Valve Guide Seal: Service and Repair

Valve Stem Seals

(with 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)

Removing

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

- Remove the hydraulic adjusting elements and set them down on a clean surface. Make sure that they are not interchanged.

- Using (3122 B), remove the spark plugs.

- Install the (VAS 5161/19) using (VAS 5161/12) to the cylinder head as shown.





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

- Install (T40012) into the spark plug threads and connect compressed air of at least 6 bar positive pressure.

- Using (VAS 5161/3) and a plastic mallet, loosen any stuck valve retainers by tapping (VAS 5161/3).





- Install the (VAS 5161/6) with (VAS 5161/5) to the (VAS 5161/19).





- Install the (VAS 5161/8) to the (VAS 5161/19).

- Engage the (VAS 5161/2) on the (VAS 5161/6).

• On the exhaust side, (VAS 5161/2) must be engaged as shown.





- Press down the (VAS 5161/8). At the same time, turn the knurled end of the (VAS 5161/8) clockwise until the points engage in the valve retainers.

- Lightly move the knurled end back and forth, this causes the valve retainers to be pressed apart and captured in the (VAS 5161/8).

- Release the (VAS 5161/2).

- Take out the (VAS 5161/8).

- Remove the valve stem seal using (3364).





- If the (3364) cannot be used due to restricted clearance, drive the roll pin - arrow - out with a drift and remove the impact attachment.





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





- Insert a punch - 1 - into the bore in the lower part of the (3364).

- Using the punch - 1 - as a lever, remove the valve stem oil 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 oil seal - B -.





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

- Remove the plastic sleeve - A -.

- Install the valve spring and valve spring retainer.

- Install the (VAS 5161) as shown.

Intake Side





Exhaust Side





• If the valve retainers were removed from the (VAS 5161/18), then they must be inserted into the (VAS 5161/18) next.





• Press the (VAS 5161/8) onto insertion device from above and take up valve retainers.

- Press down the (VAS 5161/8) with the (VAS 5161/2) and turn the knurled end of the (VAS 5161/8) back and forth while pulling it upward at the same time.

- Release the (VAS 5161/2) with the knurled end pulled.

- Remove the (VAS 5161).

The rest of the installation is basically a reverse of the removal sequence.

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