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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• Extracting Tool:T40429  for the exhaust side, not illustrated
• Intake side: Seal Installer - Valve Stem:3365 
  Fig 2: Identifying Seal Installer - Valve Stem 3365

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• Exhaust side: Valve Stem Seal Driver:T40376A/2 
  Fig 3: Exhaust side: Fitting Tool

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• Valve Keeper Tool Kit:VAS 5161A  with the Valve Keeper Tool Kit - Guide Plate 2.5L TFSI:VAS 5161A/39 
  Fig 4: Valve Keeper Tool Kit VAS5161A

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• Engine and Transmission Holder:VAS 6095A 
  Fig 5: Engine And Transmission Holder

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• Cylinder Head Tensioning Device:VAS 6419 
  Fig 6: Cylinder Head Tensioning Device

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• Pliers - Valve Seal:VAS 6770 
  Fig 7: Pliers - Valve Seal

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• Mounting Sleeve. Refer to the Parts Information.

Procedure 

• Turbocharger removed. Refer to TURBOCHARGER, 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.

-- 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 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.

-- Place the Valve Keeper Tool Kit - Guide Plate 2.5L TFSI : VAS 5161A/39  on the cylinder head.

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-- Secure the guide plate with the Valve Cotter Tool Kit - Knurled Thumb Screws :VAS 5161/12  .

-- 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.

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

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-- Push the Valve Cotter Tool Kit - Assembly Cartridge :VAS 5161/8A  into the guide plate.

-- 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 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.

-- Release the pressure fork.

-- Remove the assembly cartridge.

-- Remove the guide plate and turn it aside.

-- 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  or the Pliers - Valve Seal:VAS 6770  .

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-.

-- Insert the valve stem seal in the Seal Installer - Valve Stem:3365  -item 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  -item 4- and carefully press on over valve stem sleeve -2- on the valve guide -1- all the way.

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 the valve spring retainer. Refer to Figure.

-- Attach the Valve Keeper Tool Kit - Guide Plate 2.5L TFSI: VAS 5161A/39  again on the cylinder head.

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-- Insert the assembly cartridge into the guide plate.

-- Press the pressure fork down and pull the knurled bolt up while turning left and right. This inserts the valve keepers.

-- Release the pressure fork with the knurled bolt still raised.

-- Repeat the procedure on each valve.

Assembling

Assemble in the reverse order of removal. Note 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.