Valve Stem Seals, Cylinder Head Removed, Replacing

WARNING: This page is about a different car, the 2009 Audi S8, 2008 Audi S8, and 2007 Audi S8. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Valve Seal Removal Tool 3364

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Valve seal removal tool 3364

Fig 2: Valve Stem Seal Driver 3365

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Valve stem seal driver 3365

Fig 3: Valve Cotter Disassembly/Assembly Device VAS 5161

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Valve cotter disassembly and assembly device VAS 5161

Fig 4: Engine And Transmission Holder VAS 6095

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine and transmission holder VAS 6095
Tensioning element VAS 6419

Procedure

Remove camshafts → Camshafts, Removing and Installing .

Fig 5: Inserting Tensioning Element VAS 6419 In Engine And Transmission Holder VAS 6095

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert tensioning element VAS 6419 in engine and transmission holder VAS 6095.
Tension cylinder head on tensioning element VAS 6419 as shown in the illustration.
Connect tensioning element VAS 6419 to compressed air.
Slide air cushion with lever - arrow - under cylinder onto valve stem seal that will be removed.

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

Fig 6: Placing Drift VAS 5161/3 On Valve Spring Plate And Loosening Stuck Valve Keepers Using Plastic Hammer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place drift VAS 5161/3 on valve spring plate and loosen stuck valve keepers using a plastic hammer.

Fig 7: Placing Guide Plate VAS 5161/19 A From Valve Cotter Disassembly/Assembly Device VAS 5161 On Cylinder Head

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place guide plate VAS 5161/19 A from valve cotter disassembly and assembly device VAS 5161 on cylinder head.
Secure guide plate with knurled screws VAS 5161/12.

Fig 8: Installing Engaging Device VAS 5161/6 With Installation Fork VAS 5161/5 Into Guide Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install engaging device VAS 5161/6 with installation fork VAS 5161/5 into guide plate.
Push installation cartridge VAS 5161/8 into guide plate.
Hook in pressure fork VAS 5161/2 at engaging device and press down installation cartridge.
At the same time, turn knurled bolt of installation cartridge to the right, until the points engage in the valve keepers.

Lightly move knurled bolt back and forth, causing the valve keepers to be pressed apart and be captured in the installation cartridge.
Release pressure fork.
Take out installation cartridge.
Remove guide plate and turn it aside.

Remove valve spring with valve spring plate.

Fig 9: Pulling Off Valve Stem Oil Seals Using Valve Seal Removal Tool 3364

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull off valve stem oil seals using Valve Seal Removal Tool 3364.

Fig 10: Identifying Plastic Sleeve, Valve Stem Oil Seal & Valve Stem Seal Driver 3365

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

A plastic sleeve - A - is supplied with the new valve shaft seals.

Place plastic sleeve - A - on valve stem to prevent damage to new valve stem seals - B -.
Lightly coat sealing lips of valve stem seal with oil.
Push valve stem seal onto plastic sleeve.
Carefully press valve stem oil seal onto valve guide using Valve Stem Seal Driver 3365.

Remove plastic sleeve again.

Fig 11: Identifying Installation Cartridge VAS 5161/8

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

The large diameter of the valve keepers point upward.

Fig 12: Identifying Tight Spring Coils Face Toward Cylinder Head

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install valve spring and valve spring plate.

The tight spring coils - arrow - face toward cylinder head.

Fig 13: Installing Engaging Device VAS 5161/6 With Installation Fork VAS 5161/5 Into Guide Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install guide plate onto cylinder head again.
Insert installation cartridge into guide plate.
Press pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve keepers.
Release pressure fork with knurled bolt still pulled.

Make sure all the roller rocker levers seat properly on the valve stem ends and are clipped onto the respective hydraulic adjusting elements.
Install camshafts → Camshafts, Removing and Installing .