Valve Shaft Seals, Removing And Installing, Cylinder Removed: Notes

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Special tools and workshop equipment required

Puller - Valve Seal 3364
Seal Installer - Valve Stem3365
Valve Cotter Tool Kit VAS5161A with Valve Cotter Tool Kit - Guide Plate 19cVAS5161/19C or as an alternative Valve Cotter Tool Kit - Guide Plate 19BVAS5161/19B
Engine And Transmission Holder VAS6095
Cylinder Head Tensioning Device VAS6419

Reworking the Valve Cotter Tool Kit - Guide Plate 19CVAS5161/19C:

Fig 1: Identifying Valve Cotter Tool Kit - Guide Plate 19BVAS5161/19B

Courtesy of AUDI OF AMERICA, LLC

NOTE:

In place of the Valve Cotter Tool Kit - Guide Plate 19cVAS5161/19C, the Valve Cotter Tool Kit - Guide Plate 19BVAS5161/19B may also be used. To do this, the following reworking must be completed as follows:

-- Lengthen the long opening to 2 mm as shown in the illustration.

NOTE:

To use this, the guide plate is only attached to the cylinder head with a knurled bolt.

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.

Fig 2: Identifying Cylinder Head Tensioning Device 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 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.

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

Fig 3: 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 4: 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 5: Installing Retainer VAS5161/6 With Guide Forks M6/M8 With Threaded Studs VAS5161/5 In Guide Plate

Courtesy of AUDI OF AMERICA, LLC

-- Push installation cartridge Valve Cotter Tool Kit - Assembly 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 thumb screw back and forth slightly. This presses the valve retainers apart and captures them in the installation 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 Seal 3364.

Fig 6: Identifying Puller - Valve Seal 3364

Courtesy of AUDI OF AMERICA, LLC

Fig 7: Identifying Plastic Sleeve, New Valve Stem Oil Seals & Valve Stem Seal Driver 3365

Courtesy of AUDI OF AMERICA, LLC

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.

-- 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 the plastic sleeve again.

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

Fig 8: 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 the valve spring and the valve spring plate, for allocation refer to Figure.

-- Attach the Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C onto the cylinder head again.

-- 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.

Fig 9: Identifying Valve Cotter Tool Kit - Guide Plate 19cVAS5161/19C

Courtesy of AUDI OF AMERICA, LLC