Audi Workshop Service and Repair Manuals

Renewing valve stem oil seals

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	Disassembly and assembly tool -VAS 5161-

t	Adapter -T40012-

Procedure   WARNING The fuel system operates under high pressure. The pressure in the high-pressure part of the injection system must be reduced to a residual pressure prior to opening the system → Chapter. A clean cloth must then be wrapped around the connection and the residual pressure dissipated by carefully loosening the connection. –  Remove engine → Chapter. –  Remove intake manifold → Rep. Gr.24. –  Remove cover for timing chain → Chapter. –  Remove camshaft timing chain → Chapter. –  Remove camshaft housing → Chapter. –  Remove fuel rail (bottom section of intake manifold) from cylinder head → Rep. Gr.24. –  Unscrew both lifting eyes from cylinder head.

–  Wrap insulating tape around tip and shaft of 2.5 mm Ø drill bit to avoid cuts. –  Press operating rod of vacuum unit towards vacuum unit and lock with 2.5 mm drill -arrow-. –  Remove bolts -1- and -2-.

–  Move vacuum unit to side -arrow 1- and detach from operating rod for intake manifold flap -arrow 2-. –  Unscrew bracket for high-pressure pipes from fuel rail (bottom section of intake manifold). –  Screw fuel rail (bottom section of intake manifold ) back onto cylinder head. –  Remove spark plugs with spark plug socket -3122 B-. –  Set piston of the respective cylinder to “bottom dead centre”. –  Screw adapter -T40012- into the spark plug hole of the relevant cylinder. –  Connect adapter -T40012- to compressed air and apply air pressure throughout the procedure. l  Air pressure: at least 6 bar

–  Fit guide plate -VAS 5161/22- onto cylinder head. –  Secure guide plate -VAS 5161/22- using the knurled screws -VAS 5161/12-. –  Insert drift -VAS 5161/3- into guide plate -VAS 5161/22- and knock valve cotters loose using a plastic hammer.

–  Screw snap-in device -VAS 5161/6- with engaging fork -VAS 5161/5- into guide plate -VAS 5161/22-. –  Insert assembly cartridge -VAS 5161/8- into guide plate -VAS 5161/22-. –  Attach pressure fork -VAS 5161/2- to snap-in device -VAS 5161/6- and push assembly cartridge -VAS 5161/8- down. –  At the same time, turn knurled screw of assembly cartridge -VAS 5161/8- clockwise until ends engage in valve cotters. –  Move knurled screw back and forth slightly; the valve cotters are thus forced apart and enter into cartridge. –  Release the pressure fork. –  Remove assembly cartridge -VAS 5161/8-. –  Unbolt guide plate -VAS 5161/22- and move to side. l  The compressed air hose remains connected. –  Remove valve spring with valve spring plate.

–  Remove valve stem oil seals using the valve stem seal puller -3364-.   Note

A plastic sleeve -A- is included with the new valve stem oil seals. –  Insert plastic sleeve -A- onto the valve stem to prevent damage to the new valve stem oil seal -B-. –  Lightly lubricate 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.

–  If valve cotters have been removed from assembly cartridge, they need to be put into insertion device -VAS 5161/18- first.   Note Larger diameter of valve cotters faces upwards.

–  Insert valve spring and valve spring plate. –  Screw guide plate -VAS 5161/22- back onto cylinder head. –  Insert assembly cartridge -VAS 5161/8- into guide plate -VAS 5161/22-. –  Push pressure fork down and pull knurled screw upwards while turning to left and right - this will insert the valve cotters. –  Release the pressure fork with knurled screw still in pulled position. –  Renew seals and O-rings for injectors → Rep. Gr.24. –  Install fuel rail (bottom section of intake manifold) → Rep. Gr.24. –  Install camshaft housing → Chapter. –  Install camshaft timing chain → Chapter. –  Install timing chain cover → Chapter. –  Renew crankshaft oil seal → Chapter. –  Install crankshaft pulley → Chapter. –  Install intake manifold → Rep. Gr.24. –  Install engine → Chapter.   Note 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. Tightening torque

Component	Nm
Vacuum unit to fuel rail (bottom section of intake manifold)	3
Engine lifting eye to cylinder head	20