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	Removal and installation device -VAS 5161-

t	Adapter -T40012-

Procedure –  Remove intake manifold → Rep. gr.24. –  Remove camshaft housing → Chapter. –  Detach engine lifting eyes from cylinder head. –  Remove spark plugs with spark plug socket and extension -3122 B-. –  Set piston of appropriate cylinder to „bottom dead centre“.

–  Screw adapter -T40012- with seal hand-tight into the corresponding spark plug thread. –  Connect adapter to compressed air line using a commercially available connection piece, and apply constant air pressure. l  Minimum pressure: 6 bar –  Fit guide plate -VAS 5161/22- onto cylinder head. –  Secure guide plate with knurled screws -VAS 5161/12- onto cylinder head. –  Apply drift -VAS 5161/3- to 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. –  Insert assembly cartridge -VAS 5161/8- in guide plate. –  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 out assembly cartridge. –  Detach guide plate and turn to one side. l  The compressed air hose remains connected. –  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-. –  Remove 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. –  Press assembly cartridge onto insertion device from above and take up valve cotters.

–  Insert valve spring and valve spring plate. –  Secure guide plate -VAS 5161/22- back onto cylinder head. –  Insert assembly cartridge -VAS 5161/8- in guide plate. –  Press down pressure fork 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. –  Repeat procedure for each valve. Assembling Installation is carried out in the reverse order; note the following: –  Install spark plugs → Booklet809. –  Install engine lifting eyes → Chapter. –  Install camshaft housing → Chapter. –  Install intake manifold → Rep. gr.24.