Valve Stem Seals With Removed Cylinder Head, Removing And Installing

Special tools and workshop equipment required 

• Puller - Valve Seal 3364
• Seal Installer - Valve Stem 3365
• Valve Cotter Tool Kit VAS5161 with Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C
• Engine And Transmission Holder VAS6095
• Cylinder Head Tensioning Device VAS6419

Procedure 

-- 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.

-- Insert the Cylinder Head Tensioning Device VAS6419 in the Engine and Transmission Holder VAS6095.

Fig 1: Tensioning Cylinder Head On Tensioning Element VAS 6419

Courtesy of AUDI OF AMERICA, LLC

-- Tension the cylinder head on the cylinder head tensioning device, as illustrated.

-- Connect the cylinder head tensioning device to the compressed air.

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

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

-- Position the drift Valve Cotter Tool Kit - Punch VAS5161/3 on the valve spring plate and loosen the stuck valve retainers with a plastic mallet.

Fig 2: Identifying Special Tool - Drift VAS 5161/3

Courtesy of AUDI OF AMERICA, LLC

-- Set the Valve Cotter Tool Kit - Guide Plate 19B VAS5161/19B on the cylinder head.

Fig 3: Identifying Guide Plate

Courtesy of AUDI OF AMERICA, LLC

-- Secure the guide plate with the Knurled Thumb Screws VAS5161/12.

-- Install the Retainer VAS5161/6 with the Valve Cotter Tool Kit - Guide Forks M6/M8 with Threaded VAS5161/5 in the guide plate.

Fig 4: Identifying Engaging Device VAS 5161/6, Installation Fork VAS 5161/5 And Guide Plate, Removal/Installation

Courtesy of AUDI OF AMERICA, LLC

-- Push installation cartridge Valve Cotter Tool Kit - Assembly Cartridge VAS5161/8 into guide plate.

-- Engage the Pressure Fork 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.

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

-- Remove the valve stem seal with the Puller - Valve Seal 3364.

Fig 5: Removing Valve Stem Seal With Puller - Valve Seal 3364

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 plastic sleeve.

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

Courtesy of AUDI OF AMERICA, LLC

If the valve keepers were removed from the installation cartridge, they must then be inserted into the Valve Insertion Device VAS5161/18.

Fig 7: Identifying Installation Cartridge VAS 5161/8

Courtesy of AUDI OF AMERICA, LLC

• The large diameter of the valve retainers point upward.

-- Press the cartridge from above onto the insertion device and capture keepers.

-- Insert valve spring and valve spring plate.

• Installed position, valve spring, refer to Figure.

-- Install the guide plate on the cylinder head.

-- Insert installation cartridge in guide plate.

-- Press the pressure fork down and pull the knurled screw up while turn left and right. This inserts the valve retainers.

-- Release the pressure fork with the knurled screw still raised.

-- Repeat the procedure on each valve.

Fig 8: Identifying Engaging Device VAS 5161/6, Installation Fork VAS 5161/5 And Guide Plate, Removal/Installation

Courtesy of AUDI OF AMERICA, LLC

Assembling 

Assembly is performed in the reverse order of disassembly, noting the following:

-- Make sure all the roller rocker levers lie on the ends of the valve stems correctly and are clipped onto the respective hydraulic adjusting elements.

-- Install the camshafts, refer to CAMSHAFT, REMOVING AND INSTALLING .