Valve Spring, Removing And Installing
Special tools and workshop equipment required
- Valve Keeper Tool Kit:VAS 5161A with the Guide Plate:VAS 5161A/38
- Spark Plug Socket Adapter 3/8" :VAS 6919 , not illustrated
- Wrench - 21mm:T40263
- Adapter:T40314
- Two M8 Bolts (part number N 108 063 01)
Guide Plate V6 TFSI: VAS 5161A/38 , Preparing
-- 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.
- 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.
- 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)".
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:
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.
-- 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.
-- 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)
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.
-- 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:
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 .
-- 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 .