Valve Shaft 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 

To remove the valve stem seals on some valves, the following components must be removed:

• For the intake valves in cylinder 1: The transport strap
• For the intake valves in cylinder 5: The camshaft adjustment valve 1 -N205-
• For the exhaust valves in cylinder 5: The secondary air injection solenoid valve -N112-

-- Remove the camshafts. Refer to CAMSHAFT .

-- Remove the roller rocker arms 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 to the cylinder head using the knurled thumb screws M6 VAS 5161/12.

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 the Bottom Dead Center (BDC) position.

-- Install the adapter T40012 into the spark plug threads and connect the compressed air hose (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 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 on the assembly cartridge 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.

-- 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.

-- If there is not enough clearance to use the valve seal removal tool 3364, drive the roll pin -arrow- out using a drift and remove the impact attachment.

Fig 6: Driving 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 the drift -1- into the bore in the lower part of the removal tool.

-- Using the drift 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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Oil 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 illustrated.

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 the assembly cartridge VAS 5161/8 with the pressure fork with lever for assembly cartridge VAS 5161/2 down. Tap lightly against the lower area of the assembly cartridge. Rotate the knurled thumb screw on the assembly cartridge back and forth and pull it upward.

-- 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.

The rest of the installation follows the reverse of the removal procedure. 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 COOLANT, DRAINING AND FILLING .