Valve Stem Seal, Replacing, Cylinder Head Removed

Special tools and workshop equipment required 

• Valve Seal Removal Tool 3364
• Valve Stem Seal Driver 3365
• Valve retainer disassembly and assembly device VAS 5161 with guide plate VAS 5161/23 and sleeve VAS 5161/23-1
• Engine and Transmission Holder VAS 6095
• Cylinder Head Tensioning Device VAS 6419
• 2x bolt M6x30

Procedure 

-- 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.

-- Insert the Cylinder Head Tensioning Device VAS 6419 into the Engine and Transmission Holder VAS 6095.

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

Fig 1: Identifying Air Cushion With Lever

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

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

-- Mount the guide plate VAS 5161/23 on the cylinder head.

Fig 2: Identifying Valve Cotter Tool Kit - Guide Plate

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the guide plate on the intake manifold side with the knurled bolt VAS 5161/12 and tighten the 2 M6x30 -1- bolts all the way by hand.

-- Insert the punch VAS 5161/3 in the guide plate and loosen the stuck valve retainers with a plastic mallet.

Fig 3: Identifying Valve Cotter Tool Kit - Punch

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-- Install engaging device VAS 5161/6 with installation fork VAS 5161/5 in guide plate.

Fig 4: Identifying Retainer

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-- Install the sleeve VAS 5161/23-1 on the installation cartridge VAS 5161/8.

-- Engage the pressure fork VAS 5161/2 on the retainer and press the installation cartridge downward.

-- At the same time, rotate the cartridge knurled screw right until points engage in valve retainers.

-- Move the knurled wheel left and right slightly. This presses the valve retainers apart and captures them in the cartridge.

-- Release the pressure fork.

-- Remove the installation cartridge with the knurled spacer ring.

-- Remove the valve spring and the valve spring plate.

-- Remove the valve stem seal with the Valve Seal Removal Tool 3364.

Fig 5: Identifying Puller - Valve Seal

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 Valve Stem Seal Driver 3365.

-- Remove plastic sleeve.

If the valve retainers were removed from the installation cartridge, they must be inserted in the valve retainer inserting tool next VAS 5161/18.

Fig 7: Identifying Installation Cartridge VAS 5161/8

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• The large diameter of the valve retainers point upward.

-- Insert valve spring and valve spring plate.

-- Press the installation cartridge onto the insertion device for the valve retainers from above and take up valve retainers.

-- Insert the installation cartridge in the guide plate VAS 5161/23.

Fig 8: Identifying Retainer

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Press the pressure fork down and pull the knurled screw up while turn left and right. This inserts the valve retainers.

-- Release the pressure fork with the knurled screw still raised.

-- Repeat the procedure on each valve.

Assembling 

Assembly is performed in reverse order. Note the following:

-- Make sure all the roller rocker levers lie on the ends of the valve stems correctly and are clipped onto the respective hydraulic adjusting elements.

-- Install the camshafts. Refer to CAMSHAFT .