Valve Stem Seals, Removing And Installing, Cylinder Head Removed

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Special tools and workshop equipment required

Puller - Valve Seal:3364

Fig 1: Identifying Puller - Valve 3364
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Seal Installer - Valve Stem:3365

Fig 2: Identifying Seal Installer - Valve Stem 3365
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Valve Cotter Tool Kit:VAS 5161A with the Valve Keeper Tool Kit - Compression Stud :VAS 5161/10

Fig 3: Valve Keeper Tool Kit VAS5161A
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Guide Plate V6 TFSI: VAS 5161A/38 , not illustrated
Engine and Transmission Holder:VAS 6095A

Fig 4: Identifying Engine and Gearbox Bracket VAS6095A
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Cylinder Head Tensioning Device:VAS 6419

Fig 5: Cylinder Head Tensioning Device
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Mounting Sleeve. Refer to the appropriate Electronic Parts Information

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

-- 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:VAS 6419 in the Engine and Gearbox Bracket:VAS 6095A .

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-- Tension the cylinder head on the cylinder head tensioning device, as shown.

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

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

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

There are four holes -a, b, c, d- in the Guide Plate V6 TFSI: VAS 5161A/38 for securing on the cylinder head. These are used after each installation situation.

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-- 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

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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.

-- Insert the Valve Cotter Tool Kit - Punch :VAS 5161/3A in the guide plate and loosen the stuck valve retainers with a plastic mallet.

-- 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 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 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.

Valve Stem Seals, Replacing:

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-- Remove the valve stem seal using the Puller - Valve Seal:3364 .

So that the new valve stem seal -2- is not damaged during installation, mount the Guide Sleeve -1- on the valve stem.

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-- Lightly oil the valve stem seal sealing lip.

-- Insert the valve stem seal in the Seal Installer - Valve Stem:3365 and carefully press on the valve guide all the way.

-- Remove the Assembly Sleeve.

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 .

Fig 6: Identifying Installation Cartridge VAS 5161/8

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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 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.