Valve Stem Seals, Removing And Installing, Cylinder Head Installed

Special tools and workshop equipment required 

• Spark Plug Removal Tool: 3122B 
• Puller - Valve Seal: 3364 
• Seal Installer - Valve Stem: 3365 
• Valve Cotter Tool Kit - Adapter: T40012 
• Torque Wrench 1331 5-50Nm: VAG1331 
• Valve Keeper Tool Kit: VAS5161A 
• Valve Cotter Tool Kit - Guide Plate 19B: VAS5161/19B 
• Valve Cotter Tool Kit Knurled Thumb Screws M6: VAS5161/12 
• Punch: VAS5161/3A 

Remove Valve Stem Seals 

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

-- Mark the allocation of the roller rocker lever and the hydraulic adjusting elements so they can be installed again.

-- If necessary, remove the roller rocker levers with the hydraulic adjusting elements and place them on a clean surface.

-- Remove the spark plugs using a : 3122B  .

-- Install the : VAS5161/19B  with the : VAS5161/12  as shown on the cylinder head.

Fig 1: Identifying Guide Plate

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-- Move piston for that cylinder to "bottom dead center position".

-- Install the : T40012  in the spark plug threads.

Fig 2: Identifying Drift VAS 5161/3 And Plastic Mallet To Loosen Stuck Valve Keepers

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-- Connect compressed air with at least 6 bar (87 psi) pressure.

-- Loosen stuck valve retainers using a : VAS5161/3A  and a plastic hammer.

For Intake Side 

Fig 3: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

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-- Install the : VAS5161/6  with : VAS5161/5  in the center thread of the : VAS5161/19B  .

-- Place the : VAS5161/8  in the : VAS5161/19B  .

-- Engage the : VAS5161/2  on the : VAS5161/6  .

For Exhaust Side 

Fig 4: Identifying Pressure Fork VAS 5161/2

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-- Install the : VAS5161/6  with : VAS5161/5  in the outer thread of the : VAS5161/19B  .

-- Press down the : VAS5161/8A  and at the same time turn the knurled thumb screw on the : VAS5161/8A  to the right until the points engage in the valve retainers.

-- Move the knurled thumb screw back and forth slightly. This presses the valve retainers apart and captures them in the installation cartridge.

-- Release the : VAS5161/2  .

-- Remove the : VAS5161/8A  .

-- Remove the valve stem seals using : 3364  .

Fig 5: Identifying Valve Seal Removal Tool 3364

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-- If the : 3364  cannot be used because there is not enough space, drive the roll pin -arrow- out using a drift and remove the impact attachment.

Fig 6: Driving Out Roll Pin

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-- Position the lower part of the : 3364  on the valve stem seal.

Fig 7: Identifying Placement Of Lower Part Of Valve Seal Removal Tool 3364 On To Valve Stem Oil Seal

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-- Place the drift -1- in the hole in the lower section of the removal tool.

-- Position the lever on the removal tool and remove the valve stem seal in direction of -arrow-.

Install Valve Stem Seals 

Fig 8: Identifying Plastic Sleeve And Valve Stem Seals

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-- Place the plastic sleeve -A- that is attached to valve stem seals -B- on valve stem.

-- Lightly oil the valve stem seal.

-- Slide the valve stem seal onto the plastic sleeve.

-- Carefully press the valve stem seal onto the valve guide with the : 3365  .

-- Remove plastic sleeve.

-- Insert the valve spring and valve spring plate.

-- Connect the : VAS5161A  as illustrated.

Intake Side 

Fig 9: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

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Exhaust Side 

Fig 10: Identifying Pressure Fork VAS 5161/2

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NOTE:

If the valve retainers were removed from the assembly cartridge, they must then be inserted into the : VAS5161/18  .

Fig 11: Identifying Installation Cartridge VAS 5161/8

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Press the A: VAS5161/8A  onto the insertion device from above and capture the valve retainers.

-- Press the : VAS5161/8  down with the : VAS5161/2  and rotate the cartridge knurled thumb screw back and forth while pulling up.

-- Release the : VAS5161/2  with the knurled thumb screw pulled.

-- Remove the : VAS5161A  .

Further assembly is performed in the reverse order of removal, thereby observing the following:

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