Valve stem seals, replacing

WARNING: This page is about a different car, the 2008 Audi RS 4 and 2007 Audi RS 4. However, it is still accessible from the selected car via links, so may be relevant.

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

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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

Removing

Remove engine → Engine, removing .
Leave engine with transmission installed on scissor lift platform VAS 6131.
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: Placing Drift VAS 5161/3 On Valve Spring Plate And Loosening Stuck Valve Keepers Using Plastic Hammer

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

Fig 3: Placing Guide Plate VAS 5161/19 A From Valve Cotter Disassembly And Assembly Device VAS 5161 On Cylinder Head

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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.
Install adapter T40012 with gasket by hand into respective spark plug thread and apply constant pressure.

Minimum pressure: 6 bar positive pressure.

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

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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 points engage in valve keepers.

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

Pressurized air hose remains connected.

Remove valve spring with valve spring plate.

Fig 5: Pulling Off Valve Stem Oil Seals Using Valve Seal Removal Tool 3364

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

Fig 6: 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 7: Identifying Installation Cartridge VAS 5161/8

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

The large diameter of valve keepers point upward.

Install valve spring and valve spring plate.

Fig 8: Identifying Tight Spring Coils Face Toward Cylinder Head

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

Fig 9: Installing Guide Plate Onto Cylinder Head

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Install guide plate onto cylinder head again.
Insert installation cartridge into guide plate.
Press down pressure fork and pull knurled bolt upward turning to left and right - the valve keepers are inserted in this manner.
Release pressure fork with knurled bolt still pulled.

Ensure that all roller rocker levers seat properly on valve stem ends and are clipped onto respective support elements.
Install sparks plugs → 28 - IGNITION/GLOW PLUG SYSTEM .
Install camshafts → Camshafts, removing and installing .
Position camshaft timing chains on camshafts Installing .

Install left and right timing chain covers Installing .
Install cylinder head cover: Left → Left cylinder head cover, removing and installing , right → Right cylinder head cover, removing and installing .
Install engine → Engine, installing .

NOTE:

After installing camshafts, do not crank engine for at least 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into 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.