Valve Stem Seals, With Cylinder Head Installed

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Valve Cotter Tool Kit - Adapter T40012
Torque Wrench 1331 5-50 Nm VAG 1331
Valve Cotter Tool Kit VAS 5161A
Valve Cotter Tool Kit - Guide Plate 19B VAS 5161/19B
Spark Plug Removal Tool 3122B
Puller - Valve Seal 3364
Seal Installer - Valve Stem 3365

Remove valve stem seals

-- Remove the camshafts, refer to CAMSHAFT .

-- Mark the allocation of the roller rocker lever and the hydraulic adjusting elements so they can be installed again.

-- If necessary, remove the roller rocker levers with the hydraulic adjusting elements and place them on a clean surface.

-- Remove the spark plugs using a Spark Plug Removal Tool 3122B.

-- Tighten the Valve Cotter Tool Kit - Guide Plate 19B VAS 5161/19B on the cylinder head as shown using the Valve Cotter Tool Kit - Knurled Thumb Screws M6 VAS 5161A/12.

Fig 1: Identifying Pressure Fork VAS 5161/12

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-- Move piston for that cylinder to "bottom dead center position".

-- Install the Valve Cotter Tool Kit - Adapter T40012 in the spark plug threads.

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

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-- Connect compressed air with at least 6 bar (87 psi) pressure.

-- Loosen stuck valve retainers using a Valve Cotter Tool Kit - Punch VAS 5161/3A and a plastic hammer.

For The 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 Valve Cotter Tool Kit - Retainer VAS 5161/6 with the Valve Cotter Tool Kit - Guide Forks M6/M8 with Threaded Studs VAS 5161/5 in the center threads of the Valve Cotter Tool Kit - Guide Plate 19B VAS 5161A/19B.

-- Insert the Valve Cotter Tool Kit - Assembly Cartridge VAS 5161/8A into the Valve Cotter Tool Kit - Guide Plate 19B VAS 5161/19B.

-- Engage the Valve Cotter Tool Kit - Pressure Fork With Lever for Assembly Cartridge VAS 5161/2 on the Valve Cotter Tool Kit - Retainer VAS 5161/6.

For the exhaust side

Fig 4: Identifying Pressure Fork VAS 5161/2

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-- Install the Valve Cotter Tool Kit - Retainer VAS 5161/6 with the Valve Cotter Tool Kit - Guide Forks M6/M8 with Threaded Studs VAS 5161/5 in the outer threads of the Valve Cotter Tool Kit - Guide Plate 19B VAS 5161A/19B.

-- Press down the Valve Cotter Tool Kit - Assembly Cartridge VAS 5161/8A and at the same time turn the knurled thumb screw on the Valve Cotter Tool Kit - Assembly Cartridge VAS 5161/8A to the right until the points engage in the valve keepers.

-- Move the knurled thumb screw back and forth slightly. This presses the valve retainers apart and captures them in the installation cartridge.

-- Release the Valve Cotter Tool Kit - Pressure Fork With Lever For Assembly Cartridge VAS 5161/2.

-- Remove the Valve Cotter Tool Kit - Assembly Cartridge VAS 5161/8A.

-- Remove valve stem seals using Puller - Valve Seal 3364.

Fig 5: Identifying Valve Seal Removal Tool 3364

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-- If the Puller - Valve Seal 3364 cannot be used because there is not enough space, drive the roll pin -arrow- out using a drift and remove the impact attachment.

Fig 6: Driving Out Roll Pin

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-- Position the lower part of the Puller - Valve Seal 3364 on the valve stem seal.

Fig 7: Identifying Placement Of Lower Part Of Valve Seal Removal Tool 3364 On To Valve Stem Oil Seal

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-- Place the drift -1- in the hole in the lower section of the removal tool.

-- Position the lever on the removal tool and remove the valve stem seal in the direction of the -arrow-.

Install valve stem seals

Fig 8: Identifying Plastic Sleeve And Valve Stem Seals

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CAUTION:

Risk of damage when installing valve stem seals.

Place the plastic sleeve -A- that is attached to valve stem seals -B- on valve stem.

-- Lightly oil the valve stem seal.

-- Slide the valve shaft seal onto the plastic sleeve.

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

-- Remove plastic sleeve.

-- Insert the valve spring and valve spring plate.

-- Connect the Valve Cotter Tool Kit VAS 5161A as illustrated.

Fig 9: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

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Fig 10: Identifying Pressure Fork VAS 5161/2

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NOTE:

If the valve keepers were removed from the assembly cartridge, they must then be inserted into the Valve Cotter Tool Kit - Valve Insertion Device VAS 5161/18.

Fig 11: Identifying Installation Cartridge VAS 5161/8

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Press the Valve Cotter Tool Kit - Assembly Cartridge VAS 5161/8A onto the Valve Cotter Tool Kit - Valve Insertion Device VAS 5161/18 from above and capture the valve retainers.

-- Press the Valve Cotter Tool Kit - Assembly Cartridge VAS 5161/8A down with the Valve Cotter Tool Kit - Pressure Fork with Lever for Assembly Cartridge VAS 5161/2 and rotate the cartridge Valve Cotter Tool Kit - Knurled Thumb Screws M6 VAS 5161A/12 back and forth while pulling up.

-- Release the Valve Cotter Tool Kit - Pressure Fork with Lever for Assembly Cartridge VAS 5161/2 with the Valve Cotter Tool Kit - Knurled Thumb Screws M6 VAS 5161A/12 pulled.

-- Remove the Valve Cotter Tool Kit VAS 5161A.

Further assembly is performed in the reverse order of removal, thereby observing the following:

-- Install the camshafts, refer to CAMSHAFT .