Valve Stem Seals, Cylinder Head Installed, Removing And Installing

Special tools and workshop equipment required 

• Puller - Valve Seal 3364
• Seal Installer - Valve Stem 3365
• Valve Cotter Tool Kit VAS5161A with Valve Cotter Tool Kit - Punch VAS5161/3AA, V Valve Cotter Tool Kit - Assembly Cartridge VAS5161/8A, Valve Cotter Tool Kit - Guide Plate 29 VAS5161/29 and Valve Cotter Tool Kit - Guide Plate 29-1 VAS5161/29-1

Procedure 

-- Remove all the glow plugs, refer to GLOW PLUG, REMOVING AND INSTALLING .

-- 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.

-- Move piston for that cylinder to "bottom dead center position".

-- Place the Valve Keeper Tool Kit - Guide Plate VAS5161A/29 on the cylinder head.

Fig 1: Identifying Valve Keeper Tool Kit - Guide Plate VAS 5161A/29

Courtesy of AUDI OF AMERICA, LLC

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

-- Insert the Punch VAS5161/3A in the guide plate and loosen the stuck valve retainers with a plastic mallet.

-- Install the Sealing Pin VAS5161/29-1 in the guide plate.

Fig 2: Identifying Sealing Pin VAS 5161/29-1

Courtesy of AUDI OF AMERICA, LLC

-- Install the Adapter for Compressed Air Connection VAS5161/11 hand tight in the glow plug threads.

-- Install the Retainer VAS5161/6 with the Guide Forks M6/M8 with Threaded Studs VAS5161/5 in the guide plate.

Fig 3: Identifying Retainer VAS 5161/6 With Threaded Studs VAS 5161/5

Courtesy of AUDI OF AMERICA, LLC

-- Insert the Installation Cartridge VAS5161/8A into the opening above the soon to be removed valve spring.

-- Connect the adapter to the compressed air using a commercially available intermediate piece and give steady pressure.

• Minimum pressure: 6 bar (87 psi)

-- Engage the 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 installation cartridge with the knurled spacer ring.

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

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

Fig 4: Removing Valve Stem Seal With Valve Seal Puller 3364

Courtesy of AUDI OF AMERICA, LLC

If puller cannot be used on several valve stem seals due to restricted clearance, proceed as follows:

-- Remove the roll pin -arrow- on the puller with a drift and remove the impact puller attachment.

Fig 5: Locating Valve Seal Puller 3364 Roll Pin

Courtesy of AUDI OF AMERICA, LLC

-- Position the lower part of the Puller - Valve Seal 3364 on the valve stem seal.

Fig 6: Positioning Lower Part Of Puller On Valve Stem Seal

Courtesy of AUDI OF AMERICA, LLC

-- Secure the puller with a drift or cotter pin drive -1- as shown in the illustration.

-- Position the valve lever on the puller and remove the valve stem seal -arrow-.

Fig 7: 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 plastic sleeve.

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 8: Identifying Installation Cartridge VAS 5161/8

Courtesy of AUDI OF AMERICA, LLC

• The large diameter of the valve retainers point upward.

-- Insert valve spring and valve spring plate.

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

-- Insert the Valve Keeper Tool Kit - Guide Plate VAS5161A/29.

Fig 9: Identifying Retainer VAS 5161/6 With Threaded Studs VAS 5161/5

Courtesy of AUDI OF AMERICA, LLC

-- 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.

Assembling

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

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

-- Install the glow plugs, refer to GLOW PLUG, REMOVING AND INSTALLING .