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 / installing device for valve cotters -VAS 5161- with guide plate -VAS 5161/25-

t	Engine and gearbox support -VAS 6095-

t	Cylinder head tensioning device -VAS 6419-

Special tools and workshop equipment required t  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.

–  Attach tensioning device -VAS 6419- to engine and gearbox support -VAS 6095-. –  Secure cylinder head in tensioning device -VAS 6419- as illustrated. –  Connect compressed air line to tensioning device -VAS 6419-. –  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.

–  Apply drift -VAS 5161/3- to valve spring plate and knock valve cotters loose using a plastic hammer.

–  Fit guide plate -VAS 5161/25- from removal / installing device for valve cotters -VAS 5161- on cylinder head. –  Secure guide plate with one nut -1-.

Procedure for rear row of valves: –  Screw snap-in device -VAS 5161/6- with engaging fork -VAS 5161/5- into guide plate. –  Insert assembly cartridge -VAS 5161/8- into 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 the pressure fork. –  Remove assembly cartridge. –  Detach guide plate and turn to one side. –  Remove valve spring with valve spring plate.

Procedure for front row of valves: –  Screw snap-in device -VAS 5161/6- with engaging fork -VAS 5161/5- onto cylinder head. –  Slide knurled spacer ring -VAS 5161/17- onto assembly cartridge -VAS 5161/8-. –  Insert assembly cartridge into 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 the pressure fork. –  Remove assembly cartridge. –  Detach guide plate and turn to one side. –  Remove valve spring with valve spring plate.

Continuation for both rows of valves: –  Remove valve stem oil seals using the valve stem seal puller -3364-.   Note t  To press on the green-coloured valve stem seals (as currently supplied), the valve stem oil seal fitting tool -3365- must be drilled out to Ø 10.5 mm. t  Mark the drilled-out fitting tool so it can be used again later.

t  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 the valve stem oil seal onto valve guide using fitting tool -3365-. –  Remove plastic sleeve.

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

–  Install valve spring and valve spring plate. Position of valve spring: l  The larger diameter -arrow- faces the cylinder head.

Procedure for rear row of valves: –  Bolt guide plate onto cylinder head again, as shown in the illustration. –  Insert assembly cartridge into guide plate. –  Push pressure fork down 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.

Procedure for front row of valves: –  Insert assembly cartridge with knurled spacer ring into guide plate. –  Push pressure fork down 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. –  Install camshafts → Anchor. –  Install spark plugs → Booklet808.   Note t  After installing camshafts, wait for approx. 30 minutes before starting engine. 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.