Valve Shaft Seals, Removing And Installing, Cylinder Removed

Special tools and workshop equipment required 

• Puller - Valve Seal3364
• Seal Installer - Valve Stem3365
• Valve Cotter Tool KitVAS5161 A with Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C or as an alternative Valve Cotter Tool Kit - Guide Plate 19B VAS5161/19B
• Engine And Transmission HolderVAS6095
• Cylinder Head Tensioning DeviceVAS6419

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 DeviceVAS6419 in the Engine and Transmission HolderVAS6095.

Fig 1: Tensioning Cylinder Head On Tensioning Element VAS 6419

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 chambers onto the valve stem seal that will be removed.

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

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

Fig 2: Identifying Valve Cotter Tool Kit - Punch VAS5161/3

Courtesy of AUDI OF AMERICA, LLC

-- Place the valve cotter tool kit - guide plate 19C VAS5161/19C on the cylinder head.

Fig 3: Placing Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C On Cylinder Head

Courtesy of AUDI OF AMERICA, LLC

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

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

Fig 4: Installing Retainer VAS5161/6 With Guide Forks M6/M8 With Threaded Studs VAS5161/5 In Guide Plate

Courtesy of AUDI OF AMERICA, LLC

-- Push the assembly cartridge VAS5161/8A 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.

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

-- Remove the valve stem seal with the Puller - Valve Seal3364.

Fig 5: Identifying 3364

Courtesy of AUDI OF AMERICA, LLC

Fig 6: 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 Stem3365.

-- Remove plastic sleeve.

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

Fig 7: Identifying Installation Cartridge VAS 5161/8

Courtesy of AUDI OF AMERICA, LLC

• The large diameter of the valve retainers point upward.

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

-- Insert valve spring and valve spring plate.

• Installed position, valve spring, refer to Figure.

-- Install the guide plate on the cylinder head.

Fig 8: Installing Retainer VAS5161/6 With Guide Forks M6/M8 With Threaded Studs VAS5161/5 In Guide Plate

Courtesy of AUDI OF AMERICA, LLC

-- 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 .