Valve Stem Seals, Removing And Installing, Cylinder Head Removed

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: VAS5161A  with the Valve Keeper Tool Kit - Compression Stud: VAS5161/10 
  Fig 3: Valve Keeper Tool Kit VAS5161A

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• Guide Plate V6 TFSI: VAS5161A/38  , not illustrated
• Engine and Transmission Holder: VAS6095A 
  Fig 4: Identifying Engine and Gearbox Bracket VAS6095A

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• Cylinder Head Tensioning Device: VAS6419 
  Fig 5: Cylinder Head Tensioning Device

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• Mounting Sleeve. Refer to Parts Information

Guide Plate V6 TFSI: VAS5161A/38  , Preparing

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-- The Guide Plate V6 TFSI: VAS5161A/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: VAS5161A/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: VAS5161A/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: VAS5161A/38  .
• There are four holes -a, b, c, d- in the Guide Plate V6 TFSI: VAS5161A/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: VAS6419  in the Engine and Gearbox Bracket: VAS6095A  .

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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 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.

There are four holes -a, b, c, d- in the Guide Plate V6 TFSI: VAS5161A/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: VAS5161A/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: VAS5161A/38  to 9 Nm.

TIP

For cylinders 4 and 8, the Guide Plate V6 TFSI: VAS5161A/38  -2- can only be secured with one bolt -2-. 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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-- Insert the Valve Cotter Tool Kit - Punch: VAS5161/3A  in the guide 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: VAS5161/8 A  into the opening above the valve spring that is to be removed.

-- 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: VAS5161/2  and remove the Assembly Cartridge: VAS5161/8A  .

• 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: 

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

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• 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 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 bolt -arrow- up while turning left and right. This inserts the valve retainers.

-- Release the Pressure Fork with Lever for Assembly Cartridge: VAS5161/2  with the knurled thumb bolt still pulled.

-- Repeat the procedure on each valve.

Assembly 

The assembly is done in reverse sequence while observing the following:

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