Valve Stem Seals, Removing And Installing, Cylinder Head Installed

WARNING: This page is about a different car, the 2023 Volkswagen Atlas. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Valve Stem Seals, Replacing

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Special tools and workshop equipment required

Spark Plug Removal Tool:3122 B
Puller - Valve Seal:3364
Seal Installer - Valve Stem:3365
Fitting Tool:T40376/1 depending on the version
Valve Cotter Tool Kit - Adapter:T40012
Torque Wrench, 6-50Nm:VAG 1331A
Valve Cotter Tool Kit:VAS 5161
Valve Cotter Tool Kit - Guide Plate 19C:VAS 5161/19C

Remove the valve stem seals

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

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

-- Remove the roller rocker lever with the hydraulic lifter and place them on a clean surface.

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

Guide plate, reworking

Fig 2: Identifying Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C

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Check if the opening -arrow- is present.

-- If necessary, rework the Valve Cotter Tool Kit - Guide Plate 19C:VAS 5161/19C -arrow- until the guide plate contacts the cylinder head and the guide pin -1- is free.

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

Fig 3: Identifying Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C

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

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

Fig 4: 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 (87.02 psi) pressure.

-- Loosen stuck valve retainers using a Punch:VAS 5161/3A and a plastic hammer.

For the intake side

Fig 5: 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 Valve Cotter Tool Kit - Guide Forks M6/M8 Threaded:VAS 5161/5 in the center threads of the Valve Cotter Tool Kit - Guide Plate:VAS 5161/19C .

-- Insert the Assembly Cartridge:VAS 5161/8A in the Valve Cotter Tool Kit - Guide Plate 19C:VAS 5161/19C .

-- Engage the Pressure Fork With Lever for Assembly Cartridge:VAS 5161/2 on the Retainer:VAS 5161/6 .

For the exhaust side

Fig 6: Identifying Pressure Fork VAS 5161/2

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-- Install the Retainer:VAS 5161/6 with the Guide Forks:VAS 5161/5 in the outer threads on the Valve Cotter Tool Kit - Guide Plate 19C:VAS 5161/19C .

-- 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 Pressure Fork With Lever For Assembly Cartridge:VAS 5161/2 .

-- Remove the Assembly Cartridge:VAS 5161/8A .

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

Fig 7: 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 spring pin -arrow- out using a drift and remove the impact attachment.

Fig 8: Driving Out Roll Pin

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

Fig 9: 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 extractor lever on the puller and remove the valve stem seal -arrow-.

Install valve stem seals

Fig 10: Identifying Plastic Sleeve And Valve Stem Seals

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-- Place the plastic sleeve -A- that is included with 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 Seal Installer - Valve Stem:3365 .

NOTE:

The Fitting Tool:T40376/1 may need to be used depending on the valve stem seal.

-- Remove the plastic sleeve.

-- Insert the valve spring and valve spring retainer.

-- Connect the Valve Keeper Tool Kit:VAS 5161A as shown.

Intake side

Fig 11: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

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Exhaust side

Fig 12: 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 Insertion Device:VAS 5161/18 .

Fig 13: Identifying Installation Cartridge VAS 5161/8

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Press the Valve Cotter Tool Kit - Assembly Cartridge:VAS 5161/8A onto the insertion tool from above.

-- Press the Valve Keeper Tool Kit Assembly Cartridge:VAS 5161/8 down with the Valve Keeper Tool Kit Pressure Fork with Lever for Assembly Cartridge:VAS 5161/2 and rotate the cartridge knurled thumb screw back and forth while pulling up.

-- Release the Pressure Fork with Lever for Assembly Cartridge:VAS 5161/2 with the knurled thumb screw pulled.

-- Remove the Valve Keeper Tool Kit:VAS 5161A .

Further assembly is performed in the reverse order of removal. Note the following:

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