Valve Stem Seals, Removing And Installing, Cylinder Head Installed: Notes

WARNING: This page is about a different car, the 2015 Audi S7, 2015 Audi RS 7, 2014 Audi S7, 2014 Audi RS 7, and 2013 Audi S7. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Spark Plug Removal Tool 3122B
Puller - Valve Seal 3364
Seal Installer - Valve Stem3365
Valve Cotter Tool Kit VAS5161A with Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C or as an alternative Valve Cotter Tool Kit - Guide Plate 19BVAS5161/19B
Valve Cotter Tool Kit - AdapterT40012

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

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

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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 all of the left and right 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 spark plugs with Spark Plug Removal Tool 3122B.

-- Move piston for that cylinder to "bottom dead center position".

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

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-- 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

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

-- Install the Valve Cotter Tool Kit - AdapterT40012 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) positive pressure.

-- Install the Retainer VAS5161/6 with the Guide Forks M6/M8 with Threaded StudsVAS5161/5 in the guide plate.

Fig 4: Installing Retainer VAS5161/6 With Guide Forks M6/M8 With Threaded StudsVAS5161/5 In Guide Plate

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-- Push Installation Cartridge VAS5161/8 into guide plate.

-- Engage the Pressure ForkVAS5161/2 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 5: Identifying Puller - Valve Seal 3364

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

Fig 6: Driving Out Roll Pin

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-- Drive out the roll pin in direction of -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 7: Positioning 3364 Valve Stem Removal Tool At Valve Stem Oil Seal

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-- 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 8: Identifying Plastic Sleeve, New Valve Stem Oil Seals & Valve Stem Seal Driver 3365

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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 9: Identifying Installation Cartridge VAS 5161/8

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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 19cVAS5161/19C 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 10: Identifying Valve Cotter Tool Kit - Guide Plate 19cVAS5161/19C

Courtesy of AUDI OF AMERICA, LLC