Valve Stem Seals With Cylinder Head Installed, Replacing: Removing

• Engine/Transmission Assembly Removed And Placed On The Scissor Lift Table:VAS6131B  .

-- Remove The Camshafts. Refer To CAMSHAFT, REMOVING AND INSTALLING .

-- 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.

-- Remove Spark Plugs With Spark Plug Removal Tool:3122B  .

-- Move Piston For That Cylinder To "Bottom Dead Center (BDC) Position".

-- Position The Valve Cotter Tool Kit - Punch:VAS5161/3  On The Valve Spring Plate And Loosen The Stuck Valve Retainers With A Plastic Mallet.

Fig 1: Identifying Special Tool - Drift VAS 5161/3

Courtesy of AUDI OF AMERICA, LLC

-- Place the Valve Cotter Tool Kit - Guide Plate 19B:VAS5161/19B  from the Valve Cotter Tool Kit:VAS5161  On The Cylinder Head.

Fig 2: Identifying Guide Plate For FSI Engine VAS 5161/19B

Courtesy of AUDI OF AMERICA, LLC

-- Secure The Guide Plate With The Knurled Thumb Screws:VAS5161/12  .

-- Install The Valve Cotter Tool Kit - Adapter:T40012  With Sealing Ring In The Spark Plug Thread And Tighten By Hand.

-- Connect The Adapter To The Compressed Air Using A Commercially Available Intermediate Piece And Give Steady Pressure.

• Minimum Pressure: 6 bar (87 psi) Positive Pressure.

-- Install the Retainer:VAS5161/6  with the Guide Forks M6/M8 with Threaded Studs:VAS5161/5  In The Guide Plate.

Fig 3: Identifying Engaging Device VAS 5161/6 With Installation Fork VAS 5161/5

Courtesy of AUDI OF AMERICA, LLC

-- Push Valve Cotter Tool Kit - Assembly Cartridge:VAS5161/8  Into Guide Plate.

-- Engage The Pressure Fork Pressure Fork With Lever For Assembly Cartridge:VAS5161/2  At The Engaging Device And Press The Installation Cartridge Downward.

-- At The Same Time, Rotate The Cartridge Knurled Screw Right Until Points Engage In Valve Retainers.

-- Move the knurled wheel left and right slightly. This presses the valve retainers apart and captures them in the cartridge.

-- Release The Pressure Fork.

-- Remove The Cartridge.

-- Unfasten Guide Plate And Turn It Aside.

• Pressurized Air Hose Remains Connected.

-- Remove The Valve Spring And The Valve Spring Plate.

-- Remove The Valve Stem Seal With The Puller - Valve Seal:3364  .

Fig 4: Identifying 3364

Courtesy of AUDI OF AMERICA, LLC

Fig 5: Identifying Plastic Sleeve, New Valve Stem Oil Seals & Valve Stem Seal Driver 3365

Courtesy of AUDI OF AMERICA, LLC

-- Lightly Oil The Valve Stem Seal.

-- Slide The Valve Stem Seal Onto The Plastic Sleeve.

-- Carefully Press The Valve Stem Seal Onto The Valve Guide With The Seal Installer - Valve Stem:3365  .

-- Remove The Plastic Sleeve Again.

If The Valve Retainers Were Removed From The Installation Cartridge, They Must Then Be Inserted Into The Valve Insertion Device (6 Dia, 7 Dia) :VAS5161/18  .

Fig 6: Identifying Installation Cartridge VAS 5161/8

Courtesy of AUDI OF AMERICA, LLC

• The Large Diameter Of The Valve Retainers Point Upward.

-- Press The Cartridge From Above Onto The Insertion Device And Capture Retainers.

-- Insert Valve Spring And Valve Spring Plate.

Fig 7: Camshaft Cylinder Head Bank 1 (Right)

Courtesy of AUDI OF AMERICA, LLC

• The Tight Spring Coils -Arrow- Face Toward Cylinder Head.

-- Install The Valve Cotter Tool Kit - Guide Plate 19B:VAS5161/19B  In The Cylinder Head.

Fig 8: Identifying Engaging Device VAS 5161/6 With Installation Fork VAS 5161/5

Courtesy of AUDI OF AMERICA, LLC

-- Insert Installation Cartridge In Guide Plate.

-- Press The Pressure Fork Down And Pull The Knurled Screw Up While Turning Left And Right. This Inserts The Valve Retainers.

-- Release The Pressure Fork With The Knurled Screw Still Raised.

-- Repeat The Procedure On Each Valve.