Audi Workshop Service and Repair Manuals

Renewing valve stem oil seals with cylinder head installed

Special tools and workshop equipment required

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

t	Valve stem seal puller -3364-

t	Valve stem seal fitting tool -3365-

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

Removing –  On vehicles with auxiliary/additional heater, remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Open quick-release fasteners -1 … 3- and take off front and rear noise insulation. –  Remove front bumper cover → General body repairs, exterior; Rep. Gr.63. –  Move lock carrier into its service position → General body repairs, exterior; Rep. Gr.50. –  Detach toothed belt from camshaft sprockets → Chapter. –  Remove camshafts → Chapter. –  Remove roller rocker fingers. –  Detach electrical connectors at glow plugs. –  Unscrew all glow plugs using U/J extension and socket, 10 mm -3220-.

–  Fit guide plate -VAS 5161/9- onto cylinder head. –  Secure guide plate onto cylinder head using knurled screws -VAS 5161/12-. –  Insert punch -VAS 5161/3- into guide plate. –  Use plastic-headed hammer to release locked valve cotters on all four valves.

–  Screw sealing pin -VAS 5161/10- into guide plate. –  Screw adapter -VAS 5161/11- finger-tight into the glow plug hole of the relevant cylinder.

–  Screw snap-in device -VAS 5161/6- with -VAS 5161/5- into guide plate -VAS 5161/9-. –  Slide knurled spacer ring -VAS 5161/17- onto assembly cartridge -VAS 5161/8-. –  Connect adapter -VAS 5161/11- to compressed air supply using a standard connection fitting. l  Air pressure: at least 6 bar –  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 the pressure fork. –  Remove valve spring and valve spring plate (magnet).

–  Pull off valve stem oil seal with valve stem seal puller -3364-.

If the valve stem seal puller -3364- cannot be used on some of the valve stem oil seals due to the confined space, proceed as follows: –  Knock out pin -arrow- from valve stem seal puller -3364- using a punch and remove the extractor attachment.

–  Apply lower part of valve stem seal puller -3364- to valve stem oil seal. –  Secure puller with a punch -1- or other suitable tool as shown in the illustration. –  Apply assembly lever to puller and pull out valve stem oil seal -arrow-.

Installing   Note A plastic sleeve -A- is included with the new valve stem oil seals. –  To prevent damage to the new valve stem seals -B-, attach plastic sleeve -A- to valve stem.   Note The illustration is a schematic diagram of the procedure; other tools are not shown. –  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 the 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-insert assembly cartridge into guide plate -VAS 5161/9-. –  Push pressure fork down 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. –  Install camshafts → Chapter. –  Install glow plugs → Rep. Gr.28. –  Install toothed belt (adjust valve timing) → Anchor. –  Install viscous fan → Chapter. –  Install lock carrier with attachments → General body repairs, exterior; Rep. Gr.50. –  Install front bumper cover → General body repairs, exterior; Rep. Gr.63.   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.