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	Disassembly and assembly tool -VAS 5161-

Procedure l  Cylinder head installed. –  Remove camshafts and camshaft adjuster → Chapter.   Note Use waterproof felt-tip pen to mark assignment of bucket tappets on back to ensure that the tappets are not interchanged.

–  Remove the bucket tappets from the guides and put them down with the contact surface downwards. –  Remove spark plugs with spark plug socket -3122 B-. –  Set piston of the respective cylinder to “bottom dead centre”. –  Connect pressure hose -VW 653/3- to compressed air supply. l  Air pressure: at least 6 bar –  Insert punch -VAS 5161/3- into bucket tappet guide. –  Knock valve cotters on all five valves loose using a plastic hammer.

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 for valve to be removed. l  Installation position: 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.

Exhaust side: –  Screw snap-in device -VAS 5161/6- with interlocking fork -VAS 5161/5- into threaded hole on cylinder head. –  Push guide bush -VAS 5161/14- as far as it will go into bucket tappet guide for valve to be removed. l  Installation position: 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 seal using the valve stem seal puller -3364-.

If the valve stem seal puller -3364- cannot be used on some of the valve stem oil seals due to the confined space, proceed as follows: –  Knock pin -arrow- of valve stem seal puller -3364- out using a punch and remove the extractor attachment.

–  Apply lower part of valve stem seal puller -3364- to valve stem oil seal. –  Secure valve stem seal puller -3364- with a punch -1- or other suitable tool, as illustrated. –  Apply an assembly lever to puller -3364- and pull out valve stem oil seal -arrow-.   Note

A plastic sleeve -A- is included with the new valve stem oil seals. –  To prevent damage to the new valve stem seals -B-, attach plastic sleeve -A- to valve stem. –  Lightly oil 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.   Note Ensure correct positioning in cylinder head when fitting valve springs of exhaust valves (otherwise assembly is not possible).

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. Installation is carried out in the reverse order; note the following: –  Insert bucket tappets. –  Install spark plugs → Rep. Gr.28. –  Install camshafts and 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.