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 -VAS 6419-, as illustrated. –  Connect cylinder head tensioning device -VAS 6419- to compressed air. –  Using lever -arrow-, slide air pad under combustion chamber where valve stem oil seals are to be removed. –  Apply just enough compressed air to bring air pad into contact with valve heads.

–  Fit guide plate -VAS 5161/19B- from removal and installation device for valve cotters -VAS 5161- on cylinder head. –  Secure guide plate with knurled screws -VAS 5161/12-.

–  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. Inlet side: –  Engage pressure fork -VAS 5161/2- at snap-in device, as shown in illustration.

Exhaust side: –  Engage pressure fork -VAS 5161/2- at snap-in device, as shown in illustration. Continuation for both sides: –  Press down with pressure fork for assembly cartridge. –  At the same time, turn knurled screw of assembly cartridge clockwise until tips engage in valve cotters. –  Turn knurled screw in both directions. l  The valve cotters are forced apart and are taken up by the cartridge. –  Release pressure fork. –  Take out assembly cartridge. –  Detach guide plate and turn to one side. –  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 back onto cylinder head. –  Insert assembly cartridge with knurled spacer ring in guide plate. –  Press down pressure fork and pull knurled screw upwards while turning screw in both directions. l  This will insert the valve cotters. –  Release the pressure fork with knurled screw still in pulled position. –  Repeat procedure for each valve. Installation is carried out in the reverse order; note the following: –  Install camshafts → Chapter.