Valve Stem Seals, Cylinder Head Installed

Valve Stem Seals, 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 5-50 Nm (V.A.G 1331)

• Valve Cotters Asm/Dis-Asm Device (VAS5161)

• Guide Plate for FSI Engine (VAS 5161/19B)

Valve Stem Seals, Removing

- Remove the camshafts. Refer to => [ Camshafts ] Service and Repair.

• 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.

- Remove the spark plugs with the (3122 B).

- Tighten the (VAS 5161/19B) on the cylinder head as shown using the knurled bolts (VAS 5161/12).






- Adjust piston of the respective cylinder to "Bottom Dead Center (BDC)".

- Install the (T40012) into the spark plug thread and connect compressed air (minimum 6 bar).






- Loosen any stuck valve retainers using a drift (VAS 5161/3) and a plastic hammer.

For the Intake Side

- Install the engaging device (VAS 5161/6) with the installation fork (VAS 5161/5) in the center threads of the (VAS 5161/19B).






- Insert the installation cartridge (VAS 5161/8) in the (VAS 5161/19B).

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

For the Exhaust Side

- Install the engaging device (VAS 5161/6) with the installation fork (VAS 5161/5) in the outer threads of the (VAS 5161/19B).






- Press the installation cartridge (VAS 5161/8) down while rotating its knurled bolt to the right until the points engage in the valve retainers.

- Move the knurled wheel back and forth slightly. This presses the valve retainers apart and captures them in the installation cartridge.

- Release the pressure fork (VAS 5161/2).

- Remove the installation cartridge (VAS 5161/8).

- Remove valve stem seals using the (3364).






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






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






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

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

Valve Stem Seals, Installing

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






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

- Remove the plastic sleeve - A -.

- Insert valve spring and valve spring retainer.

- Install the (VAS 5161) as shown.

Intake Side





Exhaust Side





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






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

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

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

- Remove the (VAS 5161).

Assemble in reverse order of disassembly.

- Install the camshafts. Refer to => [ Camshafts ] Service and Repair.