Valve Stem Seals

(with cylinder head installed)

Special tools and workshop equipment required 

• Spark plug removal tool 3122B
• Valve seal removal tool 3364
• Valve stem seal driver 3365
• Adapter T40012
• Torque wrench (5-50 Nm) VAG 1331
• Valve cotter asm/disasm device VAS 5161
• Guide plate for FSI engine VAS 5161/19

Removing 

-- Remove the camshafts. Refer to CAMSHAFTS .

-- Remove the roller cam follower and set it down on a clean surface. Make sure that roller cam followers are not interchanged.

-- Using the 3122B, remove the spark plugs.

-- Install the VAS 5161/19 using the 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 the Bottom Dead Center (BDC) position.

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

-- Using the VAS 5161/3 and a plastic faced hammer, tap to loosen stuck valve keepers.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the VAS 5161/6 with the VAS 5161/5 into the VAS 5161/19.

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 VAS 5161/8 into the VAS 5161/19.

-- Engage the VAS 5161/2 on the VAS 5161/6.

NOTE:

On the exhaust side, the VAS 5161/2 must be engaged as shown.

Fig 4: Identifying Pressure Forks VAS 5161/2 Engaged

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Lightly move the knurled bolt back and forth, this causes the valve keepers to be pressed apart and captured in the VAS 5161/8.

-- Release the VAS 5161/2.

-- Take out the VAS 5161/8.

-- Remove the valve stem seal using the 3364.

Fig 5: Identifying Valve Seal Removal Tool 3364

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- In the event the 3364 cannot be used due to constrained spatial arrangements, drive out the dowel pin -arrow- using a drift and remove the impact device.

Fig 6: Driving Out Spring Dowel Sleeve

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the lower part of the 3364 onto the valve stem oil 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 3364.

-- Using the drift as a lever, pull out the valve stem oil seal -arrow-.

Installing 

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

-- Remove the plastic sleeve -A-.

-- Install the valve spring and valve spring retainer.

-- Install the VAS 5161 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 keepers were removed from the VAS 5161/8, they must be inserted into the VAS 5161/18 next.

Fig 11: Identifying Installation Cartridge VAS 5161/8

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Press the VAS 5161/8 onto the VAS 5161/18 from above and take up the valve keepers.

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

-- Release the VAS 5161/2 with the knurled bolt pulled.

-- Remove the VAS 5161.

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

-- Install the camshafts. Refer to CAMSHAFT ADJUSTER .