Valve Stem Seals, Cylinder Head Installed, Removing And Installing

Special tools and workshop equipment required 

• Spark Plug Removal Tool 3122B
• Puller - Valve Seal 3364
• Seal Installer - Valve Stem 3365
• Valve Keeper Tool Kit VAS5161A with the Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C
• Valve Cotter Tool Kit - Adapter T40012

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.

-- Remove the spark plugs with Spark Plug Removal Tool 3122B.

-- Move piston for that cylinder to "Bottom Dead Center (BDC) position".

-- Position the Drift VAS5161/3 on the valve spring plate and loosen the stuck valve retainers with a plastic mallet.

Fig 1: Positioning Drift VAS5161/3 On Valve Spring Plate

Courtesy of AUDI OF AMERICA, LLC

-- Place Valve Cotter Tool Kit - Guide Plate VAS5161/19B from Valve Keeper 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 VAS 161/12.

-- 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)

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

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

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-- Push Installation 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.

• 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: Removing Valve Stem Seal

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If the Puller - Valve Seal 3364 cannot be used on several valve stem seals due to restricted clearance, proceed as follows:

Fig 5: Driving Out Roll Pin

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

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

Fig 6: Positioning Valve Seal Puller 3364 On Valve Stem Oil 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: Pressing Valve Stem Seal Onto Valve Guide

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-- 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 be inserted into the Valve Cotter Tool Kit - Valve Insertion Device VAS5161/18 first.

Fig 8: Identifying Installation Cartridge VAS 5161/8

Courtesy of AUDI OF AMERICA, LLC

• The large diameter of the valve retainers point upward.

-- Press assembly cartridge from above onto valve insertion device and capture retainers.

-- Insert the valve spring and the valve spring plate, refer to Figure.

Fig 9: Identifying Tight Spring Coils

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-- Install the guide plate on the cylinder head.

Fig 10: Identifying Engaging Device VAS 5161/6 With Installation Fork VAS 5161/5

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-- 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.

Assembling 

Assemble in reverse order of disassembling. Note 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 .

-- Install the spark plugs, refer to 6-CYLINDER 3.2 FSI GASOLINE ENGINE .