Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Pressure hose VW 653/3
• ◆ Spark plug socket and extension 3122 B
• ◆ Puller 3364
• ◆ Fitting tool 3365
• ◆ Removal and installing tool VAS 5161

Removing

• ● Cylinder head installed

• ‒ Remove camshafts and camshaft adjuster
  .

Notes:

• ◆ Ensure that bucket tappets are not interchanged.
• ◆ Mark installation position on back of tappets with water-proof felt pen.

• ‒ Remove the bucket tappets from guides and put them down with the contact surface downwards.
• ‒ Remove spark plugs with spark plug spanner 3122B.

• ‒ Set piston of appropriate cylinder to "bottom dead centre".
• ‒ → Screw compressed air hose VW 653/3 into spark plug thread and apply a continuous pressure of at least 6 bar.
• ‒ Insert punch VAS 5161/3 in bucket tappet guide.
• ‒ Knock sticking valve cotters on all valves loose using a plastic-tip hammer.

Inlet side

• ‒ → Screw retainer VAS 5161/6 with guide fork VAS 5161/4 onto threaded stud on cylinder head.
• ‒ Insert guide sleeve VAS 5161/13 all the way into bucket tappet guide of the valve to be removed.
• ‒ Mounting position: knurled surfaces have to align transversely to direction of travel.
• ‒ Slide knurled spacer ring 5161/17 onto cartridge VAS 5161/8.
• ‒ Insert cartridge into guide bush.
• ‒ Hook pressure fork VAS 5161/2 into retainer VAS 5161/6 and press cartridge downwards.
• ‒ While doing this turn knurled screw of cartridge clockwise until the ends engage in the valve cotters.
• ‒ Turn knurled screw back and forth slightly to press valve cotters apart so they are taken up by the cartridge.
• ‒ Release pressure fork.

• ‒ Remove cartridge with knurled spacer ring, guide bush, valve spring plate and valve spring.

Exhaust side

• ‒ → Screw retainer VAS 5161/6 with guide fork VAS 5161/4 onto a stud on the cylinder head.
• ‒ Insert guide bush VAS 5161/14 all the way into bucket tappet guide of the valve to be removed.
• ‒ Mounting position: knurled surfaces have to align transversely to direction of travel.
• ‒ Slide knurled spacer ring 5161/17 onto cartridge VAS 5161/8.
• ‒ Insert cartridge into guide bush.
• ‒ Hook pressure fork VAS 5161/2 into retainer VAS 5161/6 and press cartridge downwards.
• ‒ While doing this turn knurled screw of cartridge clockwise until the ends engage in the valve cotters.

• ‒ Turn knurled screw back and forth slightly to press valve cotters apart so they are taken up by the cartridge.
• ‒ Release pressure fork.
• ‒ Remove cartridge with knurled spacer ring, guide bush, valve spring plate and valve spring.

All models

• ‒ → Pull off valve stem seals with 3364.

If the space is not sufficient to pull off individual valve stem seals with puller 3364, proceed as described below:

• ‒ → Knock pin -arrow- of puller 3364 out using a drift and remove the extractor attachment.

• ‒ → Place bottom part of puller 3364 on valve stem seal.
• ‒ Secure the puller with a drift or punch -1- as shown in the illustration.
• ‒ Apply a suitable lever to puller 3364 and pull out valve stem seal -arrow-.

Installing

Note:

New valve stem seals come with a plastic sleeve -A-.

• ‒ → To prevent damage to the new valve stem seals -B-, place plastic sleeve -A- on valve stem.
• ‒ Lightly oil sealing lip of valve stem seal.
• ‒ Slide valve stem seal over plastic sleeve.
• ‒ Carefully press valve stem seal with fitting tool 3365 down onto valve guide.
• ‒ Remove plastic sleeve.

• ‒ → If valve cotters had been removed from assembly cartridge they need to be put into insertion device VAS 5161/18 first.

Note:

The larger diameter of the valve cotters points upwards.

• ‒ Press cartridge VAS 5161/8 onto insertion device from above and take up valve cotters.

• ‒ → Re-insert cartridge VAS 5161/8 into guide bush VAS 5161/13 or VAS 5161/14.
• ‒ To install valve cotters, press down pressure fork and pull knurled screw upwards, turning it back and forth.
• ‒ Release pressure fork with knurled screw still pulled upwards.
• ‒ Insert tappets.
• ‒ Install camshafts and camshaft adjuster
  => Page 15-62.

Notes:

• ◆ Wait about 30 minutes after installing the camshafts before starting the engine. The hydraulic valve compensating elements must settle (otherwise the valves will strike the pistons).
• ◆ 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.