Audi Workshop Service and Repair Manuals

Renewing valve stem oil seals with cylinder head installed

Special tools and workshop equipment required

t	Spark plug socket and extension -3122 B-

t	Valve stem seal puller -3364-

t	Valve stem seal fitting tool -3365-

t	Adapter -T40012-

t	Torque wrench -V.A.G 1331-

t	Removal and installation device for valve cotters -VAS 5161-

t	Guide plate for 2.0 ltr. and 3.0 ltr. FSI engine -VAS 5161/19B-

Removing valve stem oil seals –  Remove camshafts: engine codes BYT, BPU → Chapter; engine codes BZB, CAWB, CBFA, CCTA, CDAA, CCZA → Chapter. –  Carefully remove roller rocker fingers and place them on a clean surface. When doing so, make sure that roller rocker fingers are not interchanged. –  Remove spark plugs with spark plug spanner -3122 B-.

–  Secure guide plate for 2.0 ltr. and 3.0 ltr. FSI engine -VAS 5161/19B- to cylinder head with knurled screws -VAS 5161/12- as shown. –  Set piston of appropriate cylinder to “bottom dead centre”.

–  Screw adapter -T40012- into spark plug thread. –  Connect to compressed air supply of at least 6 bar. –  Knock loose sticking valve cotters using punch -VAS 5161/3- and a plastic-headed hammer.

For inlet side –  Screw snap-in device -VAS 5161/6- with engaging fork -VAS 5161/5- into centre thread on guide plate for 2.0 ltr. and 3.0 ltr. FSI engine -VAS 5161/19B-. –  Insert assembly cartridge -VAS 5161/8- into guide plate for 2.0 ltr. and 3.0 ltr. FSI engine -VAS 5161/19B-. –  Engage pressure fork -VAS 5161/2- on snap-in device -VAS 5161/6-.

For exhaust side –  Screw snap-in device -VAS 5161/6- with engaging fork -VAS 5161/5- into outer thread on guide plate for 2.0 ltr. and 3.0 ltr. FSI engine -VAS 5161/19B-. –  Press down assembly cartridge -VAS 5161/8- and at the same time, turn knurled screw of assembly cartridge -VAS 5161/8- 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 assembly cartridge. –  Release pressure fork -VAS 5161/2-. –  Take out assembly cartridge -VAS 5161/8-.

–  Pull off valve stem oil seal with valve stem seal puller -3364-.

–  If valve stem seal puller -3364- cannot be used on account of restricted space, knock out pin -arrow- with a punch and remove the impact extractor attachment.

–  Position lower part of valve stem seal puller -3364- on valve stem oil seal. –  Insert a punch -1- through hole in lower section of puller. –  Apply assembly lever to puller and pull out valve stem oil seal -arrow-. Installing valve stem oil seals

–  To prevent damage to the new valve stem seals -B-, attach plastic sleeve -A- to valve stem. –  Lubricate sealing lip of valve stem oil seal -B-, place it in the valve stem oil seal fitting tool -3365- and push carefully onto valve guide. –  Remove plastic sleeve -A-. –  Insert valve spring and valve spring plate. –  Set up removal and installation device for valve cotters -VAS 5161- as shown.

For inlet side

For exhaust side   Note

t  If valve cotters have been removed from assembly cartridge, they need to be put into insertion device -VAS 5161/18- first. t  Press assembly cartridge -VAS 5161/8- onto insertion device from above and pick up valve cotters. –  Press down assembly cartridge -VAS 5161/8- using pressure fork -VAS 5161/2-. Turn knurled screw back and forth while pulling upwards. –  Release pressure fork -VAS 5161/2- with knurled screw in pulled position. –  Detach removal and installation device for valve cotters -VAS 5161-. Further assembly is basically carried out in reverse order of dismantling. –  Install camshafts: engine codes BYT, BPU → Chapter; engine codes BZB, CAWB, CBFA, CCTA, CDAA, CCZA → Chapter.