Valve stem oil seals, replacing

WARNING: This page is about a different car, the 2006 Audi A4, 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Valve Stem Oil Seals, Replacing

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Special tools and equipment

Adapter T40012
3122B Spark plug removal tool
3364 Valve Seat Tool
3365 Valve Stem Seat Fitting Tool

VAS 5161 Removal and installation device

Removing

Cylinder head installed

Remove camshafts. Refer to Camshafts and camshaft adjusters, removing and installing .

NOTE:

Be careful not to switch valve lifters.
Mark allocation of the valve lifters on back side using a waterproof felt-tip marker.

Remove valve lifters from guides and place aside with contact surface facing down.
Using 3122B spark plug removal tool, remove spark plugs.
Adjust piston of respective cylinder to BDC.

Fig 2: Threading T40012 Adapter Into Spark Plug Thread

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Thread T40012 adapter into spark plug thread and apply constant pressure; at least 6 bar positive pressure.
Insert VAS5161/3 drift into valve lifter guide.
Loosen by hitting all stuck valve keys at all five valves using a plastic hammer.

Intake side

Fig 3: Removing/Installing VAS5161/6, VAS5161/5 In Threaded Hole At Cylinder Head (Intake Side)

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Thread VAS5161/6 engaging device with VAS5161/5 engaging fork into one threaded hole at cylinder head.
At valve to be removed, slide VAS5161/13 guide bushing into valve lifter guide up to stop.

Installed position: Hatched areas point horizontally to direction of travel

Slide VAS5161/17 knurled spacer ring onto VAS5161/8 installation cartridge.
Slide installation cartridge into guide bushing.
Hook in VAS5161/2 pressure fork at VAS 5161/6 engaging device and press installation cartridge downward.
At same time, turn knurled bolt of installation cartridge toward right, until points engage in valve keys.

Lightly move knurled bolt back and forth, this causes valve keys to be pressed apart and captured in cartridge.

Fig 4: Removing/Installing VAS5161/6, VAS5161/5 In Threaded Hole At Cylinder Head (Intake Side)

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Release pressure fork.
Remove installation cartridge with spacer ring, guide bushing, valve plate and valve spring.

Exhaust side

Fig 5: Removing/Installing VAS5161/6, VAS5161/5 In Threaded Hole At Cylinder Head (Exhaust Side)

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Thread VAS5161/6 engaging device with VAS5161/5 engaging fork into one threaded hole at cylinder head.
At valve to be removed, slide VAS5161/14 guide bushing into valve lifter guide up to stop.

Installed position: Hatched areas point horizontally to direction of travel

Slide VAS5161/17 knurled spacer ring onto VAS5161/8 installation cartridge.
Slide installation cartridge into guide bushing.
Hook in VAS5161/2 pressure fork at VAS 5161/6 engaging device and press installation cartridge downward.
At same time, turn knurled bolt of installation cartridge toward right, until points engage in valve keys.

Lightly move knurled bolt back and forth, this causes valve keys to be pressed apart and captured in cartridge.
Release pressure fork.
Remove installation cartridge with spacer ring, guide bushing, valve plate and valve spring.

All

Fig 6: Removing Valve Stem Oil Seals Using 3364 Valve Seat Tool

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Remove valve stem oil seals using 3364 valve seat tool.

If due to limited space 3364 valve stem removal tool cannot be used at some valve stem oil seals, continue as follows:

Fig 7: Identifying Valve Seal Removal Tool 3364

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Drive out spring dowel sleeve (arrow) at 3364 valve stem removal tool using a drift and remove impact extractor device.

Fig 8: Positioning Lower Part Of 3364 Valve Stem Removal Tool At Valve Stem Oil Seal

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Position lower part of 3364 valve stem removal tool at valve stem oil seal.
Secure 3364 valve stem removal tool using a drift or cotter pin driver -1- as shown in illustration.
Position a lever at 3364 valve stem removal tool and remove valve stem oil seal (arrow).

Installing

NOTE: A plastic sleeve -A- supplements the new valve shaft seals.

Fig 9: Identifying Plastic Sleeve, Valve Stem Oil Seal & Valve Stem Seal Driver 3365

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Place plastic sleeve -A- on valve stem to prevent damage to new valve stem oil seals -B-.
Lightly oil sealing lip of valve stem oil seal.
Slide valve stem oil seal onto plastic sleeve.
Carefully press valve stem oil seal onto valve guide using 3365 valve stem seal driver.

Remove plastic sleeve.

Fig 10: Identifying Installation Cartridge VAS 5161/8

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If valve keepers were removed from installation cartridge, they must be inserted into VAS5161/18 insertion device next.

NOTE: The large diameter of the valve keepers points upward.

Press VAS5161/8 installation cartridge onto insertion device from top and take up valve keepers.

Fig 11: Removing/Installing VAS5161/6, VAS5161/5 In Threaded Hole At Cylinder Head (Intake Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Set VAS5161/8 installation cartridge into VAS5161/13 guide sleeve or VAS5161/14.
Press down pressure fork and pull knurled bolt upward while turning left and right - valve keepers are inserted in this manner.
Release pressure fork with the knurled bolt still pulled.
Insert valve lifters.

Install camshafts. Refer to Installing .

NOTE:

After installing camshafts, do not start engine for at least 30 minutes. The hydraulic valve lifters have to settle (otherwise valves will strike the pistons).
After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.