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

-- Using the spark plug removal tool -3122 B-, remove spark plugs.

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

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

-- Install the adapter -T40012- into the spark plug hole and connect 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 UNITED STATES, INC.

-- Using the punch -VAS 5161/3- and a plastic mallet, tap on any stuck valve retainers in order to loosen them.

Intake Side 

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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

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

Exhaust Side 

Fig 4: Identifying Pressure Forks VAS 5161/2 Engaged

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

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

-- Lightly move the knurled knob 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 UNITED STATES, INC.

-- If the valve seal removal tool -3364- cannot be used due to restricted clearance, drive the roll pin -arrow- out with a drift and remove the impact attachment.

Fig 6: Identifying Valve Seal Removal Tool 3364

Courtesy of VOLKSWAGEN UNITED STATES, 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 UNITED STATES, INC.

-- Insert a drift -1- into the bore in the lower part of the removal tool.

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

Installing 

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

-- 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-.

-- Install the valve spring, spring plate and valve spring retainers.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Install the special tools as shown.

Fig 10: Identifying Pressure Forks VAS 5161/2 Engaged

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-- Install the special tools 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 UNITED STATES, 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 knob on 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 knob pulled.

-- Remove the special tools.

The rest of the installation is basically a reverse of the removal sequence.