Valve stem seals, replacing

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2009 Audi S4, 2008 Audi S4, 2007 Audi S4, 2006 Audi S4, and 2005 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Valve Stem Seals, Replacing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Spark plug removal tool 3122 B
Valve seal removal tool 3364
Valve stem seal driver 3365
Valve cotter disassembly and assembly device VAS 5161

Adapter T40012

Work procedure

Remove engine: Vehicles with manual transmission → Engine (vehicles with manual transmission) , vehicles with automatic transmission → Engine (vehicles with automatic transmission), removing .
Remove camshaft timing chains from camshafts → Camshaft timing chains, removing from camshafts .
Remove camshafts → Camshafts, removing and installing .
Using spark plug removal tool 3122 B , remove spark plugs.

Fig 2: Turning Roller Rocker Lever Upward And Securing With A Rubber Band

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn roller rocker lever upward and secure it with a rubber band.

Fig 3: Placing Guide Plate VAS 5161/7 From Valve Cotter Disassembly, Assembly Device VAS 5161 On Cylinder Head & Securing Guide Plate VAS 5161/7 With Knurled Screws VAS 5161/12

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place guide plate VAS 5161/7 from valve cotter disassembly and assembly device VAS 5161 on cylinder head.
Secure guide plate VAS 5161/7 with knurled screws VAS 5161/12.

NOTE:

If guide plate cannot be installed, drill mounting bores to approx. 0.5 mm.

Insert drift VAS 5161/3 into guide plate and loosen stuck valve keepers using a plastic hammer.

Fig 4: Installing Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Into Guide Plate VAS 5161/7

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install engaging device VAS 5161/6 with installation forks VAS 5161/5 into guide plate VAS 5161/7.
Guide installation cartridge VAS 5161/8 into guide plate VAS 5161/7.
Install adapter T40012 with gasket by hand into respective spark plug thread and apply constant pressure.

Minimum pressure: 6 bar positive pressure.

Engage pressure fork VAS 5161/2 at engaging device VAS 5161/6 and press down installation cartridge VAS 5161/8.
At the same time, turn knurled bolt of installation cartridge VAS 5161/8 toward right, until points engage in valve keepers.
Lightly move knurled bolt back and forth, this causes valve keys to be pressed apart and captured in installation cartridge VAS 5161/8.
Release pressure fork VAS 5161/2.

Take out installation cartridge VAS 5161/8.
Remove guide plate VAS 5161/7.

Pressurized air hose remains connected

Remove valve spring with valve spring plate.

Fig 5: Identifying Valve Seal Removal Tool 3364

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Installing

NOTE:

For pressing on valve stem seals from delivery program, the Valve Stem Seal Driver 3365 must be drilled to dia. of 10.5 mm.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

A plastic sleeve - A - is supplied with 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 7: Identifying Installation Cartridge VAS 5161/8

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If valve keepers were removed from Installation Cartridge VAS 5161/8 , they must then be inserted into Insertion Device VAS 5161/18.

NOTE:

The large diameter of the valve keepers points upward.

Insert valve spring and valve spring plate.
Install Guide Plate VAS 5161/7 onto cylinder head again.

Fig 8: Installing Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Into Guide Plate VAS 5161/7

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert installation cartridge VAS 5161/8 into guide plate VAS 5161/7.
Press down Pressure Fork VAS 5161/2 and pull knurled bolt upward - the valve keepers are inserted in this manner.
Release pressure fork VAS 5161/2 with knurled bolt still pulled.
Install sparks plugs →
- 01 - MAINTENANCE
- 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET
.

Install camshafts → Camshafts, removing and installing .
Install camshaft timing chains Installing .
Install engine: Vehicles with manual transmission → Engine (vehicles with manual transmission), installing , vehicles with automatic transmission → Engine (vehicles with automatic transmission), installing .

NOTE:

After installing camshafts, do not crank engine for at least 30 minutes. The hydraulic equalization elements must seat themselves (otherwise valves will strike the pistons).
After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.