Valve Stem Seals, Cylinder Head Installed

WARNING: This page is about a different car, the 2009 Audi TT and 2008 Audi TT. However, it is still accessible from the selected car via links, so may be relevant.

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 VAS5161
Guide Plate for FSI Engine VAS 5161/19B

Valve Stem Seals, Removing

-- Remove the camshafts. Refer to CAMSHAFTS .

NOTE:

To replace the valve stem seals of the exhaust valves for cylinder 3 and 4, the EGR vacuum regulator solenoid valve -N18- must also be removed.

-- Remove roller rocker levers and place them on a clean surface. Make sure that roller cam followers are not interchanged.

-- Remove the spark plugs with the 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

-- Adjust piston of the respective cylinder to "Bottom Dead Center (BDC)".

-- Install the T40012 into the spark plug thread and connect compressed air (minimum 6 bar).

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

Courtesy of AUDI OF AMERICA, LLC

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

For the Intake Side

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

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

-- 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

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

Fig 4: Identifying Pressure Forks VAS 5161/2 Engaged

Courtesy of AUDI OF AMERICA, LLC

-- 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 pressure fork VAS 5161/2.

-- Remove the installation cartridge VAS 5161/8.

-- Remove valve stem seals using the 3364.

Fig 5: Identifying Valve Seal Removal Tool 3364

Courtesy of AUDI OF AMERICA, LLC

-- In the event the 3364 cannot be used due to constrained spatial arrangements, drive out spring dowel sleeve -arrow- using a drift and remove impact device.

Fig 6: Driving Out Spring Dowel Sleeve

Courtesy of AUDI OF AMERICA, LLC

-- Place the lower part of the 3364 onto the valve stem seal.

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

Courtesy of AUDI OF AMERICA, LLC

-- Insert a drift -1- into the bore in lower part of extractor device.

-- Place a lever at the removal tool and pull out the valve stem seal -arrow-.

Valve Stem Seals, Installing

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

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

Courtesy of AUDI OF AMERICA, LLC

-- Oil the sealing lip of valve stem seal -B-, insert into the 3365 and carefully slide onto valve guide.

-- Remove the plastic sleeve -A-.

-- Insert valve spring and valve spring retainer.

-- Install the VAS 5161 as shown.

Fig 9: 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

Fig 10: Identifying Pressure Forks VAS 5161/2 Engaged

Courtesy of AUDI OF AMERICA, LLC

NOTE:

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

Fig 11: Identifying Installation Cartridge VAS 5161/8

Courtesy of AUDI OF AMERICA, LLC

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

-- Press down the VAS 5161/8 with the pressure fork VAS 5161/2 and turn the knurled screw of the installation cartridge back and forth while pulling it upward at the same time.

-- Release the VAS 5161/2 with the knurled bolt pulled.

-- Remove the VAS 5161.

Assemble in reverse order of disassembly.

-- Install the camshafts. Refer to CAMSHAFTS .