Valve Stem Seals With Installed Cylinder Head, Removing And Installing: Removing: Notes

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

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

-- Remove the roller rocker levers with the hydraulic adjuster and place them on a clean surface.

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

-- Set the piston for the respective cylinder to "bottom dead center".

-- Position the Valve Cotter Tool Kit - Punch: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 Valve Cotter Tool Kit - Guide Plate 19B:VAS5161/19B  from Valve Cotter Tool Kit:VAS5161  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 gasket 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 (87 psi)

-- Install the Valve Cotter Tool Kit - Retainer:VAS5161/6  with the Guide Forks M6/M8 with Valve Cotter Tool Kit - 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 Valve Cotter Tool Kit - Assembly 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 the valve keepers.

-- Move the knurled bolt left and right slightly. This presses the valve keepers apart and captures them in the installation cartridge.

-- Release the pressure fork.

-- Remove the cartridge.

-- Remove the guide plate and turn it aside.

• The pressurized air hose remains connected.

-- Remove the valve spring and the valve spring retainer.

-- 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 some valve stem seals due to restricted clearance:

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

Fig 5: Driving Out Roll Pin

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

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

-- Position the extractor lever on the puller and remove the valve stem seal in direction of -arrow-.

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

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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 sealing lip.

-- 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 installation cartridge, they must be inserted into the Valve Cotter Tool Kit - Valve Insertion Device:VAS5161/18  first.

Fig 8: Identifying Installation Cartridge VAS 5161/8

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• The large diameter of the valve keepers point upward.

-- Press the installation cartridge from above onto valve retainer inserting tool and valve keepers.

-- Insert the valve spring and the valve spring retainer.

Fig 9: Camshaft Cylinder Head Bank 1 (Right)

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• The tight spring coils -arrow- face toward cylinder head.

-- Install the guide plate on the cylinder head.

-- Insert the installation cartridge into the guide plate.

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

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

-- Repeat the procedure on each valve.

Fig 10: Identifying Engaging Device VAS 5161/6 With Installation Fork VAS 5161/5

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