Valve Stem Seals, Cylinder Head Installed, Removing And Installing: Procedure

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

-- 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 the spark plugs with Spark Plug Removal Tool:3122B  .

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

-- Position the Valve Cotter Tool Kit - Drift:VAS5161/3  on the valve spring plate and loosen the stuck valve retainers with a plastic mallet.

Fig 1: Identifying Special Tool - Drift VAS 5161/3

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-- Place the Valve Cotter Tool Kit - Guide Plate:VAS5161/19B  on the cylinder head.

Fig 2: Identifying Guide Plate For FSI Engine VAS 5161/19B

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-- Secure the guide plate with the Valve Cotter Tool Kit - Knurled Thumb Screws:VAS5161/12  .

-- Install the Valve Cotter Tool Kit - Adapter:T40012  with sealing ring in the spark plug thread and tighten by hand.

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

• Minimum pressure: 6 bar

-- Install the Valve Cotter Tool Kit - Retainer:VAS5161/6  with the Valve Cotter Tool Kit - Guide Forks M6/M8 with Threaded Studs:VAS5161/5  in the guide plate.

Fig 3: Identifying Engaging Device VAS 5161/6 With Installation Fork VAS 5161/5

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-- Push installation Valve Cotter Tool Kit - Cartridge:VAS5161/8  into guide plate.

-- Engage the Valve Cotter Tool Kit - Pressure Fork:VAS5161/2  at the engaging device and press the installation cartridge downward.

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

-- Move the knurled wheel left and right slightly. This presses the valve retainers apart and captures them in the cartridge.

-- Release the pressure fork.

-- Remove the cartridge.

-- Unfasten guide plate and turn it aside.

• Pressurized air hose remains connected.

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

-- Remove the valve stem seal with the Puller - Valve Seal:3364  .

Fig 4: Identifying 3364

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

Fig 5: Driving Out Roll Pin

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

-- Position the lower part of the puller - Puller - Valve Seal:3364  on the valve stem seal.

Fig 6: Positioning 3364 Valve Stem Removal Tool At Valve Stem Oil Seal

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-- 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-.

Fig 7: Identifying Plastic Sleeve, New Valve Stem Oil Seals & Valve Stem Seal Driver 3365

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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 Seal Installer - Valve Stem:3365  .

-- Remove the plastic sleeve again.

If the valve keepers were removed from the assembly cartridge, they must then be inserted into the Valve Cotter Tool Kit - Valve Insertion Device:VAS5161/18  .

Fig 8: Identifying Installation Cartridge VAS 5161/8

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• The large diameter of the valve retainers point upward.

-- Press assembly cartridge from above onto valve insertion device and capture keepers.

-- Insert valve spring and valve spring plate.

• Installed position, valve spring. Refer to Figure.

-- Install the guide plate on the cylinder head.

Fig 9: Identifying Engaging Device VAS 5161/6 With Installation Fork VAS 5161/5

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-- Insert installation cartridge in guide plate.

-- Press the pressure fork down and pull the knurled screw up while turn left and right. This inserts the valve retainers.

-- Release the pressure fork with the knurled screw still raised.

-- Repeat the procedure on each valve.