Valve Guide Seal: Service and Repair

Valve Shaft 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

To remove the valve stem seals on some valves, the following components must be removed:

• For the intake valves in cylinder 1: The transport strap

• For the intake valves in cylinder 5: The camshaft adjustment valve 1 (N205)

• For the exhaust valves in cylinder 5: The secondary air injection solenoid valve (N112)

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

- Remove the roller rocker arms and lay them on a clean surface. Make sure that the 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 M6 (VAS 5161/12).






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

- 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.






- Install the retainer (VAS 5161/6) with the guide forks M6/M8 with threaded studs (VAS 5161/5) into 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).

• The pressure fork with lever for assembly cartridge (VAS 5161/2) must engage on the exhaust side as illustrated.






- 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 on the assembly cartridge 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) , valve spring retainers and valve springs.

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






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






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






- Insert the drift - 1 - into the bore in the lower part of the removal tool.

- Using the drift as a lever, pull out the valve stem seal in the - direction of the arrow -.

Installing

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






- Oil 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 -.

- Insert the valve spring and valve spring retainers.

- Install the valve cotters asm/disasm device (VAS 5161) components as illustrated.

Intake Side





Exhaust Side





• 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 take up the valve retainers.

- Press the assembly cartridge (VAS 5161/8) with the pressure fork with lever for assembly cartridge (VAS 5161/2) down. Tap lightly against the lower area of the assembly cartridge. Rotate the knurled thumb screw on the assembly cartridge back and forth and pull it upward.

- 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.

The rest of the installation follows the reverse of the removal procedure. Note the following:

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

• Fill the coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.