Valve Stem Seals, Removing And Installing, Cylinder Head Removed

WARNING: This page is about a different car, the 2017 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Puller - Valve Seal: 3364
Seal Installer - Valve Stem: 3365
Valve Cotter Tool Kit: VAS5161A
Valve Cotter Tool Kit - Guide Plate 19B: VAS5161/19B
Engine and Gearbox Bracket VAS6095A: VAS6095A
Cylinder Head Tensioning Device: VAS6419

Procedure

-- Remove the camshafts. Refer to CAMSHAFT, REMOVING AND INSTALLING .

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

-- Remove the roller rocker levers with the hydraulic adjuster and place them on a clean surface.

-- Insert the : VAS6419 in the : VAS6095A .

Fig 1: Identifying Air Cushion With Lever

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tension the cylinder head on the cylinder head tensioning device, as shown.

-- Connect the cylinder head tensioning device to the compressed air.

-- Slide the air cushion with the lever -arrow- under the combustion chambers onto the valve stem seal that will be removed.

-- Let enough compressed air flow into the air cushion until it contacts the valve plate.

Guide Plate, Reworking

Fig 2: Identifying Valve Cotter Tool Kit - Guide Plate 19cVAS5161/19C

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Check if the opening -arrow- is present.

-- If necessary, rework the : VAS5161/19C -arrow- until the guide plate touches the cylinder head and the guide pin -1- is free.

-- Fasten the : VAS5161/19C on the cylinder head as shown using the : VAS5161/12 .

Fig 3: Identifying Valve Cotter Tool Kit - Guide Plate 19cVAS5161/19C

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the : VAS5161/3 in the guide plate and loosen the stuck valve retainers with a plastic mallet.

For the Intake Side

Fig 4: 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 : VAS5161/6 with : VAS5161/5 in the center thread of the : VAS5161/19B .

-- Place the : VAS5161/8 in the : VAS5161/19B .

-- Engage the : VAS5161/2 on the : VAS5161/6 .

For the Exhaust Side

Fig 5: Identifying Pressure Fork VAS 5161/2

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-- Install the : VAS5161/6 with : VAS5161/5 in the outer thread of the : VAS5161/19B .

-- Press down the : VAS5161/8A and at the same time turn the knurled thumb screw on the : VAS5161/8A to the right until the points engage in the valve retainers.

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

-- Release the : VAS5161/2 .

-- Remove the : VAS5161/8A .

-- Remove the valve stem seals using : 3364 .

Fig 6: Identifying Valve Seal Removal Tool 3364

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Install Valve Stem Seals

Fig 7: Identifying Plastic Sleeve And Valve Stem Seals

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Lightly oil the valve stem seal sealing lip.

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

-- Carefully press the valve stem seal onto the valve guide with the : 3365 .

-- Remove the plastic sleeve.

-- Insert the valve spring and valve spring retainer.

-- Install the : VAS5161A as illustrated below.

Intake Side

Fig 8: 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.

Exhaust Side

Fig 9: Identifying Pressure Fork VAS 5161/2

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

If the valve retainers were removed from the installation cartridge, they must then be inserted into the : VAS5161/18 .

Fig 10: Identifying Installation Cartridge VAS 5161/8

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Press the : VAS5161/8A onto the insertion device from above and capture the valve retainers.

-- Press the : VAS5161/8 down with the : VAS5161/2 and rotate the cartridge knurled thumb screw back and forth while pulling up.

-- Release the : VAS5161/2 with the knurled thumb screw pulled.

-- Remove the : VAS5161A .

Further assembly is performed the reverse order of the removal. Pay attention to the following:

-- Install the camshafts. Refer to CAMSHAFT, REMOVING AND INSTALLING .