Valve Stem Seals With Cylinder Head Installed, Replacing

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
Valve Retainer Disassembly and Assembly Device VAS 5161 with Guide Plate VAS 5161/25
Adapter T40012

Procedure

Engine removed.

-- Camshafts, removing. Refer to CAMSHAFTS .

-- Remove ignition coils. Refer to Removal and Installation .

-- Remove spark plugs with 3122 B.

-- Position drift VAS 5161/3 on valve spring plate.

Fig 1: Placing Drift VAS 5161/3 On Valve Plate

Courtesy of AUDI OF AMERICA, LLC

-- Loosen stuck valve retainers with a plastic hammer.

-- Mount the VAS 5161/25 from the VAS 5161 on the cylinder head.

Fig 2: Placing Guide Plate VAS 5161/25 From Valve Keeper Disassembly And Assembly Device VAS 5161 On Cylinder Head

Courtesy of AUDI OF AMERICA, LLC

-- Tighten guide plane on cylinder head with nut -1-.

-- Install T40012 with sealing ring in respective spark plug thread and hand tighten.

-- Connect hose to compressed air.

Minimum pressure: 6 bar positive pressure.

Rear valve row:

-- Install VAS 5161/6 with VAS 5161/5 in guide plate.

Fig 3: Procedure For Outer Rows Of Valves

Courtesy of AUDI OF AMERICA, LLC

-- Slide VAS 5161/8 in guide plate.

-- Engage VAS 5161/2 on engaging device and press installation cartridge down.

-- At the same time, rotate installation cartridge knurled screw right until points engage in valve retainer.

-- Move knurled screw back and forth slightly.

Valve retainers are pressed against each other and capture 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.

Front valve row:

-- Tighten VAS 5161/6 with VAS 5161/5 on cylinder head.

Fig 4: Procedure For Inner Rows Of Valves

Courtesy of AUDI OF AMERICA, LLC

-- Slide VAS 5161/17 onto installation cartridge VAS 5161/8.

-- Slide installation cartridge in guide plate.

-- Engage VAS 5161/2 on engaging device and press installation cartridge down.

-- At the same time, rotate installation cartridge knurled screw right until points engage in valve retainer.

-- Move knurled screw back and forth slightly.

Valve retainers are pressed against each other and capture 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.

Procedure for both valve rows:

-- Pull off valve stem seals with 3364.

Fig 5: Identifying Valve Seal Removal Tool 3364

Courtesy of AUDI OF AMERICA, LLC

NOTE:

To press on green-colored valve shaft seals from current delivery package, 3365 must be drilled to dia. 10.5 mm.

Mark the drilled driver for later reuse.

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

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Risk of damage when installing valve stem seals.

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

-- Lightly oil valve stem seal.

-- Slide valve shaft seal onto plastic sleeve.

-- Carefully press valve stem seal onto valve guide with Valve Stem Seal Drive 3365.

-- Remove plastic sleeve.

If valve retainers were removed from installation cartridge, they must next be inserted in valve retainer inserting tool VAS 5161/18:

Fig 7: Identifying Installation Cartridge VAS 5161/8

Courtesy of AUDI OF AMERICA, LLC

The large diameter of the valve retainers point upward.

-- Press installation cartridge from above onto valve retainer inserting tool and capture retainers.

-- Insert valve spring and valve spring plate.

Fig 8: Valve Spring And Valve Plate

Courtesy of AUDI OF AMERICA, LLC

Installation position: Large diameter -arrow- on valve spring faces toward cylinder head.

Rear valve row:

-- Fasten guide plate on cylinder head again as shown in illustration.

Fig 9: Procedure For Outer Rows Of Valves

Courtesy of AUDI OF AMERICA, LLC

-- Insert installation cartridge in guide plate.

-- Press pressure fork down and pull knurled screw up, turning left and right.

The valve retainers are inserted in this manner.

-- Release pressure fork with knurled screw still raised.

Front valve row:

Fig 10: Procedure For Inner Rows Of Valves

Courtesy of AUDI OF AMERICA, LLC

-- Insert installation cartridge with knurled spacer ring in guide plate.

-- Press pressure fork down and pull knurled screw up, turning left and right.

The valve retainers are inserted in this manner.

-- Release pressure fork with knurled screw still raised.

-- Install camshafts. Refer to CAMSHAFTS .

-- Install spark plugs.

CAUTION:

Risk of damaging valves and piston heads after working on valvetrain.

The motor must not be started for about 30 minutes after installing camshafts because the hydraulic equalization elements must seat themselves.
To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.