Valve Stem Seals With Cylinder Head Installed

Special tools and workshop equipment required 

• Spark Plug Removal Tool 3122 B
• Valve Seal Removal Tool 3364
• Valve Stem Seal Driver 3365
• Valve Cotters Asm/Dis-Asm Device VAS 5161 with Guide Plate for 2.0L FSI Engine VAS 5161/19B
• Adapter T40012

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.

-- Remove spark plugs with 3122 B.

-- Move piston for respective cylinder to "Bottom Dead Center (BDC) position".

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

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

-- Install the T40012 with sealing ring in respective spark plug thread and hand tighten.

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

-- Connect the adapter to the compressed air using a commercially available intermediate piece and give steady pressure.

• Minimum pressure: 6 bar positive pressure.

-- 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 retainer.

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

• Valve retainers 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.

• Pressurized air hose remains connected.

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

-- Pull off valve stem seals with the 3364.

If the 3364 cannot be used, on several valve stem seals due to restricted clearance, proceed as follows:

-- Drive out the roll pin -arrow- on the puller with a drift and remove the impact puller attachment.

-- Position the lower part of the 3364 on the valve stem seal.

-- Secure the puller with a drift or cotter pin drive -1- as shown in the illustration.

-- Position the valve lever on the puller and remove the valve stem seal -arrow-.

-- Lightly oil valve stem seal.

-- Slide valve shaft seal onto plastic sleeve.

-- Carefully press valve stem seal onto valve guide with Valve Stem Seal Drive 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 retainers are inserted in this manner.

-- Release pressure fork with knurled screw still raised.

-- Repeat the procedure on each valve.

Assembling 

Assemble in reverse order of disassembling. Note the following:

-- Install the camshafts. Refer to CAMSHAFTS .

-- Install spark plugs. Refer to SPARK PLUGS, REMOVING AND INSTALLING