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 Retainers Assembling/Disassembling Device (VAS 5161)

• Guide Plate for FSI engine (VAS 5161/19B)

• Engine and Transmission Holder (VAS 6095)

• Cylinder Head Tensioning Device (VAS 6419)

Procedure

- Camshafts, removing. Refer to => [ Camshafts ] Camshafts.

- 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) in 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.

- Tighten the (VAS 5161/19B) to the cylinder head with the knurled bolts (VAS 5161/12) as illustrated.






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

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

Intake Side

- Install the engaging device (VAS 5161/6) and the installation fork (VAS 5161/5) into the center thread on the (VAS 5161/19B).






- Install the installation cartridge (VAS 5161/8) into the (VAS 5161/19B).

- Attach the pressure fork (VAS 5161/2) to the (VAS 5161/6).

Exhaust Side

- Install the (VAS 5161/6) and the (VAS 5161/5) into the outer thread on the (VAS 5161/19B).






- Push the (VAS 5161/8) downward while rotating its knurled bolt to the right until the points engage in the valve retainers.

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

- Release the (VAS 5161/2).

- Remove the (VAS 5161/8).

- Remove the valve stem seals using the (3364).






Valve Stem Seals, Installing


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.

- Insert the valve spring and valve spring plate.

- Install the (VAS 5161) as illustrated.

Intake Side





Exhaust Side





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






• Press the (VAS 5161/8) onto the insertion device from above and capture the valve retainers.

- Press the (VAS 5161/8) down with the pressure fork (VAS 5161/2) and rotate the cartridge knurled bolt back and forth while pulling up.

- Release the (VAS 5161/2) with the knurled bolt pulled.

- Remove the (VAS 5161).

The rest of the assembly is basically a reverse of the disassembling sequence. When doing this note the following:

- Install camshafts. Refer to => [ Camshafts ] Camshafts.