Audi Workshop Service and Repair Manuals

Renewing valve stem oil seals

Special tools and workshop equipment required

t	Pressure hose -VW 653/3-

t	Spark plug socket and extension -3122 B-

t	Valve stem seal puller -3364-

t	Valve stem seal fitting tool -3365-

t	Removal / installing device for valve cotters -VAS 5161-

Procedure l  Cylinder head installed. –  Remove camshafts and hydraulic chain tensioner/camshaft adjuster → Chapter.   Note Use waterproof felt-tip pen to mark original positions on back of bucket tappets to ensure that tappets are not interchanged. –  Take bucket tappets out of guides and set them down with contact surface facing downwards. –  Remove spark plugs with spark plug socket -3122 B-. –  Set piston of the respective cylinder to “bottom dead centre”.

–  Screw pressure hose -VW 653/3- into spark plug hole and connect to compressed air supply. l  Minimum pressure: 6 bar. –  Insert punch -VAS 5161/3- in bucket tappet guide. –  Knock sticking valve cotters loose on all 5 valves using a plastic hammer.

Exhaust side: –  Screw snap-in device -VAS 5161/6- with interlocking fork -VAS 5161/4- onto stud on cylinder head. –  Push guide bush -VAS 5161/14- as far as it will go into bucket tappet guide of the valve spring to be removed. l  Knurled surfaces face perpendicular to direction of travel. –  Slide knurled spacer ring -VAS 5161/17- onto assembly cartridge -VAS 5161/8-. –  Insert assembly cartridge into guide bush. –  Attach pressure fork -VAS 5161/2- to snap-in device -VAS 5161/6- and push assembly cartridge down. –  At the same time, turn knurled screw of assembly cartridge clockwise until tips engage in valve cotters. –  Move knurled screw back and forth slightly; the valve cotters are thus forced apart and taken up by the cartridge. –  Release the pressure fork. –  Take off assembly cartridge with knurled spacer ring. –  Remove guide bush, valve spring plate and valve spring.

Inlet side –  Screw snap-in device -VAS 5161/6- with interlocking fork -VAS 5161/4- onto stud on cylinder head. –  Push guide bush -VAS 5161/13- as far as it will go into bucket tappet guide of the valve spring to be removed. l  Knurled surfaces face perpendicular to direction of travel. –  Slide knurled spacer ring -VAS 5161/17- onto assembly cartridge -VAS 5161/8-. –  Insert assembly cartridge into guide bush. –  Attach pressure fork -VAS 5161/2- to snap-in device -VAS 5161/6- and push assembly cartridge down. –  At the same time, turn knurled screw of assembly cartridge clockwise until tips engage in valve cotters. –  Move knurled screw back and forth slightly; the valve cotters are thus forced apart and taken up by the cartridge. –  Release the pressure fork. –  Take off assembly cartridge with knurled spacer ring. –  Remove guide bush, valve spring plate and valve spring.

Continuation for both sides: –  Remove valve stem oil seals using the valve stem seal puller -3364-.

If the puller cannot be used on some of the valve stem oil seals due to the confined space, proceed as follows: –  Knock out pin -arrow- of puller using a drift and remove the extractor attachment.

–  Apply lower part of puller to valve stem oil seal. –  Secure puller with a punch -1- or other suitable tool as shown in the illustration. –  Apply assembly lever to puller and pull out valve stem oil seal -arrow-.   Note

A plastic sleeve -A- is included with the new valve stem oil seals. –  Fit plastic sleeve -A- onto the valve stem to prevent damage to the new valve stem oil seal -B-. –  Lightly lubricate sealing lip of valve stem oil seal. –  Slip valve stem oil seal over plastic sleeve. –  Carefully press valve stem oil seal onto valve guide using valve stem seal fitting tool -3365-. –  Remove the plastic sleeve.

–  If valve cotters have been removed from assembly cartridge, they need to be put into insertion device -VAS 5161/18- first. l  Larger diameter of valve cotters faces upwards. –  Press assembly cartridge onto valve insertion device from above and take up valve cotters. –  Insert guide bush -VAS 5161/13- or -VAS 5161/14-, valve spring and valve spring plate.

–  Re-insert cartridge into guide bush. –  Push pressure fork down and pull knurled screw upwards while turning screw in both directions - this will insert the valve cotters. –  Release the pressure fork with knurled screw still in pulled position. –  Insert bucket tappets. Installation is carried out in the reverse order; note the following: –  Install spark plugs → Rep. Gr.28. –  Install camshafts and hydraulic chain tensioner/camshaft adjuster → Chapter.   Note t  After installing camshafts, wait for approx. 30 minutes before starting engine. Hydraulic valve compensation elements have to settle (otherwise valves will strike pistons). t  After working on the valve gear, turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.