Valve Stem Seals, Removing And Installing, Cylinder Head Installed

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Special tools and workshop equipment required

Puller - Valve Seal:3364
Seal Installer - Valve Stem:3365 for intake side
or (depending on the version/manufacturer of the valve stem seal) Fitting Tool:T40376/1 for intake side
Fitting Tool:T40376/2 for exhaust side
Valve Keeper Tool Kit:VAS5161A with Valve Keeper Tool Kit - Guide Plate V6/V8 TFSI :VAS5161A/38
Spark Plug Socket Adapter - 3/8" :VAS6919
Valve Cotter Tool Kit - Adapter:T40012
Wrench - 21mm:T40263
Adapter:T40314
Retainer:VAS5161/6
Guide Forks M6/M8 with Threaded Studs:VAS5161/5
Pliers - Valve Seal:VAS6770 for exhaust side

Tools, Preparing

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-- Tighten the M8 hex socket bolt with large bolt head diameter -arrows- (from the tool delivery package) on the bottom of the :VAS5161A/38 as shown.

The guide plate is centered to the cylinder head via the hex socket bolts.

Procedure

-- Remove the applicable camshaft housing. Refer to CAMSHAFT HOUSING, REMOVING AND INSTALLING .

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

-- Remove the roller rocker lever with the hydraulic lifter and place them on a clean surface.

-- Remove the spark plugs using the :VAS6919 .

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CAUTION:

Risk of damaging camshaft timing chain.

- If the crankshaft is turned the camshaft timing chains must be guided.

-- Turn the crankshaft using the :T40263 and :T40314 -arrow- until the pistons of the corresponding cylinder are in "bottom dead center (BDC)".

-- Align the :VAS5161A/38 on the cylinder head at the same time pay attention to the marking:

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A - Exhaust side

E - Intake side

-- Tighten the guide plate bolts -arrows- to 9 Nm.

-- Position the Punch :VAS5161/3A on the valve spring plate and loosen the secured valve retainers with a plastic mallet.

-- Install the :VAS5161/10 in the :VAS5161A/38 hand-tight.

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-- Install the Valve Cotter Tool Kit - Adapter:T40012/1 with sealing ring in the corresponding spark plug thread and tighten by hand.

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

Minimum pressure: 6 bar (87.02 psi)

-- Install the :VAS5161/6 with the :VAS5161/5 in the guide plate.

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-- Insert the :VAS5161/8A into guide plate.

-- Engage the :VAS5161/2 at the engaging device and press the installation cartridge downward.

-- At the same time, turn the installation cartridge knurled bolt -arrow- right until points engage in the valve retainers.

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

The knurled bolt slides all the way in the assembly cartridge.

-- Release the pressure fork.

-- Remove the assembly cartridge.

CAUTION:

Risk of damaging the valves due to a pressure decrease in the cylinder.

- Never remove the guide plate or the compression stud.

- keep the pressure in the cylinder at a minimum of 6 bar (87.02 psi).

-- For the reinstallation of the valve springs for the exhaust valve mark the installation position with pant.

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

-- Remove the valve stem seal using the : 3364 or the :VAS6770 .

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Intake Side:

-- Use the :3364 for this.

Exhaust Side:

-- Use the :VAS6770 for this. If difficult to move, warm up using the :VAG1416 .

Continuation:

Fig 1: Driving Out Roll Pin

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If the :3364 cannot be used on some valve stem seals due to a limited amount of space, proceed as follows:

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

-- Secure the lower section of the :3364 using the drift or cotter pin drive -1-.

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-- Place the puller on the valve stem seal.

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

Intake Side:

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-- Lightly oil the valve stem seal sealing lip -3-.

Depending on the version/manufacturer of the valve stem seal, use the Seal Installer - Valve Stem:3365 or Fitting Tool:T40376/1

-- Insert the valve stem seal in the seal driver -4- and carefully press on over valve stem sleeve -2- on the valve guide -1- all the way.

Exhaust Side:

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-- Lightly oil the valve stem seal sealing lip -3-.

-- Insert the valve stem seal in the Valve Stem Seal Driver:T40376/2 -position 4- and carefully press on over valve stem sleeve -2- on the valve guide -1- all the way.

Exhaust Side:

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In order not to damage the valve stem seal -4- during installation, mount the Mounting Sleeve -3- on the valve stem -2-.

-- Lightly oil the valve stem seal sealing lip.

-- Insert the valve stem seal in the :T40376/2 and carefully press on over the Mounting Sleeve on the valve guide -1- all the way.

-- Remove the Mounting Sleeve.

Continuation:

Fig 2: Identifying Installation Cartridge VAS 5161/8

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If the valve keepers were removed from the assembly cartridge, they must then be inserted into the :VAS5161/18 .

The large diameter of the valve keepers point upward.

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

-- Insert the valve spring and the valve spring retainer:

Intake valve installation position. Refer to Figure.
Exhaust valve installation position. Refer to Figure.

-- Insert the :VAS5161/8A back into the :VAS5161A/38 .

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-- Press the :VAS5161/2 down and pull the knurled screw -arrow- up while turning left and right. This inserts the valve retainers.

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

-- Repeat the procedure on each valve.

Assembling

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

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

-- Install the spark plugs. Refer to OVERVIEW - IGNITION SYSTEM .