Valve Stem Seals, Removing And Installing With Cylinder Head Removed

Special tools and workshop equipment required 

• Puller - Valve Seal3364
• Seal Installer - Valve Stem3365
• Valve Cotter Tool KitVAS 5161 with Valve Cotter Tool Kit - Guide Plate 19CVAS5161/19C
• Engine And Transmission HolderVAS6095
• Cylinder Head Tensioning DeviceVAS6419

Procedure

-- Remove the camshafts. Refer to CAMSHAFTS, 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 DeviceVAS6419 in the Engine And Transmission HolderVAS6095.

Fig 1: Identifying Cylinder Head Tensioning Device VAS 6419

Courtesy of AUDI OF AMERICA, LLC

-- 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 DriftVAS5161/3A on the valve spring plate and loosen the stuck valve retainers with a plastic mallet.

Fig 2: Identifying Valve Cotter Tool Kit - Punch VAS 5161/3

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-- Place Valve Cotter Tool Kit - Guide PlateVAS5161/19C from Valve Cotter Tool KitVAS 5161 on the cylinder head.

Fig 3: Placing Valve Cotter Tool Kit - Guide Plate 19C VAS 5161/19C On Cylinder Head

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-- Secure the guide plate with the Knurled ScrewsVAS5161/12.

-- Install the RetainerVAS5161/6 with the Threaded StudsVAS5161/5 in the guide plate.

Fig 4: Identifying Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C

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-- Push Installation CartridgeVAS5161/8A into guide plate.

-- Engage the Pressure ForkVAS5161/2 at the engaging device and press the installation cartridge downward.

-- At the same time, rotate the cartridge knurled screw right until points engage in 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 pressure fork.

-- Remove the cartridge.

-- Unfasten guide plate and turn it aside.

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

-- Remove the valve stem seal with the Puller - Valve Seal3364.

Fig 5: Identifying 3364

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Fig 6: Identifying Plastic Sleeve, New Valve Stem Oil Seals & Valve Stem Seal Driver 3365

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-- Lightly oil the valve stem seal.

-- Slide the valve shaft seal onto the plastic sleeve.

-- Carefully press the valve stem seal onto the valve guide with the Seal Installer - Valve Stem3365.

-- Remove the plastic sleeve again.

If the valve retainers were removed from the installation cartridge, they must then be inserted into the Insertion DeviceVAS5161/18.

Fig 7: Identifying Installation Cartridge VAS 5161/8

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• The large diameter of the valve retainers point upward.

-- Press the cartridge from above onto the insertion device and capture retainers.

-- Insert valve spring and valve spring plate.

Fig 8: Identifying Tight End Of Spring Coils

Courtesy of AUDI OF AMERICA, LLC

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

-- Install the Valve Cotter Tool Kit - Guide Plate 19CVAS5161/19C in 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.

Fig 9: Identifying Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C

Courtesy of AUDI OF AMERICA, LLC

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, REMOVING AND INSTALLING .