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 roller rocker arms and place them on a clean surface. Make sure they 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) as shown.
- Adjust piston of the respective cylinder to Bottom Dead Center (BDC).
- Install adapter (T40012) into the spark plug threads and connect the compressed air of at least 6 bar positive pressure.
- Loosen any stuck valve retainers using the punch (VAS 5161/3) and a plastic mallet.
Intake Side:
- Install the retainer (VAS 5161/6) using guide forks M6/M8 with threaded studs (VAS 5161/5) into the center thread in the guide plate for FSI engine (VAS 5161/19B).
- Install the assembly cartridge (VAS 5161/8) into the guide plate for FSI engine (VAS 5161/19B).
- Attach the pressure fork with lever for assembly cartridge (VAS 5161/2) to 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 thread in the guide plate for FSI engine (VAS 5161/19B).
- Press the assembly cartridge (VAS 5161/8) down. 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).
- Take out the assembly cartridge (VAS 5161/8).
- Remove the valve stem seal using the valve seal removal tool (3364).
- In the event the valve seal removal tool (3364) cannot be used due to limited space, drive out the roll pin - arrow - using a drift and remove the impact device.
- Install the lower part of the valve seal removal tool (3364) onto the valve stem seal.
- Insert a drift - 1 - into the hole in the lower part of the valve seal removal tool (3364).
- Using the drift - 1 - as a handle, 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 new valve stem seal - B -.
- Lubricate the sealing lip of valve stem seal - B -, insert it into the valve stem seal driver (3365) , and carefully push it onto the valve guide.
- Remove the plastic sleeve - A -.
- Install the valve spring and valve spring retainers.
Intake Side:
- Install the valve cotters asm/disasm device (VAS 5161) as shown:
Exhaust Side:
- Install the valve cotters asm/disasm device (VAS 5161) 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 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 of 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 still pulled.
- Remove the valve cotters asm/disasm device (VAS 5161).
- Install the spark plugs. Refer to => [ Ignition System Component Overview ] Service and Repair.
- Install the ignition coils with power output stages. Refer to => [ Ignition Coil with Power Output Stage ] Service and Repair.
Further installation is in the reverse order of removal.