Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSAUDI2004A8REPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCETUNE-UP4.2L - ENGINE MECHANICAL, ENGINE CODE(S): BFM15 - ENGINE - CYLINDER HEAD, VALVETRAINVALVETRAIN, ASSEMBLY OVERVIEWVALVE STEM SEALS, REPLACING

2004 Audi A8

Valve stem seals, replacing

2004 Audi A8SECTION Valve stem seals, replacing

Fig 1: Identifying Special Tools - Valve Stem Seals, Replacing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Spark plug removal tool 3122 B
Valve seal removal tool 3364
Valve stem seal driver 3365
Valve cotter disassembly and assembly device VAS 5161

Adapter T40012

Removing

Engine removed → Engine, removing and installing .

Remove camshafts and camshaft adjusters for right cylinder head → Camshafts and camshaft adjusters (left cylinder head), removing and installing and left cylinder head → Camshafts and camshaft adjusters (right cylinder head), removing and installing .
Using spark plug removal tool 3122 B , remove spark plugs.

Fig 2: Turning Roller Rocker Lever Upward And Securing It With Rubber Band

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn roller rocker lever upward and secure it with a rubber band.

Fig 3: Placing Guide Plate VAS 5161/7 From Valve Cotter Disassembly And Assembly Device VAS 5161 On Cylinder Head

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place Guide Plate VAS 5161/7 from Valve Cotter Disassembly and Assembly Device VAS 5161 on cylinder head.
Secure guide plate VAS 5161/7 with knurled screws VAS 5161/12.
Insert drift VAS 5161/3 into guide plate and loosen stuck valve keepers using a plastic hammer.

Fig 4: Installing Engaging Device VAS 5161/6 With VAS 5161/5 Into Guide Plate VAS 5161/7

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install engaging device VAS 5161/6 with VAS 5161/5 into guide plate VAS 5161/7.
Guide installation cartridge VAS 5161/8 into guide plate VAS 5161/7.
Install adapter T40012 with gasket by hand into respective spark plug thread and apply constant pressure.

Minimum pressure: 6 bar pressure

Engage pressure fork VAS 5161/2 at engaging device VAS 5161/6 and press down installation cartridge.
At the same time, turn knurled bolt of installation cartridge to right, until points engage in valve keepers.
Lightly move knurled bolt back and forth, causing valve keepers to be pressed apart and be captured in installation cartridge.
Release pressure fork.

Remove installation cartridge.
Remove guide plate.

Pressurized air hose remains connected.

Fig 5: Removing Valve Stem Seals Using Valve Seal Removal Tool 3364

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove valve stem seals using Valve Seal Removal Tool 3364.

Installing

NOTE:

For pressing on valve stem seals from delivery program, the Valve Stem Seal Driver 3365 must be drilled to 6.5 mm dia.

Fig 6: Identifying Plastic Sleeve, Valve Stem Oil Seal & Valve Stem Seal Driver 3365

Courtesy of VOLKSWAGEN UNITED STATES, INC.

A plastic sleeve - A - is supplied with the new valve shaft seals.

Place plastic sleeve - A - on valve stem to prevent damage to new valve stem oil seals - B -.
Lightly oil valve stem seal.
Push valve stem seal onto plastic sleeve.
Carefully press valve stem oil seal onto valve guide using valve stem seal driver 3365.

Remove plastic sleeve again.

Fig 7: Identifying Installation Cartridge VAS 5161/8

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If valve keys were removed from the installation cartridge, they must be inserted into insertion device VAS 5161/18 next.

NOTE:

The large diameter of the valve keepers point upward.

Insert valve spring and valve spring plate.
Install Guide Plate VAS 5161/7 onto cylinder head again.

Fig 8: Installing Engaging Device VAS 5161/6 With VAS 5161/5 Into Guide Plate VAS 5161/7

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert installation cartridge VAS 5161/8 into guide plate.
Press down pressure fork and pull knurled-head bolt upward - thereby valve keepers are inserted.
Release pressure fork with knurled bolt still pulled.
Install camshafts and camshaft adjusters → Camshafts and camshaft adjusters (right cylinder head), removing and installing for left cylinder head and → Camshafts and camshaft adjusters (left cylinder head), removing and installing for right cylinder head.

NOTE:

After installing the camshaft, the engine may not be started for approx. 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into the pistons).
After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.

RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.