Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Puller 3047 A
• ◆ Pressing-on tool 3129
• ◆ Jointed spanner 3220
• ◆ Dismantling and assembly tool kit VAS 5161

Removing

• ● Cylinder head fitted

Note:

With the cylinder head removed, the valve stem seals can be replaced using special tool 2037.

• ‒ Remove camshaft => Page 15-61.
• ‒ Take camshaft bearing shells out of cylinder head.

Notes:

• ◆ Take care not to interchange camshaft bearing shells.
• ◆ Use waterproof felt-tip pen to mark assignment of camshaft bearing shells on back.

• ‒ → Unplug connector -2-.
• ‒ Screw out bolt -3-.
• ‒ Lift fuel filter out of holder and place aside together with connected fuel hoses.

• ‒ → Unbolt fuel filter holder -arrows-.

Notes:

• ◆ Take care not to interchange bucket tappets.
• ◆ Use waterproof felt-tip pen to mark assignment of bucket tappets on back.

• ‒ Take bucket tappets out of guides and set them down with bearing surface facing downwards.

• ‒ → Insert tool VAS 5161/3 in bucket tappet guide.
• ‒ Release the sticking valve keys from all valves by hitting them with a plastic hammer.
• ‒ Disconnect connectors from glow plugs.
• ‒ Remove all glow plugs with jointed spanner 3220.

• ‒ → Screw adapter VAS 5161/11 hand-tight into respective glow plug thread.
• ‒ Screw locking element VAS 5161/6 with locking fork (M6) VAS 5161/5 into a tapped hole on cylinder head.
• ‒ Push guide bush VAS 5161/16 all the way into bucket tappet guide on valve being removed.
• ‒ Installation position: Ribbed surfaces are oriented transverse to direction of travel
• ‒ Slot assembly cartridge VAS 5161/15 into guide bush.

• ‒ → Connect adapter VAS 5161/11 to compressed air port by a standard commercially available intermediate section.
• ‒ Minimum pressure: 6 bar
• ‒ Engage VAS 5161/2 at VAS 5161/6 and press down assembly cartridge.
• ‒ At the same time, turn knurled screw of assembly cartridge clockwise until ends engage in valve keys.
• ‒ Move knurled screw back and forth slightly; valve keys are thus forced apart and enter into cartridge.
• ‒ Release VAS 5161/2.
• ‒ Take out assembly cartridge, guide bush, valve disk and valve springs.
• ‒ Detach valve stem seals with 3047 A.

Installing

Note:

A plastic sleeve -A- is included with the new valve stem seals.

• ‒ → So as not to damage new valve stem seals -B-, attach plastic sleeve -A- to valve stem.
• ‒ Lubricate sealing lip of valve stem seal slightly.
• ‒ Slip valve stem seal over plastic sleeve.
• ‒ Press valve stem seal carefully onto valve guide using press-on tool 3129.
• ‒ Detach plastic sleeve again.

• ‒ → If valve keys are removed from assembly cartridge, they must first be placed in insertion tool VAS 5161/18.

Note:

Large valve key diameter faces upwards.

• ‒ Press assembly cartridge VAS 5161/15 from above onto insertion tool and insert into valve keys.

• ‒ → Re-insert assembly cartridge VAS 5161/15 into guide bush VAS 5161/16.
• ‒ Press down tool VAS 5161/2 and pull up knurled screw by twisting it in both directions, thus inserting the valve keys.
• ‒ Release tool VAS 5161/2 with knurled screw still pulled.

• ‒ Insert bucket tappets.
• ‒ Fit camshaft => Page 15-64.

Notes:

• ◆ Engine is not to be started for approx. 30 minutes after installing camshaft, so as to allow hydraulic valve lifters to settle (valves would otherwise strike piston).
• ◆ After working on valve gear, carefully crank engine through at least 2 revolutions to ensure that no valves make contact on starting.

Tightening torques