Renewing valve stem seals with cylinder head installed — AUDI

🧭 Before you start

Fits: platform code 2C0

• Special tools named: VAS 5161/23, VAS 5161/12, VAS 5161/10, VAS 5161/11, VAS 5161/3, VAS 5161/6, VAS 5161/5, VAS 5161/8

Don't miss

• Mark allocation of roller rocker fingers and hydraulic compensation elements for reinstallation.
• A plastic sleeve (A) is included with the new valve stem oil seals.
• Risk of damage when installing valve stem seals. — Fit plastic sleeve (A) onto valve stem to prevent damage to new valve stem oil seal (B).
• Ensure that all roller rocker fingers contact valve stem ends correctly and are clipped into relevant hydraulic compensation elements.

🔧 Engine codes this applies to

📐 61 workshop diagrams for CFHC

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Remove all glow plugs .
2. Remove camshafts .
3. Mark allocation of roller rocker fingers and hydraulic compensation elements for reinstallation.
4. Remove roller rocker fingers together with hydraulic compensation elements and place down on a clean surface.
5. Set piston of respective cylinder to "“bottom dead centre”".

6. Place guide plate VAS 5161/23 onto cylinder head.
7. Tighten guide plate on intake manifold side by hand using knurled screw VAS 5161/12 and 2 M6x30 bolts (item 1) until it makes contact.
8. Screw sealing pins VAS 5161/10 into guide plate.
9. Screw adapter VAS 5161/11 hand-tight into relevant glow plug thread.
10. Insert drift VAS 5161/3 into guide plate and use a plastic hammer to knock loose the firmly seated valve cotters.
11. Screw toothed piece VAS 5161/6 with hooking fork VAS 5161/5 into guide plate.
12. Push sleeve VAS 5161/23-1 onto assembly cartridge VAS 5161/8.
13. Connect adapter to compressed air supply using a commercially available union and apply pressure continuously.
14. Attach pressure fork VAS 5161/2 to toothed piece and press assembly cartridge down.
15. At the same time, turn knurled screw of assembly cartridge clockwise until tips engage in valve cotters.
16. Move knurled screw back and forth to press apart valve cotters and capture them in assembly cartridge.
17. Release pressure fork.
18. Remove assembly cartridge together with spacer.
19. Remove valve spring and valve spring plate.
20. Pull off valve stem seal using valve stem seal puller3364. [Note: A plastic sleeve (A) is included with the new valve stem oil seals.]
21. ⚠ Risk of damage when installing valve stem seals. — Fit plastic sleeve (A) onto valve stem to prevent damage to new valve stem oil seal (B).
22. Lightly oil sealing lip of valve stem seal.
23. Push valve stem oil seal onto plastic sleeve.
24. Carefully press valve stem oil seal onto valve guide using valve stem seal fitting tool3365.
25. Remove plastic sleeve.
26. If valve cotters have been removed from assembly cartridge, they need to be put into insertion deviceVAS 5161/18 first.
27. Insert valve spring and valve spring plate.
28. Press assembly cartridge onto valve cotter insertion device from above and pick up valve cotters.
29. Insert assembly cartridgeVAS 5161/8 into guide plateVAS 5161/23 again.
30. Press pressure fork downwards and pull knurled screw upwards, turning it clockwise and anticlockwise. This inserts the valve cotters.
31. Reduce pressure on pressure fork whilst pulling on knurled screw.
32. Repeat procedure on each valve.
33. Ensure that all roller rocker fingers contact valve stem ends correctly and are clipped into relevant hydraulic compensation elements.
34. Install camshafts .
35. Install glow plugs .

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