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Home >> Volkswagen >> 2006 >> GTI 1.8 E, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 25 (2.0L - Cylinder Head, VALVETRAIN - Engine Code(S): BPY) >> 15 Cylinder Head, VALVETRAIN >> Removal And Installation >> Valve Stem Seals

Valve Stem Seals

WARNING: This page is about a different variant/trim than selected.

(with the cylinder head installed)

Special tools and workshop equipment required 

Removing 

-- Remove the camshafts. Refer to CAMSHAFTS .

-- Remove the roller rocker arms and lay them on a clean surface. Make sure that the roller 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 5161/19- 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
GWWN15-10110Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

-- Install the adapter -T40012- into the spark plug threads 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
GWWN15-10111Courtesy of VOLKSWAGEN UNITED STATES, 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 5161/19-.

Fig 3: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19
GWWN15-10112Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

-- 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
GWWN15-10113Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Press down the assembly cartridge -VAS 5161/8-. At the same time, turn the knurled thumb screw of 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
GWWA15-0559Courtesy 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 using a drift and remove the impact attachment.

Fig 6: Identifying Driving Out Of Spring Dowel Sleeve
GWWA15-0493Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Position 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
GWWA15-0585Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

-- Using the drift -1- as a lever, 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 the new valve stem seal -B-.

Fig 8: Identifying Plastic Sleeve, New Valve Stem Oil Seals & Valve Stem Seal Driver 3365
GWWA15-0282Courtesy of VOLKSWAGEN UNITED STATES, 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 retainer.

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

Fig 9: Identifying Installation Of Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Into Guide Plate VAS 5161/19
GWWN15-10112Courtesy of VOLKSWAGEN UNITED STATES, INC.
Fig 10: Identifying Pressure Forks VAS 5161/2 Engaged
GWWN15-10113Courtesy of VOLKSWAGEN UNITED STATES, 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
GWWA15-0445Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press the assembly cartridge -VAS 5161/8- onto the insertion device from above and take up 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 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 thumb screw pulled.

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

Further installation is in reverse order of removal.

-- Install the camshafts. Refer to CAMSHAFTS .

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