Audi Workshop Service and Repair Manuals

Renewing valve stem oil seals with cylinder head installed Special tools and workshop equipment required

t  Valve stem seal puller -3364-

t  Valve stem seal fitting tool -3365-

t  Removal and installation device for valve cotters -VAS 5161- with guide plate for 3.0 ltr. TDI engine -VAS 5161/23- and sleeve -VAS 5161/23-1- t  Bolt M6x30 (2x) Procedure –  Remove all glow plugs → Rep. gr.28. –  Remove camshafts → Chapter. –  Mark original positions of roller rocker fingers and hydraulic compensation elements for reinstallation. –  Remove roller rocker fingers together with hydraulic compensation elements and put down on a clean surface. –  Set piston of appropriate cylinder to „bottom dead centre“.

–  Fit guide plate for 3.0 ltr. TDI engine -VAS 5161/23- onto cylinder head. –  Secure guide plate on intake manifold side with knurled screw -VAS 5161/12- and 2 M6x30 bolts -item 1- by hand until they make contact.

–  Screw sealing pin -VAS 5161/10- into guide plate. –  Screw adapter -VAS 5161/11- hand-tight into corresponding glow plug thread.

–  Insert drift -VAS 5161/3- into guide plate and use plastic-headed hammer to release sticking valve cotters.

–  Screw snap-in device -VAS 5161/6- with engaging fork -VAS 5161/5- into guide plate. –  Slide sleeve -VAS 5161/23-1- onto assembly cartridge -VAS 5161/8-. –  Connect adapter to compressed air line using a commercially available connection piece, and apply constant air pressure. l  Minimum pressure: 6 bar –  Attach pressure fork -VAS 5161/2- to snap-in device 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 assembly cartridge. –  Release pressure fork. –  Take off assembly cartridge with knurled spacer ring. –  Detach valve spring with valve spring plate.

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

Caution Make sure valve stem oil seals are not damaged when installing. New valve stem oil seals -B- are supplied with plastic sleeve; fit plastic sleeve -A- onto valve stem. –  Lightly oil sealing lip of valve stem oil seal. –  Slide valve stem oil seal onto plastic sleeve. –  Carefully press valve stem oil seal onto valve guide using valve stem seal fitting tool -3365-. –  Take off plastic sleeve.

If valve cotters have been removed from assembly cartridge, they must first be inserted in insertion device -VAS 5161/18-. l  Larger diameter of valve cotters faces upwards. –  Insert valve spring and valve spring plate. –  Press assembly cartridge onto insertion device from above and take up valve cotters.

–  Insert assembly cartridge in guide plate for 3.0 ltr. TDI engine -VAS 5161/23- again. –  Press down pressure fork and pull knurled screw upwards while turning screw in both directions - this will insert the valve cotters. –  Release pressure fork with knurled screw still in pulled position. –  Repeat procedure for each valve. Assembling Installation is carried out in the reverse order; note the following: –  Ensure that all roller rocker fingers make contact with the ends of the valve stems correctly and are clipped onto their respective hydraulic compensation elements. –  Install camshafts → Chapter. –  Install glow plugs → Rep. gr.28.