Valve Stem Seals, Removing And Installing, Cylinder Head Installed: Procedure

-- 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 .

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CAUTION:

Risk of damaging camshaft timing chain.

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

-- 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)".

-- Align the Valve Keeper Tool Kit - Guide Plate V6/V8 TFSI :VAS 5161A/38 on the cylinder head at the same time pay attention to the marking:

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A - Exhaust side
E - Intake side

-- Tighten the guide plate bolts -arrows- to 9 Nm.

-- 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)

-- 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 5161/8A into 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 -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.

-- Remove the assembly cartridge.

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).

-- 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.

-- Remove the valve stem seal.

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Intake side:

-- To do so use the Puller - Valve Seal :3364 .

Exhaust side:

-- For this, use the Extracting Tool :T40429 .

The illustration above shows the procedure using the Puller - Valve Seal :3364 . The procedure using the Extracting Tool :T40429 is identical.

Continuation:

Fig 1: Driving Out Roll Pin

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If the Puller - Valve Seal :3364 cannot be used on some valve stem seals due to a limited amount of space, proceed as follows:

-- Drive out the tensioning pin -arrow- on the puller with a drift and remove the impact puller attachment.

-- Secure the lower section of the Puller - Valve Seal :3364 using the drift or cotter pin drive -1-.

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-- Place the puller on the valve stem seal.

-- Position the extractor lever on the puller and remove the valve stem seal -arrow-.

Intake side:

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-- Lightly oil the valve stem seal sealing lip -3-.

Depending on the version/manufacturer of the valve stem seal, use the Seal Installer - Valve Stem :3365 or Fitting Tool :T40376/1

-- Insert the valve stem seal in the seal driver -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/2A -4- and carefully press on over valve stem sleeve -2- on the valve guide -1- all the way.

Continuation:

Fig 2: 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 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 the knurled bolt still raised.

-- Repeat the procedure on each valve.

Assembling

-- 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 camshafts. Refer to CAMSHAFT, REMOVING AND INSTALLING .

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