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 Cotter Disassembly/Assembly Device (VAS 5161) with Guide Plate for FSI Engine (VAS 5161/19B)

• Adapter (T40012)

• Drift (VAS 5161/3)

• Installation Cartridge (VAS 5161/8)

• Pressure Fork (VAS 5161/2)

• Installation Fork (VAS 5161/5)

• Engaging Device (VAS 5161/6)

• Knurled Screws (VAS 5161/12)

• Insertion Device (VAS 5161/18)

Procedure

- 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 (DC) position".

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






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






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

- Install (T40012) with sealing ring in respective spark plug thread and hand tighten.

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

• Minimum pressure: 6 bar positive pressure.

- Install (VAS 5161/6) with (VAS 5161/5) in guide plate.






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

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

- At the same time, rotate installation cartridge knurled screw right until points engage in the 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 several valve stem seals due to restricted clearance, proceed as follows:






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

- Lightly oil valve stem seal.

- Slide valve shaft seal onto plastic sleeve.

- Carefully press valve stem seal onto valve guide with (3365).

- Remove plastic sleeve.

If the valve retainers were removed from the installation cartridge, they must then be inserted into the (VAS 5161/18).






• The large diameter of the valve retainers point upward.

- Press installation cartridge from above onto valve retainer inserting tool and capture retainers.

- Insert valve spring and valve spring plate.

• Installed position, valve spring. Refer to => [ Installed Position, Valve Spring ] Valve Train Overview.

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






- Insert installation cartridge in guide plate.

- Press the pressure fork down and pull the knurled screw up while turning 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

Assemble in reverse order of disassembling. Note the following:

- 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 the spark plugs.

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

Risk of damaging valves and piston heads after working on the valve train.

• The motor must not be started for about 30 minutes after installing camshafts because the hydraulic equalization elements must seat themselves.

• To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.