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	Engine and gearbox support -VAS 6095-

t	Cylinder head tensioning device -VAS 6419-

Removing –  Remove camshafts and hydraulic chain tensioner → Chapter.   Note t  Take care not to interchange bucket tappets. t  Use waterproof felt-tip pen to mark assignment of bucket tappets on back of tappets.

–  Take bucket tappets out of guides and set them down with contact surface facing downwards. –  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.

–  Insert punch -VAS 5161/3- into bucket tappet guide. –  Knock valve cotters on all five valves loose using a plastic hammer.   Note Disregard adapter -T40012-.

Inlet side: –  Screw snap-in device -VAS 5161/6- with engaging fork -VAS 5161/5- into cylinder head. –  Push guide bush -VAS 5161/13- as far as it will go into bucket tappet guide for valve to be removed. l  Installation position: knurled surfaces face perpendicular to direction of travel. –  Slide knurled spacer ring -VAS 5161/17- onto assembly cartridge -VAS 5161/8-. –  Insert assembly cartridge into guide bush. –  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 cartridge. –  Release pressure fork. –  Take out assembly cartridge with spacer ring, guide bush, valve spring plate and valve spring.

Exhaust side: –  Screw snap-in device -VAS 5161/6- with engaging fork -VAS 5161/5- into cylinder head. –  Push guide bush -VAS 5161/14- as far as it will go into bucket tappet guide for valve to be removed. l  Installation position: knurled surfaces face perpendicular to direction of travel. –  Slide knurled spacer ring -VAS 5161/17- onto assembly cartridge -VAS 5161/8-. –  Insert assembly cartridge into guide bush. –  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 cartridge. –  Release pressure fork. –  Take out assembly cartridge with spacer ring, guide bush, valve spring plate and valve spring.

Continuation for both sides: –  Pull off valve stem oil seal with valve stem seal puller -3364-.

Installing   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. –  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, 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.

–  Re-fit assembly cartridge -VAS 5161/8- into guide bush -VAS 5161/13- or -VAS 5161/14-. –  Push pressure fork down and pull knurled screw upwards while turning to left and right - this will insert the valve cotters. –  Release pressure fork with knurled screw still in pulled position. –  Insert bucket tappets. –  Install camshafts and hydraulic chain tensioner → Anchor.   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.