Valve Guide Seal: Service and Repair
Valve Stem Seals, Removing and Installing
(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 (V.A.G 1331)
• Valve cotters assembly/disassembly device (VAS 5161)
• Guide Plate F/2.0 Ltr FSI Engine (VAS 5161/19B)
Valve Stem Seals, Removing
- Remove camshafts => [ Camshafts, Removing and Installing ] Service and Repair.
- Remove roller rocker levers and place them on a clean surface. Make sure that roller cam followers are not interchanged.
- Using spark plug removal tool (3122 B), remove spark plugs.
- Tightly screw guide plate (VAS 5161/19B) with knurled bolts (VAS 5161/12) on cylinder head as shown.
- Adjust piston of the respective cylinder to "Bottom Dead Center position".
- Screw adapter (T40012) into spark plug thread and connect compressed air of at least 6 bar positive pressure.
- Using drift (VAS 5161/3) and a plastic mallet, tap to loosen stuck valve keepers.
for the intake side
- Install the engaging device (VAS 5161/6) using installation forks (VAS 5161/5) into the center thread in the guide plate (VAS 5161/19B).
- Insert installation cartridge (VAS 5161/8) into guide plate (VAS 5161/19B).
- Engage pressure fork (VAS 5161/2) on engaging device (VAS 5161/6).
for the exhaust side
- Install the engaging device (VAS 5161/6) using installation forks (VAS 5161/5) into the outer thread in the guide plate (VAS 5161/19B).
- Press down installation cartridge (VAS 5161/8). At the same time, turn knurled bolt of installation cartridge (VAS 5161/8) clockwise until the points engage in the valve keepers.
- Lightly move knurled bolt back and forth, this causes the valve keepers to be pressed apart and captured in the installation cartridge.
- Release pressure fork (VAS 5161/2).
- Take out installation cartridge (VAS 5161/8).
- Remove valve stem seals using Valve Seal Removal Tool (3364).
- In the event the valve stem seal driver (3364) cannot be used due to constrained spatial arrangements, drive out spring dowel sleeve - arrow - using a drift and remove impact device.
- Place the lower part of the valve seal removal tool (3364) onto the valve stem seal.
- Insert a drift - 1 - into bore in lower part of extractor device.
- Place a lever at the removal tool and pull out the valve stem seal - arrow -.
Valve Stem Seals, Installing
- Place plastic sleeve - A - on valve stem to prevent damage to new valve stem oil seals - B -.
- Oil the sealing lip of valve stem oil seal - B -, insert into valve stem seal driver (3365) and carefully slide onto valve guide.
- Remove plastic sleeve - A -.
- Insert valve spring and valve spring retainer.
Intake side
- Install valve cotter disassembly and assembly device (VAS 5161) as shown.
Exhaust side
- Install valve cotter disassembly and assembly device (VAS 5161) as shown.
• If the valve keepers were removed from the installation cartridge, they must then be inserted into the insertion device (VAS 5161/18).
• Press the installation cartridge (VAS 5161/8) onto the insertion device from above and capture the valve keepers.
- Press down the installation cartridge (VAS 5161/8) with the pressure fork (VAS 5161/2) and turn the knurled screw of the installation cartridge back and forth while pulling it upward at the same time.
- Release pressure fork (VAS 5161/2) with the knurled bolt pulled.
- Remove the valve cotter assembly/disassembly device (VAS 5161).
The rest of the assembly is basically a reverse of the disassembling sequence.