12 to the cylinder head as shown.

Fig 1: Identifying Install Guide Plate VAS 5161/19 With Knurled Bolts VAS 5161/12 On Cylinder Head

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Install the adapter T40012 into the spark plug hole and connect the compressed air (minimum 6 bar).

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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.

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

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

NOTE:

The pressure fork with lever for assembly cartridge VAS 5161/2 must engage on the exhaust side as illustrated.

Fig 4: Identifying Pressure Forks VAS 5161/2 Engaged

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

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

-- Remove the assembly cartridge VAS 5161/8, valve spring retainers and valve springs.

-- 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 space constraints, drive the out pin -arrow- using a drift and remove the impact device.

Fig 6: Identifying Direction To Drive Out Spring Dowel Sleeve

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place 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 bore in the lower part of the valve seal removal tool.

-- Using the drive -1- as a lever, pull out the valve stem seal -arrow-.

Installing 

-- Place the plastic sleeve -A- on the valve stem to prevent damage to the 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 the valve stem seal -B-, insert it into the valve stem seal driver 3365 and carefully slide it onto the valve guide.

-- Remove the plastic sleeve -A-.

-- Insert the valve spring and valve spring retainers.

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

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.

Fig 10: Identifying Pressure Forks VAS 5161/2 Engaged

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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 valve insertion device from above and take up the valve retainers.

-- Press down the assembly cartridge VAS 5161/8 using the pressure fork with lever for assembly cartridge VAS 5161/2, knock lightly against the assembly cartridge in the lower area, rotate the knurled bolt on the assembly cartridge back and forth and pull upward while doing this.

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

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

The rest of the installation follows the reverse of the removal procedures. When doing this note the following:

-- Remove the locking pin T40069 from the rear of the cylinder block and install the locking bolt.

-- Fill the coolant. Refer to one of the following:

• Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10, refer to DRAINING AND FILLING .