Valve Stem Seals With Cylinder Head Removed

Special tools and workshop equipment required 

• Valve Seal Removal Tool 3364
• Valve Stem Seal Driver 3365
• Valve Cotters Asm/Dis-Asm Device VAS 5161
• Guide Plate for FSI Engine VAS 5161/19B
• Engine and Transmission Holder VAS 6095
• Cylinder Head Tensioning Device VAS 6419

Procedure 

-- Remove the camshafts. Refer to CAMSHAFTS .

-- Mark the allocation of the roller rocker lever and the hydraulic adjusting elements so they can be installed again.

-- If necessary, remove the roller rocker levers with the hydraulic adjusting elements and place them on a clean surface.

-- Mount the VAS 6419 into the VAS 6095.

-- Tension the cylinder head on the VAS 6419 as illustrated.

-- Connect the VAS 6419 to the compressed air.

-- Slide the air cushion with the lever -arrow- under the combustion chamber onto the valve stem seals that will be removed.

-- Let enough compressed air flow into the air cushion until it contacts the valve plate.

-- Place the guide plate VAS 5161/19B from the VAS 5161 on the cylinder head.

-- Secure the guide plate with the knurled screws VAS 5161/12.

-- Insert the drift VAS 5161/3 in the guide plate and loosen the stuck valve retainers with a plastic mallet.

-- Install engaging device VAS 5161/6 with installation fork VAS 5161/5 in guide plate.

-- Slide installation cartridge VAS 5161/8 in guide plate.

Intake Side: 

-- Engage the pressure fork VAS 5161/2 on the engaging device as illustrated.

Exhaust Side: 

-- Engage the pressure fork VAS 5161/2 on the engaging device as illustrated.

Continued for Both Sides: 

-- Press the installation cartridge down with the pressure fork.

-- At the same time, rotate installation cartridge knurled screw right until points engage in valve retainers.

-- Move the knurled bolt to the left and right.

• Valve retainer are pressed against each other and capture in the installation cartridge.

-- Release the pressure fork.

-- Remove installation cartridge.

-- Unfasten guide plate and turn it aside.

-- Remove the valve spring and the valve spring plate.

-- Remove the valve stem seal with the 3364.

-- Lightly oil valve stem seal.

-- Slide valve shaft seal onto plastic sleeve.

-- Carefully press valve stem seal onto valve guide with the 3365.

-- Remove plastic sleeve again.

When the valve retainers were removed from the installation cartridge, they must be inserted in the valve retainer inserting tool VAS 5161/18 next.

• The large diameter of the valve retainers point upward.

-- Press installation cartridge from above onto valve retainer inserting tool and capture retainers.

-- Insert valve spring and valve spring plate.

-- Install the guide plate on the cylinder head.

-- Insert installation cartridge with knurled spacer ring in guide plate.

-- Press pressure fork down and pull knurled screw up, turning left and right.

• The valve keepers are inserted in this manner.

-- Release pressure fork with knurled screw still raised.

-- Repeat the procedure on each valve.

Assemble in reverse order of disassembling. Note the following:

-- Install the camshafts. Refer to CAMSHAFTS .