Valve Stem Seals With Cylinder Head Removed

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

Valve Seal Removal Tool 3364
Valve Stem Seal Driver 3365
Valve Retainer Disassembly and Assembly Device VAS 5161 with Guide Plate VAS 5161/25
Engine and Transmission Holder VAS 6095
Cylinder Head Tensioning Device VAS 6419

Procedure

-- Remove camshafts. Refer to CAMSHAFTS .

-- Mark the allocation of the roller rocker lever and the hydraulic adjusting elements so they can be installed again.

-- If necessary, remove the roller rocker levers with the hydraulic adjusting elements and place them on a clean surface.

-- Insert the VAS 6419 in the VAS 6095.

Fig 1: VAS 6419

Courtesy of AUDI OF AMERICA, LLC

-- Tension the cylinder head on the VAS 6419 as shown in the illustration.

-- Connect the VAS 6419 to compressed air.

-- Slide the air cushion with the lever -arrow- under the combustion chamber onto the valve stem seals that will be removed.

-- Let enough compressed air flow into the air cushion until it contacts the valve plate.

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

Fig 2: Placing Drift VAS 5161/3 On Valve Plate

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-- Place VAS 5161/25 from VAS 5161 on cylinder head.

Fig 3: Place VAS 5161/25 From VAS 5161 On Cylinder Head.

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-- Secure guide plate with a nut -1-.

Rear valve row procedure:

-- Screw VAS 5161/6 with VAS 5161/5 into guide plate.

Fig 4: Screw VAS 5161/6 With VAS 5161/5 Into Guide Plate.

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-- Push VAS 5161/8 into guide plate.

-- Hook in 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 the points engage in the valve retainers.

-- Lightly move knurled bolt back and forth, causing the valve retainers to be pressed apart and be captured in the installation cartridge.

-- Release pressure fork.

-- Take out installation cartridge.

-- Unfasten guide plate and turn it aside.

-- Remove valve spring with valve spring plate.

Front valve row procedure:

-- Screw VAS 5161/6 with VAS 5161/5 onto cylinder head.

Fig 5: Screw VAS 5161/6 With VAS 5161/5 Onto Cylinder Head.

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-- Push the VAS 5161/17 onto the VAS 5161/8.

-- Push installation cartridge into guide plate.

-- Hook in 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 the points engage in the valve retainers.

-- Lightly move knurled bolt back and forth, causing the valve retainers to be pressed apart and be captured in the installation cartridge.

-- Release pressure fork.

-- Take out installation cartridge.

-- Unfasten guide plate and turn it aside.

-- Remove valve spring with valve spring plate.

Procedure for both valve rows:

-- Pull off valve stem oil seals using 3364.

Fig 6: Identifying Valve Seal Removal Tool 3364

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NOTE:

For pressing on green-colored valve stem seals from delivery program, the 3365 must be drilled to dia. 10.5 mm.

Mark the drilled driver for later reuse.

A plastic sleeve -A- is supplied with new valve shaft seals.

Fig 7: Identifying Plastic Sleeve, New Valve Stem Oil Seals & Valve Stem Seal Driver 3365

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-- 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 3365.

-- Remove plastic sleeve again.

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

Fig 8: Identifying Installation Cartridge VAS 5161/8

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The large diameter of the valve retainers point upward.

-- Install valve spring and valve spring plate.

Installed position of valve spring:

The larger diameter -arrow- faces toward cylinder head.

Fig 9: Valve Spring And Valve Plate
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Rear valve row procedure:

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

Fig 10: Screw VAS 5161/6 With VAS 5161/5 Into Guide Plate.

Courtesy of AUDI OF AMERICA, LLC

-- Insert installation cartridge into guide plate.

-- Press the pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve retainers.

-- Release pressure fork with the knurled bolt still pulled.

Front valve row procedure:

-- Insert installation cartridge with knurled spacer wheel into guide plate.

Fig 11: Screw VAS 5161/6 With VAS 5161/5 Onto Cylinder Head.

Courtesy of AUDI OF AMERICA, LLC

-- Press the pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve retainers.

-- Release pressure fork with the knurled bolt still pulled.

-- Install camshafts. Refer to CAMSHAFTS .

-- Install sparks plugs.

NOTE:

After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on 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.