Valve Stem Seals, Removing And Installing, Cylinder Head Installed

Special tools and workshop equipment required

Spark Plug Removal Tool: 3122B
Valve Keeper Tool Kit: VAS5161A with Valve Keeper Tool Kit - Guide Plate 32: VAS5161A/32 .
Sleeve: VAS5161A/32-3
Valve Cotter Tool Kit - Punch: VAS5161/3A
Guide Forks M6/M8 with Valve Cotter Tool Kit - Threaded Studs: VAS5161/5
Valve Cotter Tool Kit - Retainer: VAS5161/6
Knurled Thumb Screws M6: VAS5161/12
Guide Plate: VAS5161/32-1
Valve Keeper Tool Kit - Guide Plate 32: VAS5161A/32-1
Installation Cartridge: VAS5161/32-2
Sleeve: VAS5161A/32-3
Adapter: VAS5161A/35
Seal Installer - Valve Stem: 3365
Pliers - Valve Seal: VAS6770

Procedure

Golf Sportsvan

-- Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Remove the plenum chamber bulkhead. Refer to BULKHEAD, REMOVING AND INSTALLING .

-- Remove the bolts -arrows-. Remove the right drive axle heat shield.

Fig 1: Drive Axle Heat Sheild

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-- Remove the bolts -arrows- and the oil supply line -1-.

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Continuation for All Vehicles

-- Remove the camshaft housing. Refer to CAMSHAFT HOUSING, REMOVING AND INSTALLING .

-- Remove the spark plugs using the : 3122B .

-- Remove the : T10340 .

Fig 2: Identifying Crankshaft Locking Pin - T10340-

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-- Set the piston for the respective cylinder to "bottom dead center (BDC)".

-- Position the : VAS5161A/32-1 on the cylinder head and tighten using the : VAS5161/12 .

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-- Install the : VAS5161A/35 hand-tight in the respective spark plug thread.

-- Connect the adapter to the compressed air using a commercially available intermediate piece and give steady pressure.

Minimum pressure: 6.0 bar (87.02 psi)

-- Insert the : VAS5161/3A into the guide plate.

-- Loosen the secured valve retainers with a plastic mallet.

-- Install the : VAS5161/6 with the : VAS5161/5 in the guide plate.

Fig 3: Identifying Valve Keeper Tool Kit

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-- Insert the : VAS5161/32-2 with the : VAS5161A/32-3 installed into the guide plate.

-- Engage the : VAS5161/2 at the engaging device and press the installation cartridge downward.

-- At the same time, turn the installation cartridge knurled bolt right until points engage in the valve retainers.

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

-- Release the pressure fork.

-- Remove the assembly cartridge.

-- Remove the guide plate and turn it aside.

The pressurized air hose remains connected.

-- Remove the valve spring and the valve spring retainer.

-- Remove the valve stem seal using the : VAS6770 .

Fig 4: Identifying Valve Seal Pliers

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NOTE:

There is a risk of damage when installing valve stem seals.

-- Place the plastic sleeve -A- that is included with the new valve stem seals -B- on the valve stem.

Fig 5: Identifying Plastic Sleeve And Valve Stem Seals

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-- Lightly oil the valve stem seal -B- sealing lip.

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

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

-- Remove the plastic sleeve again.

If the valve retainers were removed from the installation cartridge, they must be inserted in the valve insertion device next.

Fig 6: Identifying Sleeve

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The large diameter of the valve retainers point upward.

-- Press the cartridge from above onto the insertion device and valve retainers.

-- Install the valve spring and valve spring retainer, valve spring installed position. Refer to Figure.

-- Fasten the : VAS5161/32-1 to the cylinder head again.

Fig 7: Identifying Valve Keeper Tool Kit

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-- Insert the : VAS5161/32-2 with the : VAS5161A/32-3 in the guide plate.

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

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

-- Repeat the procedure on each valve.

Assembling

Install in reverse order of removal and note the following:

Golf Sportsvan

-- Replace the seals and O-rings.

-- Install the oil supply line -1-, and tighten the bolts -arrows- to 9 Nm.

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-- Install the plenum chamber bulkhead. Refer to BULKHEAD, REMOVING AND INSTALLING .

-- Install the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

Continuation for All Vehicles

-- Install the spark plugs. Refer to SPARK PLUGS, REPLACING .

-- Install the camshaft housing. Refer to CAMSHAFT HOUSING, REMOVING AND INSTALLING .

Tightening Specifications

Fig 8: Drive Axle Heat Sheild

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Component	Tightening Specification
Bolts -1-	25 Nm