Valve Stem Seals, Removing And Installing With Cylinder Head Removed

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 VAS 5161/3 A, Valve Cotter Tool Kit - Assembly Cartridge VAS5161/8A and Valve Cotter Tool Kit - Guide Plate 29 VAS5161/29.
• Engine and Transmission Holder VAS6095
• Cylinder Head Tensioning Device VAS6419

Procedure 

-- 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: Identifying Air Cushion With Lever

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 chamber onto the valve stem seal that will be removed.

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

-- Mark the roller rocker lever so it can be installed later and remove them.

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

Fig 2: Identifying Valve Keeper Tool Kit - Guide Plate VAS 5161A/29

Courtesy of AUDI OF AMERICA, LLC

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

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

-- 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 Valve Cotter Tool Kit - Assembly Cartridge VAS5161/8A into the opening above the soon to be removed valve spring.

-- 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

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 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 6: 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 7: 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 reverse order.