Valve Stem Seals With Installed Cylinder Head, Removing And Installing

Special tools and workshop equipment required 

• Spark Plug Removal Tool 3122B
• Puller - Valve Seal 3364
• Seal Installer - Valve Stem 3365
• Valve Cotter Tool Kit VAS5161Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C
• Valve Cotter Tool Kit - Adapter T40012

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 - 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 the Valve Cotter Tool Kit - Guide Plate 19B 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 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 (87 psi)

-- Install the 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 - Assembly Cartridge VAS5161/8 into guide plate.

-- Engage the 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: Removing Valve Stem Seal With Puller - Valve Seal 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:

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

Fig 5: Locating Puller - Valve Seal 3364 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 valve lever on the puller and remove the valve stem seal in direction of -arrow-.

Fig 6: Removing Valve Stem Seal With Puller

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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 plastic sleeve.

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

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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 the cartridge from above onto the 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.

-- 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.

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

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Assembling 

Assembly is performed in the reverse order of disassembly, noting the following:

-- Make sure all the roller rocker levers lie on the ends of the valve stems correctly and are clipped onto the respective hydraulic adjusting elements.

-- Install the spark plugs.

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