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)

• Removal and Installation Device for Valve Cotters (VAS 5161)

• Guide Plate for FSI Engine (VAS 5161/19B)

Note the following whenever working inside the engine compartment due to limited space:

• Route all lines and wires in their original locations.

• Ensure sufficient clearance to all moving or hot components.

Removing

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

• Intake valves for cylinder 1: Transport strap

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

• Exhaust valves for 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 rocker arms are not interchanged.

- Remove the spark plugs using the spark plug removal tool (3122 B).

- Install the guide plate for FSI engines (VAS 5161/19B) to the cylinder head using the knurled thumb screws M6 (VAS 5161/12) as shown.






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

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

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






- Install the retainer (VAS 5161/6) with the guide forks M6/M8 with threaded studs (VAS 5161/5) into the guide plate for FSI engines (VAS 5161/19B).






- Insert the assembly cartridge (VAS 5161/8) into the guide plate for FSI engines (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 on the assembly cartridge (VAS 5161/8) clockwise until the points engage in the valve retainers.

- Lightly move the knurled thumb screw on the assembly cartridge (VAS 5161/8) 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, spring seat and valve spring.

- 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 space constraints, drive out the roll pin - arrow - using a drift and remove the impact device.






- 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 valve seal removal tool (3364).

- Using the drift - 1 - as a lever, pull out the valve stem seal - arrow -.

Installing

- Place the plastic sleeve - A - on the valve stem to prevent damage to the new valve stem seal - B -.






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

- Remove the plastic sleeve - A -.

- Install the valve spring, spring seat and valve spring retainers.

- Install the removal and installation device for valve cotters (VAS 5161) 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 valve 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 removal and installation device for valve cotters (VAS 5161).

The rest of the installation follows the reverse of the removal procedure. 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 ] Procedures.