Valve Guide Seal: Service and Repair
Valve Stem Seals
(With the 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/Disasm Device (VAS 5161)
• Guide Plate for FSI Engine (VAS 5161/19B)
Removing
- Remove the camshafts. Refer to => [ Camshafts ] Service and Repair.
- Remove the roller rocker arms and place them on a clean surface. Make sure that they are not interchanged.
- Using the spark plug removal tool (3122 B) , remove spark plugs.
- Secure the guide plate for FSI engine (VAS 5161/19B) using the knurled thumb screws (VAS 5161/12) onto the cylinder head as shown.
- Adjust the piston of the respective cylinder to the Bottom Dead Center (BDC) position.
- Install the adapter (T40012) into the spark plug hole and connect compressed air of at least 6 bar positive pressure.
- Using the punch (VAS 5161/3) and a plastic mallet, tap any stuck valve retainers in order to loosen.
Intake Side:
- Install the retainer (VAS 5161/6) using the guide forks M6/M8 with threaded stud (VAS 5161/5) into the center threads in the guide plate for FSI engine (VAS 5161/19B).
- Install the assembly cartridge (VAS 5161/8) into the guide plate (VAS 5161/19B).
- Install the pressure fork with lever for assembly cartridge (VAS 5161/2) onto the retainer (VAS 5161/6).
Exhaust Side:
- Install the retainer (VAS 5161/6) using the guide forks M6/M8 with threaded stud (VAS 5161/5) into the outer threads in the guide plate for FSI engine (VAS 5161/19B).
- Press down the assembly cartridge (VAS 5161/8). At the same time, turn the knurled knob on the assembly cartridge (VAS 5161/8) clockwise until the points engage in the valve retainers.
- Lightly move the knurled knob back and forth, this causes the valve retainers to be pressed apart and captured in the assembly cartridge.
- Release the pressure fork with lever for assembly cartridge (VAS 5161/2).
- Take out the assembly cartridge (VAS 5161/8).
- Remove the valve stem seal using the valve seal removal tool (3364).
- If the valve seal removal tool (3364) cannot be used due to restricted clearance, drive the roll pin - arrow - out with a drift and remove the impact attachment.
- Place the lower part of the valve seal removal tool (3364) onto the valve stem seal.
- Insert a drift - 1 - into the bore in the lower part of the removal tool.
- Using the drift - 1 - as a lever, pull out the valve stem seal in the - direction of the arrow -.
Installing
- Place a plastic sleeve - A - on the valve stem to prevent damage to the new valve stem seal - B -.
- Lubricate the sealing lip of the valve stem seal - B -, insert it into the valve stem seal driver (3365) and carefully slide it onto the valve guide.
- Remove the plastic sleeve - A -.
- Install the valve spring, spring plate and valve spring retainers.
Intake Side:
- Install the special tools as shown.
Exhaust Side:
- Install the special tools as shown.
• If the valve retainers were removed from the assembly cartridge, they must be inserted into the valve insertion device (VAS 5161/18) next.
• Press the assembly cartridge (VAS 5161/8) onto the insertion device from above and capture the valve retainers.
- Press down the assembly cartridge (VAS 5161/8) with the pressure fork with lever for assembly cartridge (VAS 5161/2) and turn the knurled knob on the assembly cartridge back and forth while pulling it upward at the same time.
- Release the pressure fork with lever for assembly cartridge (VAS 5161/2) with the knurled knob pulled.
- Remove the special tools.
The rest of the installation is basically a reverse of the removal sequence.