Valve Stem Seals with Cylinder Head Removed

Valve Stem Seals with Cylinder Head Removed

Special tools, testers and auxiliary items required

• 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)

• Engine and Transmission Holder (VAS 6095)

• Cylinder Head Tensioning Device (VAS 6419)

• 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)

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.

- Mount the (VAS 6419) into the (VAS 6095).






- Tension the cylinder head on the cylinder head tensioning device, as illustrated.

- Connect the cylinder head tensioning device to the compressed air.

- Slide the air cushion with the lever - arrow - under the combustion chamber onto the valve stem seal that will be removed.

- Let enough compressed air flow into the air cushion until it contacts the valve plate.

- 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 (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.

- Remove the valve spring and the valve spring plate.

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







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.

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






• 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.