Valve Stem Seals: Removing

-- Remove the camshafts. Refer to CAMSHAFTS .

-- Remove roller rocker arms and place them on a clean surface. Make sure they 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 M6VAS 5161/12 as shown.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Install adapter T40012 into the spark plug threads and connect the compressed air of at least 6 bar (87 psi) positive pressure.

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

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

Intake Side:

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

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

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

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

Exhaust Side:

Fig 4: Identifying Pressure Forks VAS 5161/2

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

-- Press the assembly cartridge VAS 5161/8 down. 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 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

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-- In the event the valve seal removal tool 3364 cannot be used due to limited space, drive out the roll pin -arrow- using a drift and remove the impact device.

Fig 6: Driving Out Roll Pin

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-- Install 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 hole in the lower part of the valve seal removal tool 3364.

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