Valve Shaft Seals, Removing And Installing, Cylinder Removed

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Special tools and workshop equipment required

Puller - Valve Seal 3364
Seal Installer - Valve Stem 3365
Valve Keeper Tool Kit VAS5161A
Valve Cotter Tool Kit - Guide Plate 19B VAS5161/19B
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.

-- 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.

Fig 1: Identifying Air Cushion With Lever

Courtesy of AUDI OF AMERICA, LLC

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

-- Tighten the Valve Cotter Tool Kit - Guide Plate 19B VAS5161/19B on the cylinder head as shown using the Knurled Thumb Screws M6 VAS5161A/12.

Fig 2: Identifying Guide Plate

Courtesy of AUDI OF AMERICA, LLC

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

For Intake Side

Fig 3: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

Courtesy of AUDI OF AMERICA, LLC

-- Install the Retainer VAS5161/6 with the Guide Forks M6/M8 with Threaded Studs VAS5161/5 in the center threads of the Valve Cotter Tool Kit - Guide Plate 19B VAS5161A/19B.

-- Insert the Assembly Cartridge VAS5161/8A into the Valve Cotter Tool Kit - Guide Plate 19B VAS5161/19B.

-- Engage the Pressure Fork With Lever for Assembly Cartridge VAS5161/2 on the Retainer VAS5161/6.

For Exhaust Side

Fig 4: Identifying Pressure Fork VAS 5161/2

Courtesy of AUDI OF AMERICA, LLC

-- Install the Retainer VAS5161/6 with the Guide Forks M6/M8 with Threaded Studs VAS5161/5 in the outer threads of the Valve Cotter Tool Kit - Guide Plate 19B VAS5161A/19B.

-- Press down the Assembly Cartridge VAS5161/8A and at the same time turn the knurled thumb screw on the Assembly Cartridge VAS5161/8A to the right until the points engage in the valve keepers.

-- Move the knurled thumb screw back and forth slightly. This presses the valve retainers apart and captures them in the installation cartridge.

-- Release the Pressure Fork With Lever For Assembly Cartridge VAS5161/2.

-- Remove the Assembly Cartridge VAS5161/8A.

-- Remove the valve stem seals using Puller - Valve Seal 3364.

Fig 5: Identifying Valve Seal Removal Tool 3364

Courtesy of AUDI OF AMERICA, LLC

Install Valve Stem Seals

CAUTION:

Risk of damage when installing valve stem seals.

Place the plastic sleeve -A- that is attached to valve stem seals -B- on valve stem.

Fig 6: Identifying Plastic Sleeve And Valve Stem Seals

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.

-- Insert the valve spring and valve spring plate.

-- Install the Valve Keeper Tool Kit VAS5161A as illustrated.

Fig 7: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

Courtesy of AUDI OF AMERICA, LLC

Fig 8: Identifying Pressure Fork VAS 5161/2

Courtesy of AUDI OF AMERICA, LLC

NOTE:

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

Fig 9: Identifying Installation Cartridge VAS 5161/8

Courtesy of AUDI OF AMERICA, LLC

Press the Assembly Cartridge VAS5161/8A onto the insertion device from above and capture the valve retainers.

-- Press the Valve Keeper Tool Kit Assembly Cartridge VAS5161/8 down with the Valve Keeper Tool Kit Pressure Fork with Lever for Assembly Cartridge VAS5161/2 and rotate the cartridge knurled thumb screw back and forth while pulling up.

-- Release the Pressure Fork with Lever for Assembly Cartridge VAS5161/2 with the knurled thumb screw pulled.

-- Remove the Valve Keeper Tool Kit VAS5161A.

Further installation is done in the reverse order of removal. Note the following:

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