Volkswagen Workshop Service and Repair Manuals

Renewing valve stem seals (With cylinder head installed)

Special tools and workshop equipment required

t	Spark plug socket and extension -3122 B-

t	Valve stem seal puller -3364-

t	Valve stem seal fitting tool -3365-

t	Adapter -T40012-

t	Torque wrench -V.A.G 1331-

t	Removal and installation device -VAS 5161-

t	Guide plate for 2.0 l and 3.0 l FSI engine -VAS 5161/19B-

Removing valve stem oil seals: –  Remove camshafts → Chapter. –  Remove roller rocker fingers and place onto a clean surface. When doing this, ensure that the roller rocker fingers are not interchanged. –  Remove spark plugs using spark plug socket and extension -3122 B-.

–  Bolt guide plate -VAS 5161/19B- to cylinder head using knurled bolts -VAS 5161/12- as shown. –  Set piston of respective cylinder to „bottom dead centre“.

–  Screw adapter -T40012- into spark plug thread and connect compressed air of at least 6 bar. –  Strike tight valve cotters with drift -VAS 5161/3- and a plastic hammer.

For inlet side –  Screw toothed piece -VAS 5161/6- with hooking fork -VAS 5161/5- into centre tread of guide plate -VAS 5161/19B-. –  Insert assembly cartridge -VAS 5161/8- into guide plate -VAS 5161/19B-. –  Attach pressure fork -VAS 5161/2- to snap-in device -VAS 5161/6-.

For exhaust side –  Screw toothed piece -VAS 5161/6- with hooking fork -VAS 5161/5- into outer tread of guide plate -VAS 5161/19B-. –  Press down assembly cartridge -VAS 5161/8-. Simultaneously turn knurled screw of assembly cartridge -VAS 5161/8- to right until tips lock into valve cotters. –  Move knurled screw back and forth lightly to press apart valve cotters and capture them in the assembly piece. –  Release pressure fork -VAS 5161/2-. –  Remove assembly cartridge -VAS 5161/8-.

–  Pull off valve stem seals using valve stem seal puller -3364-.

–  If valve stem seal puller -3364- cannot be used on account of restricted space, knock out pin -arrow- with a punch and remove the impact extractor attachment.

–  Position lower part of valve stem seal puller -3364- on valve stem oil seal. –  Insert a drift -1- in hole in lower part of puller device. –  Apply assembly lever to puller and pull out valve stem oil seal -arrow-.

Installing valve stem oil seals: –  To prevent damage to new valve stem seals -B-, attach plastic sleeve -A- to valve stem. –  Lubricate sealing lip of valve stem seal -B-, place it in the valve stem oil seal fitting tool -3365- and push carefully onto valve guide. –  Remove plastic sleeve -A-. –  Insert valve spring and valve spring plate.

Inlet side –  Set up disassembly and assembly tool -VAS 5161- as shown.

Exhaust side –  Set up disassembly and assembly tool -VAS 5161- as shown.   Note

t  If the valve cotters have been removed from the installation cartridge, they must first be inserted into the insertion device -VAS 5161/18-. t  Press assembly cartridge -VAS 5161/8- onto insertion device from above and pick up valve cotters. –  Press assembly cartridge -VAS 5161/8- down using pressure fork -VAS 5161/2- and turn knurled screw of assembly cartridge back and forth while pulling upwards. –  Release pressure fork -VAS 5161/2- whilst still pulling the knurled screw upwards. –  Remove disassembly and assembly tool -VAS 5161-. Further assembly is basically the reverse of the dismantling sequence.