Valve Guide Seal: Service and Repair

Valve Stem Seals, 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)

• Thrust piece (T40012)

• Torque wrench 5-50 Nm (VAG 1331)

• Valve cotters asm/dis-asm 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 levers and place them on a clean surface. Make sure that roller cam followers are not interchanged.

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

- Install 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) to the spark plug threads and connect a compressed air hose 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.

For the Intake Side





- Install the (VAS 5161/6) and the (VAS 5161/5) into the center thread in the (VAS 5161/19B).

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

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

For the Exhaust Side





- Install the (VAS 5161/6) and the (VAS 5161/5) into the outer thread in the (VAS 5161/19B).

- 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 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).

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





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





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





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

- Place a lever at the (3364) and pull out the valve stem seal - arrow -.

Installing

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





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

- Remove the plastic sleeve - A -.

- Insert the valve spring and valve spring retainers.

For the Intake Side





- Install the (VAS 5161) as shown:

For the Exhaust Side





- Install the (VAS 5161) as shown:

• If the valve keepers were removed from the (VAS 5161/8), they must then be inserted into the (VAS 5161/18).





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

- Press down the (VAS 5161/8) with the (VAS 5161/2) and turn the knurled screw on the (VAS 5161/8) 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).

- Install the spark plugs. Refer to --> [ Ignition Assembly Overview ] Service and Repair.

- Install the ignition coils with power output stages. Refer to --> [ Ignition Coils with Power Output Stages ] Service and Repair.

The rest of the installation is basically a reverse of the removal sequence.