Removing and installing valve stem seals (cylinder head installed)

Special tools and workshop equipment required

Spark plug socket and extension -3122 B-

Compressed air adapter -VAS 5161 A/35- (not illustrated)

Valve stem seal fitting tool -3365-

Valve stem pliers -VAS 6770-

Procedure

Golf SV

• Remove plenum chamber cover → Rep. gr.50.

• Remove plenum chamber bulkhead → Rep. gr.50.

• Remove bolts -arrows-. Remove heat shield from right drive shaft.
• Unscrew bolts -arrows-, and remove oil supply line -1-.

Continuation for all vehicles

• Remove camshaft housing → Chapter.
• Unscrew spark plugs with spark plug spanner -3122 B-.

• Unscrew locking pin -T10340-.
• Set piston of respective cylinder to “bottom dead centre”.

• Fit guide plate -VAS 5161A/32-1- onto cylinder head and secure with knurled screws -VAS 5161/12-.
• Screw compressed air adapter -VAS 5161 A/35- into the respective park plug thread hand-tight.
• Connect adapter to compressed air supply using a commercially available union and apply pressure continuously.

Minimum pressure: 6 bar

• Insert punch -VAS 5161/3A- into guide plate and use a plastic hammer to knock loose the firmly seated valve cotters.

• Screw toothed piece -VAS 5161/6- with hooking fork -VAS 5161/5- into guide plate.
• Slide sleeve -VAS 5161A/32-2- onto assembly cartridge and insert cartridge into guide plate -VAS 5161A/32-3-.
• Attach pressure fork -VAS 5161/2- to toothed piece and press assembly cartridge down.
• At the same time, turn knurled screw of assembly cartridge clockwise until tips engage in valve cotters.
• Move knurled screw back and forth to press apart valve cotters and capture them in assembly cartridge.
• Release pressure fork.
• Remove installation cartridge.
• Unbolt guide plate and move to side.

The compressed air hose remains connected.

• Remove valve spring and valve spring plate.

• Pull off valve stem seal using valve stem pliers -VAS 6770-.

Note

Risk of damage when installing valve stem seals.

• Place plastic sleeve -A-, enclosed with new valve stem seals -B-, onto valve stem.
• Lightly oil sealing lip of valve stem seal.
• Push valve stem seal onto plastic sleeve.
• Carefully press valve stem seal onto valve guide using valve stem seal fitting tool -3365-.
• Remove plastic sleeve.

Larger diameter of valve cotters faces upwards.

• Press assembly cartridge onto insertion device from above and pick up valve cotters.
• Insert valve spring and valve spring plate. For installation position of valve spring refer to → Fig..

• Bolt guide plate -VAS 5161A/32-1- onto cylinder head again.
• Insert assembly cartridge -VAS 5161A/32-2- with sleeve -VAS 5161A/32-3- into guide plate.
• Press pressure fork downwards and pull knurled screw upwards, turning it clockwise and anticlockwise. This inserts the valve cotters.
• Reduce pressure on pressure fork whilst pulling on knurled screw.
• Repeat procedure on each valve.

Reassembly

Installation is carried out in the reverse order; note the following:

Golf SV

• Install oil supply line -1-, and tighten bolts -arrows- to 9 N·m.
• Install plenum chamber bulkhead → Rep. gr.50.
• Install plenum chamber cover → Rep. gr.50.

Continuation for all vehicles

• Install spark plugs → Booklet.
• Install camshaft housing → Chapter.

Specified torques