Valve Stem Seals With Cylinder Head Installed

Valve Stem Seals with 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 2.0L FSI Engine (VAS 5161/19B)

• Adapter (T40012)

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 spark plugs with (3122 B).

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

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






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

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






- Insert the drift (VAS 5161/3) in the guide plate and loosen the stuck valve retainers with a plastic mallet.

- 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.

Intake Side:

- Engage the pressure fork (VAS 5161/2) on the engaging device as illustrated.

Exhaust Side:

- Engage the pressure fork (VAS 5161/2) on the engaging device as illustrated.






Continued for Both Sides:

- Press the installation cartridge down with the pressure fork.

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

- Move the knurled bolt to the left and right.

• Valve retainers are pressed against each other and capture 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.

- Pull off valve stem seals with the (3364).






If the (3364) cannot be used, on several valve stem seals due to restricted clearance, proceed as follows:

- 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 press valve stem seal onto valve guide with Valve Stem Seal Drive (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 valve retainer inserting tool and capture retainers.

- Insert valve spring and valve spring plate.

- Install the guide plate on the cylinder head.

- Insert installation cartridge with knurled spacer ring in guide plate.

- Press pressure fork down and pull knurled screw up, turning left and right.

• The valve retainers are inserted in this manner.

- Release pressure fork with knurled screw still raised.

- Repeat the procedure on each valve.

Assembling

Assemble in reverse order of disassembling. Note the following:

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

- Install spark plugs.