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-

t	Guide plate for 2.0 ltr. TDI engine -VAS 5161/21-

Procedure –  Remove camshafts → Chapter. –  Remove unit injectors → Rep. Gr.23.

–  Set piston of the respective cylinder to “bottom dead centre”. –  Fit guide plate -VAS 5161/21-1- onto cylinder head. –  Secure guide plate using the knurled screws -VAS 5161/21-4-. –  Insert drift -VAS 5161/3- into guide plate and knock valve cotters loose using a plastic hammer.

–  Screw adapter -VAS 5161/21-2- finger-tight into guide plate. –  Secure snap-in device -VAS 5161/6- with engaging forks -VAS 5161/5- to cylinder head. –  Slide knurled spacer ring -VAS 5161/21-5- onto assembly cartridge -VAS 5161/8-. –  Insert assembly cartridge into guide plate. –  With cylinder head installed, connect the adapter -VAS 5161/21-2- to compressed air line using a commercially available connection piece, and apply constant air pressure. l  Air pressure: at least 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 the pressure fork. –  Take out assembly cartridge with knurled spacer ring, valve spring plate and valve spring.

–  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. –  Fit 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 plastic sleeve.

–  If valve cotters have been removed from assembly cartridge -VAS 5161/8-, they need to be put into insertion device for valve cotters -VAS 5161/18- first.   Note Larger diameter of valve cotters faces upwards. –  Press assembly cartridge onto insertion device from above and take up valve cotters.

–  Insert assembly cartridge into guide plate. –  Press down pressure fork and pull up knurled screw, thus inserting 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: –  Install unit injectors → Rep. Gr.23. –  Install camshafts → Chapter.   Note t  Engine is not to be rotated for approx. 30 minutes after installing camshafts. Hydraulic valve compensation elements have to settle (otherwise valves will strike pistons). t  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.