Valve Stem Seals, Removing And Installing, Cylinder Head Removed

Special tools and workshop equipment required 

• Puller - Valve Seal:3364  for the intake side
  Fig 1: Identifying Puller - Valve 3364

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• Seal Installer - Valve Stem:3365  for the intake side
  Fig 2: Identifying Seal Installer - Valve Stem 3365

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• or (depending on the version/manufacturer of the valve stem seal) Fitting Tool:T40376/1  for intake side
  Fig 3: Exhaust side: Fitting Tool

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• Valve Stem Seal Driver:T40376/2  for the exhaust side
• Valve Keeper Tool Kit:VAS5161A  with the Guide Plate:VAS5161A/38 
  Fig 4: Valve Keeper Tool Kit VAS5161A

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• Engine and Transmission Holder:VAS6095A 
  Fig 5: Identifying Engine and Gearbox Bracket VAS6095A

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• Cylinder Head Tensioning Device:VAS6419 
  Fig 6: Cylinder Head Tensioning Device

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• Extracting Tool:T40429  for the exhaust side, not illustrated

Tool Preparation

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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 Valve Keeper Tool Kit - Guide Plate V6/V8 TFSI:VAS5161A/38  as shown.

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

Procedure

-- 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.

-- Insert the Cylinder Head Tensioning Device:VAS6419  in the Engine and Gearbox Bracket VAS6095A:VAS6095A  .

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-- Tension the cylinder head on the cylinder head tensioning device.

-- Connect the cylinder head tensioning device to compressed air.

-- Slide the air cushion with the lever -arrow- under the combustion chamber onto the valve stem seal that will be removed.

-- Let enough compressed air flow into the air cushion until it contacts the valve plate.

-- Align the Valve Keeper Tool Kit - Guide Plate V6/V8 TFSI:VAS5161A/38  on the cylinder head at the same time pay attention to the marking:

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A -  Exhaust side

B -  Intake side

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

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

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

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-- Insert the Valve Keeper Tool Kit - Assembly Cartridge:VAS5161/8A  into guide plate.

-- Engage the Valve Keeper Tool Kit - Pressure Fork: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.

-- 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:

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Intake Side:

-- To do so use the Puller - Valve Seal:3364  .

Exhaust Side:

-- For this, use the Extracting Tool:T40429  .

The illustration shows the procedure using the Puller - Valve Seal:3364  . The procedure using the Extracting Tool:T40429  is identical.

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:T40376A/2  -4- and carefully press on over valve stem sleeve -2- on the valve guide -1- all the way.

Continuation:

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

• The large diameter of the valve retainers point upward.

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

-- 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 Valve Keeper Tool Kit - Assembly Cartridge:VAS5161/8A  back into the Valve Keeper Tool Kit - Guide Plate V6/V8 TFSI:VAS5161A/38  .

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-- Press the Valve Keeper Tool Kit - Pressure Fork with Lever for Assembly Cartridge: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

Assemble in the reverse order of removal.

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