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 lay them on a clean surface while making sure not to switch the roller rocker arms.

- Remove the spark plugs using spark plug removal tool (3122 B).

- Install the guide plate for FSI engine (VAS 5161/19B) onto the cylinder head as shown using the knurled thumb screws (VAS 5161/12).






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

- Install the adapter (T40012) into the spark plug threads and apply a constant pressure of at least 6 bar positive pressure.

- Loosen any stuck valve retainers using the punch (VAS 5161/3) and a plastic mallet.






- Install the retainer (VAS 5161/6) with the guide fork M6/M8 with threaded studs (VAS 5161/5) in 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 the assembly cartridge (VAS 5161/8) down while rotating its knurled thumb screw to the right until the points engage in the valve retainers.

- Move the knurled thumb screw back and forth slightly. This presses the valve retainers apart and captures them 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 seals using the valve seal removal tool (3364).






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






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






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

- Using the drift as a lever, remove the valve stem seal - 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 valve stem seal - B -, insert it onto the valve stem seal driver (3365) and carefully slide it onto the valve guide.

- Remove the plastic sleeve - A -.

- Insert the valve spring and spring plate.

- 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 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) down with the pressure fork with lever for assembly cartridge (VAS 5161/2) and rotate the cartridge knurled thumb screw back and forth while pulling up.

- 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.

Further installation is in the reverse order of removal.

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