Valve Stem Seals, Removing And Installing, Cylinder Head Installed

Special tools and workshop equipment required 

• Spark Plug Removal Tool :3122B 
• Puller - Valve Seal :3364 
• Seal Installer - Valve Stem :3365 
• Valve Cotter Tool Kit - Adapter :T40012 
• Torque Wrench 1331 5-50Nm :VAG1331 
• Valve Cotter Tool Kit :VAS5161A 
• Valve Cotter Tool Kit - Guide Plate 19B :VAS5161/19B 

Mandatory Replacement Parts 

• Seals - Valve stem

Remove Valve Stem Seals 

-- Remove the camshafts. Refer to CAMSHAFT, REMOVING AND INSTALLING .

-- Remove the roller rocker lever and place it on a clean surface. Make sure that roller cam followers are not interchanged.

-- Remove the spark plugs using a :3122B  .

-- Tighten the :VAS5161/19B  on the cylinder head as shown using the :VAS5161A/12  .

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-- Move piston for that cylinder to "bottom dead center position".

-- Install the :T40012  in the spark plug threads.

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-- Connect compressed air with at least 6 bar (87 psi) pressure.

-- Loosen stuck valve retainers using a :VAS5161/3A  and a plastic hammer.

For the Intake Side 

-- Install the :VAS5161/6  with the :VAS5161/5  in the center threads of the :VAS5161A/19B  .

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-- Insert the :VAS5161/8A  into the :VAS5161/19B  .

-- Engage the :VAS5161/2  on the :VAS5161/6  .

For the Exhaust Side 

-- Install the :VAS5161/6  with the :VAS5161/5  in the outer threads of the :VAS5161A/19B  .

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-- Press down the :VAS5161/8A  and at the same time turn the knurled thumb screw on the :VAS5161/8A  to the right until the points engage in the valve retainers.

-- Move the knurled thumb screw back and forth slightly. This presses the valve retainers apart and captures them in the installation cartridge.

-- Release the :VAS5161/2  .

-- Remove the :VAS5161/8A  .

-- Remove valve stem seals using :3364  .

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-- If the :3364  cannot be used because there is not enough space, drive the roll pin -arrow- out using a drift and remove the impact attachment.

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

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-- Place the drift -1- in the hole in the lower section of the removal tool.

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

Install Valve Stem Seals 

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

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-- Lightly oil the valve stem seal.

-- Slide the valve stem seal onto the plastic sleeve.

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

-- Remove the plastic sleeve again.

-- Insert the valve spring and valve spring plate.

-- Connect the :VAS5161A  as illustrated.

For the Intake Side 

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For the Exhaust Side 

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-- Press the :VAS5161/8  down with the :VAS5161/2  and turn the cartridge knurled thumb screw back and forth while pulling up.

-- Release the :VAS5161/2  with the knurled thumb screw pulled.

-- Remove the :VAS5161A  .

Assemble in reverse order of disassembly.

-- Install the camshafts. Refer to CAMSHAFT, REMOVING AND INSTALLING .