Valve Spring, Removing And Installing

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Special tools and workshop equipment required

Valve Keeper Tool Kit:VAS 5161A with the Guide Plate:VAS 5161A/38

Fig 1: Valve Keeper Tool Kit VAS5161A
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Spark Plug Socket Adapter 3/8" :VAS 6919 , not illustrated
Wrench - 21mm:T40263

Fig 2: Identifying Wrench - 21mm
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Adapter:T40314

Fig 3: Adapter T40314
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Two M8 Bolts (part number N 108 063 01)

Guide Plate V6 TFSI: VAS 5161A/38 , Preparing

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-- The Guide Plate V6 TFSI: VAS 5161A/38 must be modified for cylinders 4 and 8.

-- Two M8 bolts (part number N 108 063 01) -1- must be installed in the Guide Plate V6 TFSI: VAS 5161A/38 -2- from above.

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The bolts may extend a maximum of 5 mm underneath.
The projecting ends of the bolts will be positioned on the oil channels -3-.

Depending on the installation scenario, pay attention to using the holes and secure the Guide Plate V6 TFSI: VAS 5161A/38 using the M5x40 bolts that are provided.

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For work on the other cylinders, the bolts can remain installed in the Guide Plate V6 TFSI: VAS 5161A/38 .
There are four holes -a, b, c, d- in the Guide Plate V6 TFSI: VAS 5161A/38 for securing on the cylinder head.

Procedure for valve spring cylinder 4 and 8 on the intake side:

-- For the removal of the valve springs from cylinder 4 and 8 on the intake side: remove the engine with the transmission and subframe on the removed lock carrier downward. Refer to Engine, Removing and Installing .

Procedure for all:

-- 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 Spark Plug Socket Adapter 3/8":VAS 6919 .

-- Turn the crankshaft using the Wrench - 21mm:T40263 and Adapter:T40314 -arrow- until the pistons of the corresponding cylinder are in "bottom dead center (BDC)".

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CAUTION:

Risk of damaging camshaft timing chain.

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

-- Align the Valve Keeper Tool Kit - Guide Plate V6/V8 TFSI:VAS 5161A/38 on the cylinder head while paying attention to the -A/E- markings:

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A - Exhaust side

E - Intake side

-- Tighten the bolts -arrows- for the Guide Plate V6 TFSI: VAS 5161A/38 to 9 Nm.

TIP

For cylinders 4 and 8, the Guide Plate V6 TFSI: VAS 5161A/38 -2- can only be secured with one bolt -1-. Therefore, to increase process safety, the two M8 bolts must be mounted in the guide plate. These bolts will be used to prevent rotation.

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-- Position the Valve Cotter Tool Kit - Punch :VAS 5161/3A on the valve spring plate and loosen the stuck valve keepers with a plastic mallet.

-- Install the Valve Keeper Tool Kit - Compression Stud for VAS 5161/9 :VAS 5161/10 in the Valve Keeper Tool Kit - Guide Plate V6/V8 TFSI:VAS 5161A/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 hand-tight.

-- 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)

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).

-- Install the Retainer :VAS 5161/6 with the Guide Forks M6/M8 with Threaded Studs :VAS 5161/5 in the guide plate.

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-- Insert the Valve Keeper Tool Kit - Assembly Cartridge :VAS 5161/8 A into the opening above the valve spring that is to be removed.

-- Engage the Valve Keeper Tool Kit - Pressure Fork :VAS 5161/2 at the engaging device : VAS 5161/6 and press the installation cartridge downward.

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

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

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

-- Release the pressure fork : VAS 5161/2 and remove the assembly cartridge : VAS 5161/8A .

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.

Continuation:

Fig 4: 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 Valve Keeper Tool Kit - Valve Insertion Device :VAS 5161/18 .

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 valve spring retainer in their original position:

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

-- Insert the Valve Keeper Tool Kit - Assembly Cartridge :VAS 5161/8A back into the Valve Keeper Tool Kit - Guide Plate V6/V8 TFSI:VAS 5161A/38 .

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-- Press the Valve Keeper Tool Kit - Pressure Fork with Lever for Assembly Cartridge :VAS 5161/2 down and pull the knurled screw -arrow- up while turning left and right. This inserts the valve retainers.

-- Release the Pressure Fork with Lever for Assembly Cartridge :VAS 5161/2 with the knurled thumb screw still pulled.

-- 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 .

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

-- If removed: install the engine with the transmission and subframe with the lock carrier removed. Refer to Engine, Removing and Installing .