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

-- Remove the camshafts. Refer to Camshaft, Removing and Installing  or Camshaft, Removing and Installing  .

-- Remove the bolts -arrows- at the cylinder 1 intake side and remove the engine lifting eye -1-.

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-- Remove the spark plugs. Refer to Spark Plugs, Replacing.

-- Mark the allocation of the roller rocker lever -1-, the valve spring retainer -3- and the hydraulic lifter -4-.

Fig 1: Roller Rocker Lever Installation Position

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-- Remove the roller rocker lever -1- and the hydraulic lifter -4- and put down on a clean surface.

-- Set the cylinder piston to the bottom dead center (BDC), for this turn the crankshaft at the hex fitting of the Tool - Turning Over Tool:T10531/3  -A-.

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-- Put the Valve Cotter Tool Kit - Guide Plate 19c:VAS 5161/19C  -A- on the cylinder head -2-, at the same time pay attention to the alignment pins -3- and the markings "A" and "E" :

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Requirement

• "A" = exhaust side
• "E" = intake side

-- Secure the guide plate -A- to the cylinder head using the Knurled Thumb Screws M6:VAS 5161/12  -B-.

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-- Attach the Guide Sleeve Ø 22.5 - Inlet Valve:VAS 5161/3A  -C- at the valve spring retainer -2- and loosen stuck valve retainers using a commercially available plastic mallet.

-- Insert the Valve Cotter Tool Kit - Adapter:T40012  -E- into the spark plug threads.

-- Connect the adapter -E- to compressed air using a commercially available intermediate piece -D- and keep pressure constantly.

Requirement

• Minimum pressure = 6 bar (87.02 psi)

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

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-- Push the 1 Assembly Cartridge Ø 22 for 4 cyl. - 5 V/6 cyl. - 5 V/V8 - TDI 4 V: VAS 5161/8A  -G- into the guide plate -A-.

-- Engage the 1 Pressure Fork with Lever for Assembly Cartridge: VAS 5161/2  -H- into the retainer -F-.

-- Push the assembly cartridge -G- downward and turn the assembly cartridge knurled bolt -G- to the right, until the tips engage into the valve retainers.

-- Turn the assembly cartridge knurled bolt -G- to the left and right, to pull open the valve retainers and pick up the assembly cartridge -G-.

-- Release the pressure fork -H-.

-- Remove the assembly cartridge -G-.

-- Remove the valve spring retainer -2- and the valve spring -1-.

-- Remove the valve stem seal -2- using the Puller - Valve Seal:3364  -C- in direction of -arrow-.

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-- Remove the knurled bolt -B- and turn the guide plate -A- by 90°.

Requirement

• The compressed air must stay connected.