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-

Procedure –  Remove camshafts and camshaft adjuster → Chapter. –  Mark allocation of bucket tappets for re-installation. –  Remove the bucket tappets from the guides and put them down with the contact surface downwards.

–  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 seal is 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 use plastic-headed hammer to release sticking valve cotters.

Exhaust side: –  Screw snap-in device -VAS 5161/6- with engaging fork -VAS 5161/4- onto stud on cylinder head. –  Push guide bush -VAS 5161/14- as far as it will go into bucket tappet guide on 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 in 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 assembly cartridge. –  Release pressure fork. –  Take off assembly cartridge with knurled spacer ring. –  Remove guide bush, valve spring plate and valve spring.

Inlet side: –  Screw snap-in device -VAS 5161/6- with engaging fork -VAS 5161/4- onto stud on cylinder head. –  Push guide bush -VAS 5161/13- as far as it will go into bucket tappet guide on 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 in 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 assembly cartridge. –  Release pressure fork. –  Take off assembly cartridge with knurled spacer ring. –  Remove guide bush, valve spring plate and valve spring.

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

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. –  Lightly oil sealing lip of valve stem oil seal. –  Slide valve stem oil seal onto 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 for valve cotters -VAS 5161/18- first. l  Larger diameter of valve cotters faces upwards. –  Press assembly cartridge -VAS 5161/8- onto insertion device from above and take up valve cotters.

–  Insert assembly cartridge in guide bush -VAS 5161/13- or -VAS 5161/14-. –  Press down pressure fork 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. –  Repeat procedure for each valve. Assembling Installation is carried out in the reverse order; note the following: –  Install bucket tappets. –  Install camshafts and camshaft adjuster → Chapter.