Valve Stem Seals, Removing And Installing, Cylinder Head Removed

Special tools and workshop equipment required

Valve Keeper Tool Kit: VAS5161A with Valve Keeper Tool Kit - Guide Plate 32: VAS5161A/32 .
Valve Keeper Tool Kit - Pressure Fork: VAS5161/2
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
Guide Plate: VAS5161/32-1
Installation Cartridge: VAS5161/32-2
Sleeve: VAS5161A/32-3
Engine And Transmission Holder: VAS6095
Cylinder Head Tensioning Device: VAS6419
Pliers - Valve Seal: VAS6770
Seal Installer - Valve Stem: 3365

Procedure

-- Remove the cylinder head. Refer to CYLINDER HEAD, REMOVING AND INSTALLING .

Fig 1: Identifying Cylinder Head Tensioning Device VAS 6419

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the : VAS6419 in the : VAS6095 .

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

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

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

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

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

Fig 2: Identifying Valve Keeper Tool Kit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 Installation Cartridge

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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.

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

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

Fig 4: Identifying Valve Seal Pliers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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 Installation Cartridge

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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.

-- Install the cylinder head. Refer to CYLINDER HEAD, REMOVING AND INSTALLING .