Valve Stem Seals, Removing And Installing, Cylinder Head Removed

Special tools and workshop equipment required 

• Puller - Valve Seal: 3364 
• Seal Installer - Valve Stem: 3365 
• Valve Cotter Tool Kit: VAS5161A  with the Valve Keeper Tool Kit - Compression Stud: VAS5161/10 
• Valve Keeper Tool Kit - Guide Plate: VAS5161A/43 
• Engine and Transmission Holder: VAS6095A 
• Cylinder Head Tensioning Device: VAS6419 
• Mounting Sleeve. Refer to Parts Information

Procedure 

-- Mark the allocation of the roller rocker lever and the hydraulic lifter so they can be installed again.

-- Remove the roller rocker lever with the hydraulic lifter and place them on a clean surface.

-- 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.

In the : VAS5161A/43  two M5x40 bolts and four holes -a, b, c, d- are present. These are used after each installation situation.

Courtesy of AUDI OF AMERICA, LLC

-- Align the : VAS5161A/43  -1- on the cylinder head at the same time pay attention to the marking:

Courtesy of AUDI OF AMERICA, LLC

A - Exhaust side

E - Intake side

-- Tighten the guide plate bolts -arrows- to 9 Nm.

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

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

Courtesy of AUDI OF AMERICA, LLC

-- Insert the Assembly Cartridge : VAS5161/8A  into the opening above the valve spring that is to be removed.

-- Engage the Pressure Fork : VAS5161/2  at the engaging device and press the installation cartridge downward.

-- At the same time, turn the installation cartridge knurled bolt -arrow- right until points engage in the valve retainers.

-- Move the knurled bolt left and right slightly. This presses the valve retainers apart and captures them in the assembly cartridge.

• The knurled bolt slides all the way in the assembly cartridge.

-- Release the pressure fork.

-- Remove the assembly cartridge.

-- Remove the valve spring and the valve spring retainer and mark the installation position.

-- Remove the valve stem seal with the : 3364  .

Courtesy of AUDI OF AMERICA, LLC

• So that the valve stem seal -2- is not damaged during installation, mount the Mounting Guide Sleeve -1- on the valve stem.

  Courtesy of AUDI OF AMERICA, LLC

-- Lightly oil the valve stem seal sealing lip.

-- Insert the valve stem seal in the : 3365  and carefully press on the valve guide all the way.

-- Remove the Mounting Sleeve.

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

Fig 1: 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 valve retainers.

-- Insert the valve spring and the valve spring retainer:

Intake valve installation position. Refer to Figure.

Exhaust valve installation position. Refer to Figure.

-- Insert the : VAS5161/8A  back into the : VAS5161A/43  .

Courtesy of AUDI OF AMERICA, LLC

-- Press the pressure fork down and pull the knurled bolt -arrow- up while turning left and right. This inserts the valve retainers.

-- Release the pressure fork with the knurled bolt still raised.

-- Repeat the procedure on each valve.

Assembling 

Assemble in the reverse order of removal. Note the following:

-- Make sure all the roller rocker levers lie correctly on the ends of the valve stems and are clipped onto the respective hydraulic lifters.