Valve Stem Seals, Removing And Installing, Cylinder Head Installed

WARNING: This page is about a different car, the 2024 Audi RS 3. 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:3122 B

Fig 1: Identifying Spark Plug Removal Tool 3122B
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Puller - Valve Seal:3364

Fig 2: Identifying Puller - Valve 3364
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Intake side: Seal Installer - Valve Stem:3365

Fig 3: Identifying Seal Installer - Valve Stem 3365
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Exhaust side: Valve Stem Seal Driver:T40376A/2

Fig 4: Exhaust side: Fitting Tool
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Pliers - Valve Seal:VAS 6770

Fig 5: Pliers - Valve Seal
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Valve Keeper Tool Kit:VAS 5161A with the Valve Keeper Tool Kit - Guide Plate 2.5L TFSI:VAS 5161A/39

Fig 6: Valve Keeper Tool Kit VAS5161A
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Extracting Tool:T40429 for the exhaust side, not illustrated

Removing

-- Remove the camshaft housing. Refer to CAMSHAFT HOUSING, REMOVING AND INSTALLING .

-- 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.

-- Remove the spark plugs with the Spark Plug Removal Tool:3122B .

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-- Place the Valve Keeper Tool Kit - Guide Plate 2.5L TFSI : VAS 5161A/39 on the cylinder head.

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-- Secure the guide plate with the Valve Cotter Tool Kit - Knurled Thumb Screws :VAS 5161/12 .

-- Install the Valve Cotter Tool Kit - Adapter:T40012 with the seal hand-tight in the respective spark plug thread.

-- Connect the adapter to the compressed air using a commercially available intermediate piece and give steady pressure.

Minimum pressure: 6 bar (87.02 psi)

-- Position the Valve Cotter Tool Kit - Punch :VAS 5161/3A on the valve spring plate and loosen the stuck valve keepers with a plastic mallet.

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-- Install the Valve Cotter Tool Kit - Retainer :VAS 5161/6 with the Guide Forks M6/M8 with Valve Cotter Tool Kit - Threaded Studs :VAS 5161/5 in the guide plate.

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-- Push the Valve Cotter Tool Kit - Assembly Cartridge :VAS 5161/8A into the guide plate.

-- Engage the Valve Keeper Tool Kit - Pressure Fork :VAS 5161/2 at the engaging device and press the installation cartridge downward.

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

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

-- Release the pressure fork.

-- Remove the assembly cartridge.

-- Remove the guide plate and turn it aside.

The pressurized air hose remains connected.

-- Remove the valve spring and the valve spring retainer.

-- Remove the valve stem seal.

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Intake side:

-- To do so, use the Puller - Valve Seal:3364 or the Pliers - Valve Seal:VAS 6770 .

Exhaust side:

-- For this, use the Extracting Tool:T40429 .

The illustration shows the procedure using the Puller - Valve Seal:3364 . The procedure using the Extracting Tool:T40429 is identical.

Intake side:

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-- Lightly oil the valve stem seal sealing lip -3-.

-- Insert the valve stem seal in the Seal Installer - Valve Stem:3365 -item 4- and carefully press on over valve stem sleeve -2- on the valve guide -1- all the way.

Exhaust side:

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-- Lightly oil the valve stem seal sealing lip -3-.

-- Insert the valve stem seal in the Fitting Tool:T40376A/2 -4- and carefully press on over valve stem sleeve -2- on the valve guide -1- all the way.

If the valve keepers were removed from the assembly cartridge, they must then be inserted into the Valve Keeper Tool Kit - Valve Insertion Device :VAS 5161/18 .

Fig 7: Identifying Installation Cartridge VAS 5161/8

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The large diameter of the valve keepers point upward.

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

-- Insert the valve spring and the valve spring retainer. Refer to Figure.

-- Attach the Valve Keeper Tool Kit - Guide Plate 2.5L TFSI: VAS 5161A/39 again on the cylinder head.

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-- Insert the assembly cartridge into the guide plate.

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

-- 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.

-- Install the camshaft housing. Refer to CAMSHAFT HOUSING, REMOVING AND INSTALLING .

-- Install the spark plugs. Refer to OVERVIEW - IGNITION SYSTEM .