Valve Guide Seal: Service and Repair

Valve Stem Seals

(with cylinder head installed)

Special tools, testers and auxiliary items required

• Spark plug removal tool (3122 B)

• Valve seal removal tool (3364)

• Valve stem seal driver (3365)

• Adapter (T40012)

• Torque wrench (V.A.G 1331)

• Valve cotters assembly/disassembly device (VAS 5161 )

• Guide Plate F/2.0 Ltr FSI Engine (VAS 5161/19A)

Removing

- Remove camshafts. Refer to => [ Camshafts ] Camshafts

• To replace the valve stem seals of the exhaust valves for cylinder 3 and 4, the EGR Vacuum Regulator Solenoid Valve (N18) must also be removed.

- Remove roller rocker levers and place them on a clean surface. Make sure that roller cam followers are not interchanged.

- Using spark plug removal tool (3122 B), remove spark plugs.

- Fasten Guide Plate F/2.0 Ltr FSI Engine (VAS 5161/19A ) to cylinder as shown using Knurled Screws ( VAS 5161/12).





- Adjust piston of respective cylinder to "Bottom Dead Center position".

- Install adapter (T40012) into spark plug thread and connect compressed air of at least 6 bar positive pressure.

- Using drift (VAS 5161/3) and a plastic mallet, tap to loosen stuck valve keepers.





- Install Engaging Device (VAS 5161/6) with Installation Fork (VAS 5161/5) in Guide Plate F/2.0 Ltr FSI Engine (VAS 5161/19A).





- Insert Installation Cartridge (VAS 5161/8) in Guide Plate F/2.0 Ltr FSI Engine (VAS 5161/19A ).

- Engage pressure fork (VAS 5161/2) on engaging device (VAS 5161/6).

• On the exhaust side, the pressure fork (VAS 5161/2 ) must be hooked in, as shown.





- Press down installation cartridge (VAS 5161/8 ). At the same time, turn knurled bolt of installation cartridge (VAS 5161/8) clockwise until points engage in valve keepers.

- Lightly move knurled bolt back and forth, this causes the valve keepers to be pressed apart and captured in the installation cartridge.

- Release pressure fork (VAS 5161/2).

- Remove installation cartridge (VAS 5161/8).

- Remove valve stem seals using Valve Seal Removal Tool (3364).





- In the event valve stem seal driver (3364) cannot be used due to constrained spatial arrangements, drive out spring dowel sleeve - arrow - using a drift and remove impact device.





- Place lower part of valve seal removal tool ( 3364) onto valve stem seal.





- Insert a drift - 1 - into bore in lower part of extractor device.

- Place a lever at removal tool and pull out valve stem seal - arrow -.

Installing

- Place plastic sleeve - A - on valve stem to prevent damage to new valve stem oil seals - B -.





- Oil sealing lip of valve stem oil seal - B -, insert into valve stem seal driver (3365) and carefully slide onto valve guide.

- Remove plastic sleeve - A -.

- Insert valve spring and valve spring retainer.

- Install valve cotter disassembly and assembly device (VAS 5161) as shown.

Intake side





Exhaust side





• If the valve keepers were removed from the installation cartridge, they must then be inserted into the insertion device (VAS 5161/18).





• Press installation cartridge (VAS 5161/8) onto insertion device from above and capture the valve keepers.

- Press down installation cartridge (VAS 5161/8 ) with pressure fork (VAS 5161/2) and turn knurled screw of installation cartridge back and forth while pulling it upward at the same time.

- Release pressure fork (VAS 5161/2) with knurled bolt pulled.

- Remove valve cotter assembly/disassembly device ( VAS 5161).

The rest of assembly is basically a reverse of disassembling sequence.

- How to install camshafts. Refer to => [ Camshafts ] Camshafts