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 Keeper Tool Kit VAS5161A
• Valve Cotter Tool Kit - Guide Plate 19B VAS5161/19B

Remove Valve Stem Seals

-- 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 using a Spark Plug Removal Tool 3122B.

-- Tighten the Valve Cotter Tool Kit - Guide Plate 19B VAS5161/19B on the cylinder head as shown using the Knurled Thumb Screws M6 VAS5161A/12.

Fig 1: Identifying Guide Plate

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

-- Install the Valve Cotter Tool Kit - Adapter T40012 in the spark plug threads.

Fig 2: Identifying Drift VAS 5161/3 And Plastic Mallet To Loosen Stuck Valve Keepers

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

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

For Intake Side

Fig 3: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

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-- Install the Retainer VAS5161/6 with the Guide Forks M6/M8 with Threaded Studs VAS5161/5 in the center threads of the Valve Cotter Tool Kit - Guide Plate 19B VAS5161A/19B.

-- Insert the Assembly Cartridge VAS5161/8A into the Valve Cotter Tool Kit - Guide Plate 19B VAS5161/19B.

-- Engage the Pressure Fork With Lever for Assembly Cartridge VAS5161/2 on the Retainer VAS5161/6.

For Exhaust Side

Fig 4: Identifying Pressure Fork VAS 5161/2

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-- Install the Retainer VAS5161/6 with the Guide Forks M6/M8 with Threaded Studs VAS5161/5 in the outer threads of the Valve Cotter Tool Kit - Guide Plate 19B VAS5161A/19B.

-- Press down the Assembly Cartridge VAS5161/8A and at the same time turn the knurled thumb screw on the Assembly Cartridge 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 Pressure Fork With Lever For Assembly Cartridge VAS5161/2.

-- Remove the Assembly Cartridge VAS5161/8A.

-- Remove the valve stem seals using Puller - Valve Seal 3364.

Fig 5: Identifying Valve Seal Removal Tool 3364

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

Fig 6: Driving Out Roll Pin

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

Fig 7: Identifying Placement Of Lower Part Of Valve Seal Removal Tool 3364 On To Valve Stem Oil 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

Fig 8: Identifying Plastic Sleeve And Valve Stem Seals

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

-- Oil the sealing lip of valve stem seal -B-, insert into Seal Installer - Valve Stem 3365 and carefully slide onto the valve guide.

-- Remove the plastic sleeve -A-.

-- Insert the valve spring and valve spring plate.

-- Connect the Valve Keeper Tool Kit VAS5161A as illustrated.

Fig 9: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

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Fig 10: Identifying Pressure Fork VAS 5161/2

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NOTE:

If the valve retainers were removed from the assembly cartridge, they must then be inserted into the Valve Insertion Device VAS5161/18.

Fig 11: Identifying Installation Cartridge VAS 5161/8

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Press the Assembly Cartridge VAS5161/8A onto the insertion device from above and capture the valve retainers.

-- Press the Valve Keeper Tool Kit Assembly Cartridge VAS5161/8 down with the Valve Keeper Tool Kit Pressure Fork with Lever for Assembly Cartridge VAS5161/2 and rotate the cartridge knurled thumb screw back and forth while pulling up.

-- Release the Pressure Fork with Lever for Assembly Cartridge VAS5161/2 with the knurled thumb screw pulled.

-- Remove the Valve Keeper Tool Kit VAS5161A.

Further installation is done in the reverse order of removal.

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