Valve Stem Seals, Removing And Installing, Cylinder Head Installed

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Spark Plug Removal Tool: 3122B
Puller - Valve Seal: 3364
Seal Installer - Valve Stem: 3365
Valve Cotter Tool Kit - Adapter: T40012
Torque Wrench, 6-50Nm: VAG1331A
Valve Cotter Tool Kit: VAS5161
Valve Cotter Tool Kit - Guide Plate 19C: VAS5161/19C

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 : 3122B .

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

Fig 1: Identifying Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Install the : T40012 in the spark plug threads.

Fig 2: Identifying Drift VAS 5161/3 And Plastic Mallet To Loosen Stuck Valve Keepers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect compressed air with at least 6 bar (87.02 psi) pressure.

-- Loosen stuck valve retainers using a Punch: VAS5161/3A and a plastic hammer.

For the Intake Side

Fig 3: 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 the : VAS5161/5 in the center threads on the : VAS5161/19C .

-- Insert the : VAS5161/8A in the : VAS5161/19C .

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

For the Exhaust Side

Fig 4: Identifying Pressure Fork VAS 5161/2

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the : VAS5161/6 with the : VAS5161/5 in the outer threads on the : VAS5161/19C .

-- 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 5: Identifying Valve Seal Removal Tool 3364

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- If the : 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 6: Driving Out Roll Pin

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 7: Identifying Placement Of Lower Part Of Valve Seal Removal Tool 3364 On To Valve Stem Oil Seal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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-.

Valve Stem Seals, Installing

Fig 8: Identifying Plastic Sleeve And Valve Stem Seals

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 : 3365 .

-- Remove the plastic sleeve.

-- Insert the valve spring and valve spring retainer.

-- Connect the : VAS5161A as shown.

Intake Side

Fig 9: 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 10: Identifying Pressure Fork VAS 5161/2

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

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

Fig 11: Identifying Installation Cartridge VAS 5161/8

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Press the : VAS5161/8A onto the insertion tool from above.

-- 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 in the reverse order of removal, but observe the following:

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