Valve Stem Seals, Cylinder Head Installed

Special tools and workshop equipment required 

• Puller - Valve Seal 3364
• Seal Installer - Valve Stem 3365
• Torque Wrench 1331 5-50Nm VAG1331
• Valve Cotter Tool Kit VAS5161A
• Valve Cotter Tool Kit - Guide Plate 23 VAS5161/23
• Valve Cotter Tool Kit - Guide Plate 23 - Guide Plate Sleeve VAS5161/23-1

Removing 

-- Remove the glow plugs. Refer to GLOW PLUGS .

-- Remove the camshafts. Refer to CAMSHAFTS .

-- Position the Valve Cotter Tool Kit - Guide Plate 23 VAS5161/23 on the cylinder head.

Fig 1: Identifying Guide Plate VAS 5161/23 Secured Using Knurled Screw VAS 5161/12

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the Valve Cotter Tool Kit - Guide Plate 23 VAS5161/23 to the intake manifold side using a Valve Cotter Tool Kit - Knurled Screw VAS5161/12 and on the studs using collarless M6 nuts -1- tightened by hand.

-- Install the Valve Cotter Tool Kit - Compression Stud VAS5161/10 in the Valve Cotter Tool Kit - Guide Plate 23 VAS5161/23.

Fig 2: Identifying Compression Stud VAS 5161/10 Installed In Guide Plate VAS 5161/23

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-- Install the Valve Cotter Tool Kit - Adapter for Compressed Air Connection VAS5161/11 into the respective glow plug threads and tighten by hand.

-- Insert the Valve Cotter Tool Kit - Punch VAS5161/3A into the Valve Cotter Tool Kit - Guide Plate 23 VAS5161/23 and loosen the valve retainers using a plastic mallet.

Fig 3: Identifying Punch VAS 5161/3 Installed In Guide Plate VAS 5161/23

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-- Install the Valve Cotter Tool Kit Guide Forks M6/M8 with Threaded Studs VAS5161/5 in the Valve Cotter Tool Kit - Guide Plate 23 VAS5161/23 with the Valve Cotter Tool Kit - Retainer VAS5161/6.

Fig 4: Identifying Assembly Cartridges VAS 5161/2, Valve Insertion Device VAS 5161/8 And Guide Plate VAS 5161/23

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Push the Valve Cotter Tool Kit - Guide Plate 23 - Guide Plate Sleeve VAS5161/23-1 onto the Valve Cotter Tool Kit - Assembly Cartridge VAS5161/8A.

-- Connect the Valve Cotter Tool Kit - Adapter for Compressed Air Connection VAS5161/11 to compressed air with a commercially available connector and apply a constant pressure.

• Minimum pressure: 6 bar (87.0 psi)

-- Engage the Valve Cotter Tool Kit - Pressure Fork with Lever for Assembly Cartridge VAS5161/2 at the Valve Cotter Tool Kit - Retainer VAS5161/6 and press down the Valve Cotter Tool Kit - Assembly Cartridge VAS5161/8A.

-- At the same time, turn the knurled thumb screw on the Valve Cotter Tool Kit - Assembly Cartridge VAS5161/8A 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 Valve Cotter Tool Kit - Assembly Cartridge VAS5161/8A.

-- Release the Valve Cotter Tool Kit - Pressure Fork with Lever for Assembly Cartridge VAS5161/2.

-- Remove the Valve Cotter Tool Kit - Assembly Cartridge VAS5161/8A with the Valve Cotter Tool Kit - Guide Plate 23 - Guide Plate Sleeve VAS5161/23-1, the valve plate and the valve spring.

-- Pull off the valve stem seal using the Puller - Valve Seal 3364.

Fig 5: Identifying Tool 3064 And Punch VAS 5161/3

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Installing 

NOTE:

A plastic sleeve -A- is supplied with the new valve stem seal -B-.

Fig 6: Identifying Plastic Sleeve, New Valve Stem Oil Seals & Valve Stem Seal Driver 3365

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Lightly coat the valve stem seal lips -B- with oil.

-- Slide the valve stem seal -B- onto the plastic sleeve -A-.

-- Carefully press the valve stem seal onto the valve guide using the Seal Installer - Valve Stem 3365.

-- Tap lightly on the driver with a plastic mallet until the valve stem seal is at the stop.

-- Remove the plastic sleeve again -A-.

-- Insert the valve spring and valve plate in the cylinder head.

-- If the valve retainers were removed from the Valve Cotter Tool Kit - Assembly Cartridge VAS5161/8A, they must then be inserted into the Valve Cotter Tool Kit - Valve Insertion Device VAS5161/18.

Fig 7: Identifying Installation Cartridge VAS 5161/8

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-- Press the Valve Cotter Tool Kit - Assembly Cartridge VAS5161/8A onto the Valve Cotter Tool Kit - Valve Insertion Device VAS5161/18 from above and take up the valve retainers.

-- Insert the Valve Cotter Tool Kit - Valve Insertion Device VAS5161/18 into the Valve Cotter Tool Kit - Guide Plate 23 VAS5161/23.

Fig 8: Identifying Assembly Cartridges VAS 5161/2, Valve Insertion Device VAS 5161/8 And Guide Plate VAS 5161/23

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Press the Valve Cotter Tool Kit - Pressure Fork with Lever for Assembly Cartridge VAS5161/2 down and pull the knurled thumb screw upward while turning it left and right to insert the valve retainers.

-- Release the Valve Cotter Tool Kit - Pressure Fork with Lever for Assembly Cartridge VAS5161/2 with the knurled thumb screw still pulled.

The rest of the installation is performed in reverse order of removal, noting the following: 

-- Install the camshafts. Refer to CAMSHAFTS .

-- Install the glow plugs. Refer to GLOW PLUGS .