Valve Stem Seals With Cylinder Head Removed

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Valve Seal Removal Tool 3364
Valve Stem Seal Driver 3365
Valve Cotters Asm/Dis-Asm Device VAS 5161
Engine and Transmission Holder VAS 6095
Cylinder Head Tensioning Device VAS 6419

Procedure

-- Remove the 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: Identifying 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 the guide plate for 2.0L FSI engine VAS 5161/19B from the VAS 5161 on the cylinder head.

Fig 2: Identifying FSI Engine VAS 5161/19B Guide Plate Tightened On Cylinder Head Using Knurled Bolts VAS 5161/12

Courtesy of AUDI OF AMERICA, LLC

-- Secure the guide plate with the knurled screws VAS 5161/12.

-- Insert the drift VAS 5161/3 in the guide plate and loosen the stuck valve retainers with a plastic mallet.

Fig 3: Identifying VAS 5161/3

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-- Install engaging device VAS 5161/6 with installation fork VAS 5161/5 in guide plate.

Fig 4: Engaging Device Vas 5161/6

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-- Slide installation cartridge VAS 5161/8 in guide plate.

Intake Side:

-- Engage the pressure fork VAS 5161/2 on the engaging device as illustrated.

Exhaust Side:

-- Engage the pressure fork VAS 5161/2 on the engaging device as illustrated.

Fig 5: Engaging Pressure Fork VAS 5161/2

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Continued for Both Sides:

-- Press the installation cartridge down with the pressure fork.

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

-- Move the knurled bolt to the left and right.

Valve retainers are pressed against each other and capture in the installation cartridge.

-- Release the pressure fork.

-- Remove installation cartridge.

-- Unfasten guide plate and turn it aside.

-- Remove the valve spring and the valve spring plate.

-- Remove the valve stem seal with the 3364.

Fig 6: Identifying Valve Seal Removal Tool 3364

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.

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

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-- Lightly oil valve stem seal.

-- Slide valve shaft seal onto plastic sleeve.

-- Carefully press valve stem seal onto valve guide with 3365.

-- Remove plastic sleeve again.

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

Fig 8: 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.

-- Install the guide plate on the cylinder head.

-- 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.

-- Repeat the procedure on each valve.

Assemble in reverse order of disassembling. Note the following:

-- Install the camshafts. Refer to CAMSHAFTS .