Valve Guide Seal: Service and Repair

Valve Stem Seals

(With cylinder head installed)

Special tools, testers and auxiliary items required

• Spark Plug Removal Tool (3122B)

• 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

To remove the valve stem oil seals from the listed valves, the following must also be removed:

• Intake valves cylinder 1: transport strap

• Intake valves cylinder 5: camshaft adjustment valve 1 (N205)

• Exhaust valves cylinder 5: Secondary Air Injection (AIR) solenoid valve (N112)

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

- Remove the roller cam follower and set it down on a clean surface. Make sure that roller cam followers are not interchanged.

- Using the (3122B), remove the spark plugs.

- Secure the (VAS 5161/19B) using the (VAS 5161/12) to the cylinder head as shown.





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

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

- Using the (VAS 5161/3) and a plastic mallet, tap any stuck valve retainers in order to loosen them.





- Install the (VAS 5161/6) with the (VAS 5161/5) into the (VAS 5161/19B).





- Install the (VAS 5161/8) into the (VAS 5161/19B).

- Engage the (VAS 5161/2) on the (VAS 5161/6).

• On the exhaust side, the (VAS 5161/2) must be engaged as shown.





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

- Lightly move the knurled bolt on the (VAS 5161/8) back and forth, this causes the valve retainers to be pressed apart and captured in the (VAS 5161/8).

- Release the (VAS 5161/2).

- Remove the (VAS 5161/8), valve spring retainers and valve springs.

- Remove the valve stem seal using the (3364).





- If there is not enough clearance to use the (3364), drive the roll pin - arrow - out using a drift and remove the impact attachment.





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





- Insert a drift - 1 - into the bore in the lower part of the (3364).

- Using the drift - 1 - as a lever, pull out the valve stem oil seal - arrow -.

Installing

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





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

- Remove the plastic sleeve - A -.

- Install the valve spring and valve spring retainer.

- Install the (VAS 5161) as shown.

Intake Side





Exhaust Side





• If the valve retainers were removed from the (VAS 5161/18), they must be inserted into the (VAS 5161/18) next.





• Press the (VAS 5161/8) onto the insertion device from above and take up valve retainers.

- Press the (VAS 5161/8) with the (VAS 5161/2) down. Tap lightly against the lower area of the (VAS 5161/8). Rotate the knurled bolt on the (VAS 5161/8) back and forth and pull it upward.

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

- Remove the (VAS 5161).

The rest of the installation follows the reverse of the removal procedures. When doing this note the following:

• Remove the (T40069) from the rear of the cylinder block and install the locking bolt.

• Fill with coolant. Refer to => [ Draining and Filling ] Draining and Filling.