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	Removal / installing device for valve cotters -VAS 5161- with guide plate for 2.0 ltr. FSI engine -VAS 5161/19-

t	Adapter -T40012-

Procedure l  Cylinder head installed. –  Remove camshafts → Chapter. –  Remove roller rocker fingers and place onto a clean surface. When doing so, make sure that roller rocker fingers are not interchanged. –  Remove spark plugs with spark plug socket -3122 B-.

–  Fit guide plate -VAS 5161/19- from removal / installing device for valve cotters -VAS 5161- on cylinder head. –  Secure guide plate using the knurled screws -VAS 5161/12-. –  Set piston of the respective cylinder to “bottom dead centre”.

–  Screw adapter -T40012- into spark plug hole and connect to compressed air supply. l  Minimum pressure: 6 bar. –  Insert drift -VAS 5161/3- into guide plate 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. –  Insert assembly cartridge -VAS 5161/8- into guide plate. –  Attach pressure fork -VAS 5161/2- to snap-in device -VAS 5161/6- 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. 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

t  A plastic sleeve -A- is included with the new valve stem oil seals. t  Sealing sleeves are fitted on the valve guides sleeves on certain engine versions. t  If fitted, these sealing sleeves must not be removed → Item. Also, do not remove sealant in sleeves. –  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 the 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. –  Press assembly cartridge -VAS 5161/8- onto insertion device from above and pick up valve cotters. –  Install valve spring and valve spring plate.

–  Screw guide plate back onto cylinder head. –  Screw snap-in device -VAS 5161/6- with engaging fork -VAS 5161/5- into guide plate. –  Re-insert assembly cartridge -VAS 5161/8- into guide plate. –  Attach pressure fork -VAS 5161/2- to snap-in device -VAS 5161/6-. –  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. –  Detach guide plate -VAS 5161/19- from removal / installing device for valve cotters -VAS 5161- from cylinder head. –  Ensure that all roller rocker fingers contact the ends of the valve stems correctly and are clipped onto their respective supporting elements. –  Install camshafts → Anchor. –  Install spark plugs → Rep. Gr.28.   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.