Audi Workshop Service and Repair Manuals

Renewing valve stem oil seals

Special tools and workshop equipment required

t	Pressure hose -VW 653/3-

t	Spark plug socket and extension -3122 B-

t	Valve shaft seal puller -3364-

t	Press tool for valve stem oil seal -3365-

t	Assembly and removal device for valve cotters -VAS 5161- with guide plate for 1.6 ltr. 2-valve engine -VAS 5161/20- and knurled spacer ring (height: 8.4 mm) -VAS 5161/21-5-

t  Spark plug connector pliers -V.A.G 1922- Procedure –  Remove the camshaft → Chapter.   Note Use waterproof felt-tip pen to mark the assignment of the roller rocker fingers. –  Remove roller rocker fingers and place onto a clean surface. When doing so, make sure that roller rocker fingers are not interchanged. –  Detach spark plug connectors using spark plug connector pliers -V.A.G 1922-. –  Remove spark plugs with spark plug socket -3122 B-. –  Set piston of the respective cylinder to “bottom dead centre”.

–  Fit guide plate -VAS 5161/20- onto cylinder head. l  Inscription “OBEN” (TOP) faces upwards. –  Secure guide plate with two nuts -arrows-. –  Screw pressure hose -VW 653/3- into spark plug hole and connect to compressed air supply. l  Air pressure: at least 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. –  Slide knurled spacer ring (height 8.4 mm) -VAS 5161/21-5- onto assembly cartridge -VAS 5161/8-. –  Attach pressure fork -VAS 5161/2- to snap-in device and push assembly cartridge down. –  At the same time, turn knurled screw of assembly cartridge clockwise until ends 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. –  Take out assembly cartridge with knurled spacer ring, valve head and valve spring.

–  Remove valve stem oil seals using the puller for valve stem oil seals -3364-.   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 the valve stem oil seal onto valve guide using press tool for valve stem oil seal -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.   Note Larger diameter of valve cotters faces upwards. –  Press assembly cartridge onto insertion device from above and take up valve cotters.

–  Re-insert assembly cartridge with knurled spacer ring (height: 8.4 mm) into guide plate. –  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. –  Insert bucket tappets. Installation is carried out in the reverse order; note the following: –  Install the camshaft → Chapter.   Note t  After installing the camshaft, wait for about 30 minutes before starting the 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. Tightening torque

Component	Nm
Spark plugs in cylinder head	30