Valve Stem Seals, Removing And Installing With Cylinder Head Removed

Special tools and workshop equipment required 

• Puller - Valve Seal 3364
• Seal Installer - Valve Stem 3365
• Valve Cotter Tool Kit VAS5161 with Knurled Spacer Ring VAS 5161/23-1 and Valve Cotter Tool Kit - Guide Plate 23 VAS5161/23
• Engine And Transmission Holder VAS6095
• Cylinder Head Tension Device VAS 6419

Procedure

-- Install the camshafts: left cylinder head, refer to LEFT CYLINDER HEAD CAMSHAFT, REMOVING AND INSTALLING , right cylinder head, refer to RIGHT CYLINDER HEAD CAMSHAFT, REMOVING AND INSTALLING .

-- 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.

-- Insert the Cylinder Head Tensioning Device VAS 6419 into the Engine And Transmission Holder VAS6095.

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

Fig 1: Identifying Air Cushion With Lever

Courtesy of AUDI OF AMERICA, LLC

-- 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.

-- Mount the Valve Cotter Tool Kit - Guide Plate 23 VAS5161/23 on the cylinder head.

Fig 2: Identifying Punch VAS 5161/3, Knurled Thumb Screws VAS 5161/12 And Guide Plate For 3.0 Liter TDI Engine VAS 5161/23

Courtesy of AUDI OF AMERICA, LLC

-- Secure the guide plate with the Knurled Screws VAS 5161/12.

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

-- Install Engaging Device VAS 5161/6 with Valve Cotter Tool Kit - Guide Forks M6/M8 Threaded VAS5161/5 in guide plate.

Fig 3: Identifying Engaging Device VAS 5161/6 With Installation Fork VAS 5161/5 In Guide Plate

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-- Slide the Knurled Spacer Ring VAS 5161/23-1 onto the Valve Cotter Tool Kit - Assembly Cartridge VAS5161/8.

-- Engage Pressure Fork 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 the installation cartridge with the knurled spacer ring.

-- Remove the valve spring and the valve spring plate.

-- Remove the valve stem seal with the Puller - Valve Seal 3364.

Fig 4: Identifying Valve Seal Removal Tool 3364

Courtesy of AUDI OF AMERICA, LLC

Fig 5: Identifying Plastic Sleeve, New Valve Stem Oil Seals & Valve Stem Seal Driver 3365

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-- Lightly oil valve stem seal.

-- Slide valve shaft seal onto plastic sleeve.

-- Carefully press the valve stem seal onto the valve guide with the Seal Installer - Valve Stem 3365.

-- Remove plastic sleeve.

If the valve retainers were removed from the installation cartridge, they must be inserted in the next Valve Retainer Inserting Tool VAS 5161/18.

Fig 6: Identifying Installation Cartridge VAS 5161/8

Courtesy of AUDI OF AMERICA, LLC

• The large diameter of the valve retainers point upward.

-- Insert valve spring and valve spring plate.

-- Press the installation cartridge onto the insertion device for the valve retainers from above and take up valve retainers.

-- Insert the installation cartridge in the Valve Cotter Tool Kit - Guide Plate 23 VAS5161/23.

Fig 7: Identifying Engaging Device VAS 5161/6 With Installation Fork VAS 5161/5 In Guide Plate

Courtesy of AUDI OF AMERICA, LLC

-- Press the pressure fork down and pull the knurled screw up while turn 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:

-- Install the camshafts: left cylinder head, refer to LEFT CYLINDER HEAD CAMSHAFT, REMOVING AND INSTALLING , right cylinder head, refer to RIGHT CYLINDER HEAD CAMSHAFT, REMOVING AND INSTALLING .