Valve Stem Seals With Cylinder Head Installed

Special tools and workshop equipment required

Spark plug removal tool 3122 B
Valve seal removal tool 3364
Valve stem seal driver 3365
Adapter T40012
Torque Wrench 5-50 Nm V.A.G 1331
Valve Cotters Asm/Dis-Asm Device VAS 5161
Guide Plate for FSI Engine VAS 5161/19B

Removing

-- Remove the camshafts without AVS. Refer to CAMSHAFTS .

-- Remove the roller rocker lever and place it on a clean surface. Make sure that roller cam followers are not interchanged.

-- Remove the spark plugs using a 3122 B.

-- Tighten the VAS 5161/19B on the cylinder head as shown using the knurled bolts VAS 5161/12.

Fig 1: FSI Engine VAS 5161/19B Guide Plate Tightened On Cylinder Head Using Knurled Bolts VAS 5161/12

Courtesy of AUDI OF AMERICA, LLC

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

-- Install the T40012 in the spark plug threads.

Fig 2: Identifying Drift VAS 5161/3 And Plastic Mallet To Loosen Stuck Valve Keepers

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-- Connect compressed air with at least 6 bar pressure.

-- Loosen stuck valve retainers using a drift VAS 5161/3 and a plastic hammer.

For the Intake Side

Fig 3: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

Courtesy of AUDI OF AMERICA, LLC

-- Install the engaging device VAS 5161/6 with the installation fork VAS 5161/5 in the center threads of the VAS 5161/19B.

-- Insert the installation cartridge VAS 5161/8 in the VAS 5161/19B.

-- Engage the pressure fork VAS 5161/2 on the engaging device VAS 5161/6.

For the Exhaust Side

Fig 4: Identifying Pressure Forks VAS 5161/2 Engaged

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-- Install the engaging device VAS 5161/6 with the installation fork VAS 5161/5 in the outer threads of the VAS 5161/19B.

-- Press the installation cartridge VAS 5161/8 down 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 3364.

Fig 5: Identifying Valve Seal Removal Tool 3364

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-- If the 3364 cannot be used because there is not enough space, drive the roll pin -arrow- out using a drift and remove the impact attachment.

Fig 6: Driving Out Spring Dowel Sleeve

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-- Position the lower part of the 3364 on the valve stem seal.

Fig 7: Identifying Placement Of Lower Part Of Valve Seal Removal Tool 3364 On To Valve Stem Oil Seal

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-- Place the drift -1- in the hole in the lower section of the removal tool.

-- Position the lever on the removal tool and remove the valve stem seal -arrow-.

Valve Stem Seals, Installing

Fig 8: Identifying Plastic Sleeve, New Valve Stem Oil Seals & Valve Stem Seal Driver 3365

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CAUTION:

Risk of damage when installing valve stem seals.

Place the plastic sleeve -A- that is attached to valve stem seals -B- on valve stem.

-- Place the plastic sleeve -A- on the valve stem to prevent damage to the new valve stem seals -B-.

-- Lightly oil valve stem seal.

-- Slide valve shaft seal onto plastic sleeve.

-- Carefully press valve stem seal onto the valve guide using the 3365.

-- Remove plastic sleeve again.

-- Insert the valve spring and valve spring plate.

-- Connect the VAS 5161 as illustrated.

For the Intake Side

Fig 9: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

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For the Exhaust Side

Fig 10: Identifying Pressure Forks VAS 5161/2 Engaged

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NOTE:

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

Fig 11: Identifying Installation Cartridge VAS 5161/8

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Press the installation cartridge onto the VAS 5161/8 from above and capture the valve retainers.

-- Press the VAS 5161/8 down with the 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.

Assemble in reverse order of disassembly.

-- Install the camshafts without AVS. Refer to CAMSHAFTS .