Audi Workshop Service and Repair Manuals

Renewing valve stem oil seals with cylinder head removed

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-

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

t	Engine and gearbox support -VAS 6095-

t	Cylinder head tensioning device -VAS 6419-

Procedure –  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. –  Insert cylinder head tensioning device -VAS 6419- into engine and gearbox support -VAS 6095-. –  Secure cylinder head in cylinder head tensioning device, as shown in illustration. –  Connect cylinder head tensioning device to compressed air.

–  Using lever -arrow-, slide air pad under combustion chamber where valve stem oil seal is to be removed. –  Apply just enough compressed air to bring air pad into contact with valve heads.

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

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-. Installing valve stem oil seals   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. –  Insert valve spring and valve spring plate. –  Set up removal and installation device for valve cotters -VAS 5161- as shown.

Inlet side

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. –  Use pressure fork -VAS 5161/8- to press down assembly cartridge -VAS 5161/2-, then turn knurled screw of assembly cartridge 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. Note the following: –  Install camshafts → Chapter.