Valve Stem Seals, Removing And Installing, Cylinder Head Removed

Special tools and workshop equipment required 

• Puller - Valve Seal: 3364 
• Seal Installer - Valve Stem: 3365  for valve stem seal with a simple sealing lip. Refer to Figure.
• Seal Installer - Valve Stem: T40376/1  , for valve stem seal with a double sealing lip. Refer to Figure.
• Valve Keeper Tool Kit: VAS5161A 
• Valve Keeper Tool Kit Pressure Fork with Lever for Assembly Cartridge: VAS5161/2 
• Valve Cotter Tool Kit - Punch: VAS5161/3A 
• Guide Forks M6/M8 with Threaded Studs: VAS5161/5 
• Retainer: VAS5161/6 
• Valve Cotter Tool Kit - Assembly Cartridge: VAS5161/8A 
• Knurled Thumb Screws M6: VAS5161A/12 
• Valve Cotter Tool Kit - Valve Insertion Device: VAS5161/18 
• Valve Cotter Tool Kit - Guide Plate 19c: VAS5161/19C 
• Engine and Transmission Holder: VAS6095A 
• Cylinder Head Tensioning Device: VAS6419 
• Mounting Sleeve. Refer to Parts Information

Procedure 

-- If necessary, remove the fuel rail. Refer to FUEL RAIL, REMOVING AND INSTALLING .

-- Insert the : VAS6419  in the : VAS6095A  .

Courtesy of AUDI OF AMERICA, LLC

-- Tension the cylinder head on the cylinder head tensioning device, as shown.

-- Connect the cylinder head tensioning device to 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.

Guide Plate, Reworking: 

-- Check if the opening -arrow- is present.

-- If necessary, rework the : VAS5161/19C  -arrow- until the guide plate touches the cylinder head and the guide pin -1- is free.

Continuation: 

-- Tighten the : VAS5161/19C  on the cylinder head as shown using the : VAS5161A/12  .

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

Intake Side: 

-- Install the : VAS5161/6  with the : VAS5161/5  in the center threads of the : VAS5161/19C  .

Exhaust Side: 

-- Install the : VAS5161/6  with the : VAS5161/5  in the outer threads of the : VAS5161/19C  .

Continuation: 

-- Insert the : VAS5161/8A  into the : VAS5161/19C  .

-- Engage the : VAS5161/2  on the : VAS5161/6  .

-- Press down the : VAS5161/8A  and at the same time turn the knurled thumb screw on the : VAS5161/8A  to the right until the points engage in the 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 : VAS5161/2  .

-- Remove the : VAS5161/8A  .

-- Remove the valve stem seals using : 3364  .

• In order not to damage the valve stem seal -4- during installation, mount the Mounting Sleeve -3- on the valve stem -2-.
  Fig 6: Insert The Valve Stem Seal In The 3365

  Courtesy of AUDI OF AMERICA, LLC

-- Lightly oil the valve stem seal sealing lip.

-- Insert the valve stem seal in the : 3365  -5- and carefully press on over the Mounting Sleeve on the valve guide -1- all the way.

-- Remove the Mounting Sleeve.

-- Insert the valve spring and valve spring retainer.

-- Connect the : VAS5161A  as shown.

Intake Side: 

Exhaust Side: 

Continuation: 

• If the valve retainers were removed from the assembly cartridge, they must then be inserted into the : VAS5161/18  .

-- Press the : VAS5161/8A  down with the : VAS5161/2  and rotate the cartridge knurled thumb screw back and forth while pulling up.

-- Release the : VAS5161/2  with the knurled thumb screw pulled.

-- Remove the : VAS5161A  .

-- Repeat the procedure on each valve.

Assembling 

-- Install the fuel rail. Refer to FUEL RAIL, REMOVING AND INSTALLING .