Audi Workshop Service and Repair Manuals

Renewing valve stem oil seals with cylinder head installed

Special tools and workshop equipment required

t	Puller -3047 A-

t	Fitting tool -3129-

t	U/J extension and socket, 10 mm -3220-

t	Removal and installation device for valve cotters -VAS 5161-

Procedure Different types of glow plugs can be installed in 4-cylinder 2-valve TDI engines in Audi A4 vehicles. Engine codes AVB, AVF, AWX, BRB: t  These engines are fitted exclusively with metal glow plugs. Engine codes BKE, BPW, BRC: t  These engines can be fitted with either metal or ceramic glow plugs. A -  Bosch ceramic glow plugs are colour-coded with a “white seal”-arrow- and have a chamfered shoulder (⇒ detail view) at the tip. A -  NGK ceramic glow plugs are colour-coded with a “white seal (on some versions painted over in silver)”-arrow- but do not have a chamfered shoulder at the tip. B -  Metal glow plugs are colour-coded with a “red seal”-arrow-.   Caution Important: Always observe the special instructions for handling ceramic glow plugs. The metal glow plugs do not require any special handling procedures. Vehicles with ceramic glow plugs:   Caution t  Due to the special properties of the material used, ceramic glow plugs are easily damaged and require extra care when handling and removing/installing. Always observe the special instructions when removing and installing ceramic glow plugs → Rep. Gr.28. t  Transport and store only in original packaging or packed separately in bubble wrap. t  Do not remove new ceramic glow plugs from packaging until they are ready to be fitted. t  Ceramic glow plugs are sensitive to knocks and bending. For this reason, ceramic glow plugs which have been dropped (even from a height of only about 2 cm) must not be installed, even if no damage is apparent (hair-line cracks may not be visible). t  Always install a new ceramic glow plug if you are not sure the old one is in perfect condition. t  Damaged glow plugs (e.g. heater pin of the glow plug is damaged) will invariably cause engine damage. t  If the heater pin of the glow plug is damaged, the fragments must be removed from the combustion chamber before starting the engine for the first time, otherwise this will invariably cause mechanical damage (piston seizure). t  The software of the engine control unit is programmed specifically for either the ceramic or the metal glow plugs, so it is important to install the correct type. t  Mixed installation of ceramic glow plugs and metal glow plugs on the same engine is not permissible. All vehicles: –  Remove the camshaft → Chapter. –  Remove camshaft bearing shells from cylinder head.   Note t  Make sure that the used camshaft bearing shells are not interchanged (note marking). t  Make sure that the hydraulic bucket tappets are not interchanged; mark allocation on rear with a waterproof felt-tipped pen.

Vehicles with metal glow plugs: –  Unplug electrical connector -2-. –  Loosen bolt -3-.   Note Disregard -item 1-. –  Pull fuel filter upwards out of bracket and lay it aside with fuel hoses connected. –  Detach electrical connectors at glow plugs. –  Unscrew all glow plugs using U/J extension and socket, 10 mm -3220-.

All vehicles: –  Remove bucket tappets out of guides. –  Place bucket tappets down on a clean surface with contact surface facing downwards in the order in which they were removed. –  Insert punch -VAS 5161/3- in bucket tappet guide. –  Knock valve cotters loose on all valves using a plastic hammer. –  Set piston of the respective cylinder to “bottom dead centre”.

–  Screw adapter -VAS 5161/11- hand-tight into the glow plug thread of the relevant cylinder. –  Screw snap-in device -VAS 5161/6- with interlocking fork (M6) -VAS 5161/5- into threaded hole on cylinder head. –  Push guide bush -VAS 5161/16- as far as it will go into bucket tappet guide on valve to be removed. l  Installation position of guide bush: hatched areas are perpendicular to driving direction. –  Insert assembly cartridge -VAS 5161/15- into guide bush. –  Connect adapter -VAS 5161/11- to compressed air supply using a commercially available connection piece. l  Air pressure: at least 6 bar –  Attach pressure fork -VAS 5161/2- to snap-in device -VAS 5161/6- and push assembly cartridge downwards. –  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 the pressure fork. –  Remove assembly cartridge and guide bush. –  Remove valve spring plate and valve springs.

–  Detach valve stem oil seals using puller -3047 A-.   Note

A plastic sleeve -A- is included with the new valve stem oil seals. –  Insert 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 down onto valve guide using fitting tool -3129-. –  Remove the plastic sleeve.

–  If valve cotters had been removed from assembly cartridge they must first be inserted in insertion device -VAS 5161/18-.   Note Larger diameter of valve cotters faces upwards. –  Press assembly cartridge onto insertion device from above and take up valve cotters. –  Insert valve springs and valve spring plate.

–  Re-insert assembly cartridge in guide bush -VAS 5161/16-. –  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. –  Repeat procedure for each valve. Assembling Installation is carried out in the reverse order; note the following: –  Insert bucket tappets. –  Install camshaft → Anchor. –  Install glow plugs → Rep. Gr.28.   Note t  After installing the camshaft, the engine must NOT be started for about 30 minutes. The hydraulic tappets 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.