Valve Stem Seals, Cylinder Head Installed

Valve Stem Seals, Cylinder Head Installed

Special tools, testers and auxiliary items required

• Spark Plug Removal Tool (3122 B)

• Valve Seal Removal Tool (3364)

• Valve Stem Seal Driver (3365)

• Valve Cotters Asm/Dis-Asm Device (VAS 5161) with Guide Plate for FSI Engine (VAS 5161/19B)

• Adapter (T40012)

Removing

- Remove the camshafts. Refer to => [ Camshafts ] Service and Repair.

- 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 with (3122 B).

- Move piston for respective cylinder to "Bottom Dead Center (BDC) position".

- Position the drift (VAS 5161/3) on the valve spring plate and loosen the stuck valve retainers with a plastic mallet.






- Mount the (VAS 5161/19B) , taken from (VAS 5161) on the cylinder head.






- Secure the guide plate with the knurled screws (VAS 5161/12).

- Install the (T40012) and seal into the spark plug thread so that it is hand-tight.

- Connect the adapter to the compressed air using a commercially available intermediate piece and give steady pressure.

• Minimum pressure: 6 bar positive pressure.

- Install engaging device (VAS 5161/6) with installation fork (VAS 5161/5) in guide plate.






- Slide installation cartridge (VAS 5161/8) in guide plate.

- Engage pressure fork (VAS 5161/2) on the engaging device and press installation cartridge down.

- At the same time, rotate installation cartridge knurled screw right until points engage in valve retainers.

- Move the knurled wheel left and right slightly. This presses the valve retainers apart and captures them in the installation cartridge.

- Release the pressure fork.

- Remove installation cartridge.

- Unfasten guide plate and turn it aside.

• Pressurized air hose remains connected.

- Remove the valve spring and the valve spring plate.

- Remove the valve stem seal with the (3364).






If the (3364) cannot be used on some valve stem seals due to insufficient clearance, do the following:






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

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






- Secure the puller with a drift or cotter pin drive - 1 - as shown in the illustration.

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








Risk of damage when installing valve stem seals.

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

- Lightly oil valve stem seal.

- Slide valve shaft seal onto plastic sleeve.

- Carefully push the valve stem seal onto the valve guide using the (3365).

- Remove plastic sleeve again.

When the valve retainers were removed from the installation cartridge, they must be inserted in the valve retainer inserting tool (VAS 5161/18) next.






• The large diameter of the valve retainers point upward.

- Press installation cartridge from above onto the insertion device and capture the retainers.

- Insert valve spring and valve spring plate.






• The tight spring coils - arrow - face toward cylinder head.

- Install the guide plate on the cylinder head.






- Insert installation cartridge in guide plate.

- Press the pressure fork down and pull the knurled screw up while turn left and right. This inserts the valve retainers.

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

- Repeat the procedure on each valve.

Assembling

- Make sure all the roller rocker levers lie on the ends of the valve stems correctly and are clipped onto the respective hydraulic adjusting elements.

- Install spark plugs.

- Install the camshafts. Refer to => [ Camshafts ] Service and Repair.