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)

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.

• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

Removing

To remove the valve stem seals, the following components must also be removed as follows:

• Intake valve cylinder 1: Transport strap

• Intake valve cylinder 5: Camshaft adjustment valve 1 (N205)

• Exhaust valve cylinder 5: Secondary air injection solenoid valve (N112)

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

- Remove the roller rocker arms and lay them on a clean surface. Make sure that the roller 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) using the knurled thumb screws (VAS 5161/12) to the cylinder head as shown.






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

- Install the adapter (T40012) into the spark plug threaded hole and connect the compressed air (minimum 6 bar).

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






- 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 of the assembly cartridge (VAS 5161/8) clockwise until the points engage in the valve retainers.

- Lightly move the knurled thumb screw of 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 seals using the valve seal removal tool (3364).






- In the event the valve seal removal tool (3364) cannot be used due to restricted space, drive out the roll pin - arrow - 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 a drift - 1 - into the bore in the lower part of the extracting device.

- Using the drift - 1 - 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 -.






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

- Remove the plastic sleeve - A -.

- Install the valve spring and valve spring retainers.

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

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 insertion device from above and take up the valve retainers.

- Press down the assembly cartridge (VAS 5161/8) using the pressure fork with lever for assembly cartridge (VAS 5161/2) , knock lightly against the assembly cartridge in the lower area, rotate the knurled thumb screw on the assembly cartridge back and forth and pull upward while doing this.

- 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).

The rest of the installation follows the reverse of the removal procedures. When doing this note the following:

• Remove the locking pin (T40069) from the cylinder block and install the plug.

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