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)
• Pressure Fork (VAS 5161/2)
• Drift (VAS 5161/3)
• Installation Fork (VAS 5161/5)
• Engaging Device (VAS 5161/6)
• Installation Cartridge (VAS 5161/8)
• Knurled Screws (VAS 5161/12)
• Insertion Device (VAS 5161/18)
• 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 the spark plugs with the (3122 B).
- Move piston for respective cylinder to "Bottom Dead Center (BDC) 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 the (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 the (VAS 5161/6) with the (VAS 5161/5) in guide plate.
- Slide the (VAS 5161/8) in guide plate.
- Engage the (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 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:
- 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 the (3365).
- Remove plastic sleeve.
If the valve keepers 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 the insertion device and capture keepers.
- Insert valve spring and valve spring plate.
• Installation position: the tight spring coils - arrow - face toward the 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 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 camshafts. Refer to => [ Camshafts ] Service and Repair.
- Install spark plugs.
Risk of damaging valves and piston heads after working on valvetrain.
• 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.