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 (VAS 5161)

• Knurled Bolts (VAS 5161/12)

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

Valve Stem Seals, Removing

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

- Mark the allocation of the roller rocker lever and the hydraulic adjusting elements so they can be installed again.

- If necessary, remove the roller rocker levers with the hydraulic adjusting elements and place them on a clean surface.

- Remove the spark plugs using a (3122 B).

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






- Move piston for respective cylinder to "Bottom Dead Center (BDC) position".

- Install the (T40012) in the spark plug threads.






- Connect compressed air with at least 6 bar (42.8 psi) pressure.

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

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).

Exhaust Side






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

- Press the (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 (VAS 5161/2).

- Remove the (VAS 5161/8).

- Remove valve stem seals using (3364).






- If the (3364) cannot be used because there is not enough space, drive the roll pin - arrow - out using a drift and remove the impact attachment.






- Position the lower part of the (3364) on the valve stem seal.






- Place the drift - 1 - in the hole in the lower section of the removal tool.

- Position the lever on the removal tool and remove 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 (3365) and carefully slide onto valve guide.

- Remove the plastic sleeve - A -.

- Insert the valve spring and valve spring plate.

- Connect the (VAS 5161) as illustrated.

Intake Side





Exhaust Side





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






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

- Press the (VAS 5161/8) down with the (VAS 5161/2) and rotate the cartridge knurled bolt back and forth while pulling up.

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

- Remove the (VAS 5161).

Further assembly is performed in the reverse order of removal, thereby observing the following:

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