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 the roller rocker arms are not interchanged.
- Remove the spark plugs using the spark plug removal tool (3122 B).
- Install the guide plate for FSI engine (VAS 5161/19B) to the cylinder head using the knurled thumb screws (VAS 5161/12).
- Adjust the piston of the respective cylinder to Bottom Dead Center (BDC).
- Install the adapter (T40012) into the spark plug threads and connect the compressed air hose (minimum 6 bar).
- Loosen any stuck valve retainers using the punch (VAS 5161/3) and a plastic mallet.
Intake Side
- Install the retainer (VAS 5161/6) using the guide forks M6/M8 with threaded stud (VAS 5161/5) into the center thread of the guide plate for FSI engine (VAS 5161/19B).
- Insert the assembly cartridge (VAS 5161/8) into the guide plate for FSI engine (VAS 5161/19B).
- Engage the pressure fork with lever for assembly cartridge (VAS 5161/2) on the retainer (VAS 5161/6).
Exhaust Side
- Install the retainer (VAS 5161/6) using the guide forks M6/M8 with threaded studs (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 thumb screw on the assembly cartridge (VAS 5161/8) clockwise until the points engage in the valve retainers.
- Lightly move the knurled thumb screw 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).
- Remove the assembly cartridge (VAS 5161/8).
- Remove the valve stem seal using the valve seal removal tool (3364).
- If there is not enough room to use the valve seal removal tool (3364) , drive out the roll pin - arrow - using a drift and remove impact device.
- Mount 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, remove the valve stem seal in the - direction of the arrow -.
Installing
- Place the plastic sleeve - A - on the valve stem to prevent damage to new valve stem seal - B -.
- Oil the sealing lip of the valve stem seal - B -, insert into the valve stem seal driver (3365) and carefully slide onto the valve guide.
- Remove the plastic sleeve - A -.
- Insert the valve spring and valve spring retainer.
Intake Side
- Install the valve cotters asm/disasm device (VAS 5161) components as shown:
Exhaust Side
- Install valve cotters asm/disasm device (VAS 5161) components 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 valve 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 thumb screw 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 thumb screw pulled.
- Remove the valve cotters asm/disasm device (VAS 5161) components.
- Install the spark plugs. Refer to => [ Ignition System Component Overview ] Service and Repair.
- Install the ignition coils with power output stages. Refer to => [ Ignition Coils with Power Output Stages ] Service and Repair.
Further installation is in the reverse order of removal.