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

Install in the reverse order of removal while noting the following:

-- Assign the valve stem seal:

Fig 1: Different Valve Stem Seals

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Requirement

• A = use the intake side valve stem seal with sealing lip -A- Seal Installer - Valve Stem:3365 
• B = use the exhaust side valve stem seal with two sealing lips -B- Fitting Tool:T40376A 

-- Position the valve stem seal -8- that the hose clamp -arrow- is at the top.

Fig 2: Installation Position - Valve Stem Seal

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-- Insert the assembly sleeve -3- on the valve stem -2-.

Fig 3: Insert The Valve Stem Seal In The 3365

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Assembly sleeve. Refer to Parts Information.

-- Lightly coat the sealing lip of the valve stem seal -4- with clean engine oil.

-- Insert the valve stem seal -4- into the seal installer -5- and carefully press it over the mounting sleeve -3-, all the way onto the valve guide -1-.

Requirement

• For intake valves the Seal Installer - Valve Stem:3365  must be used.
• For exhaust valves the Fitting Tool:T40376A  must be used.

-- Remove the assembly sleeve -3-.

If Valve Retainers were Taken from the Assembly Cartridge:

-- Insert the valve retainers into the Valve Cotter Tool Kit - Valve Insertion Device VAS 5161/18 -1-.

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Requirement

• The greater ring diameter of the valve retainers must face upward.

-- Push the spring washer downward until the three grooves can be seen.

-- Position the valve retainers in the grooves.

-- Let go of the washer.

Tip

The washer will be pushed upward by spring pressure and the valve retainers are secured.

-- Push the 1 assembly cartridge Ø 22 for 4 cyl. - 5 V/6 cyl. - 5 V/V8 - TDI 4 V:VAS 5161/8A  from above on the valve cotter tool kit - valve insertion device -1- and capture the valve retainers.

-- To do so move the knurled bolt left and right slightly to press apart the valve retainers and capture them in the assembly cartridge.

Continuation

-- Insert the valve spring in a way that the narrow spring coils -arrow- point toward the cylinder head.

Fig 4: Camshaft Cylinder Head Bank 1 (Right)

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Requirement

• Length of the intake side valve spring = 45.5 mm.
• Length of the exhaust side valve spring = 51.0 mm.

-- Insert the valve spring retainer.

-- Turn back the guide plate -A- and secure with knurled bolts -B-.

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-- Insert the assembly cartridge -G- into the guide plate -A-.

-- Press down the pressure fork -H- and hold.

-- Pull up the assembly cartridge knurled bolt -G- while moving it to the left and right, until the valve retainers are inserted.

-- Take the tension off the pressure fork -H- with the assembly cartridge knurled bolt -G- pulled.

-- Pay attention to the ease of movement of the roller bearing of the roller rocker levers.

Fig 5: Roller Rocker Lever, Allocation

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-- Insert the roller rocker lever, at the same time pay attention to the distance from the intake side roller rocker lever -a- and the exhaust side roller rocker lever -b- :

Requirement

• -a- = 5.4 mm
• -b- = 8.0 mm