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- with knurled spacer ring -VAS 5161/23-1- and guide plate -VAS 5161/23-

Procedure –  Remove camshafts: cylinder head (left-side) → Chapter, cylinder head (right-side) → Chapter. –  Mark fitting location of roller rocker fingers for re-installation and remove.   Note Audi A4 models with a 2.7 or 3.0 ltr. TDI engine are always equipped with steel glow plugs. –  Remove all glow plugs using U/J extension and socket, 10 mm -3220-. –  Fit guide plate -VAS 5161/23- onto cylinder head. –  Secure guide plate using knurled screws -VAS 5161/12-. –  Insert punch -VAS 5161/3- into guide plate and knock sticking valve cotters loose using a plastic hammer.

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

–  Screw snap-in device -VAS 5161/6- with engaging fork -VAS 5161/5- into guide plate. –  Slide knurled spacer ring -VAS 5161/23-1- onto assembly cartridge -VAS 5161/8-. –  Connect adapter to compressed air line using a commercially available connection piece, and apply constant air pressure. l  Minimum pressure: 6 bar –  Hook pressure fork -VAS 5161/2- into snap-in device and press 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 assembly cartridge. –  Release pressure fork. –  Take off assembly cartridge with knurled spacer ring. –  Remove valve spring plate and valve spring.

–  Remove valve stem oil seals using the valve stem seal puller -3364-.

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

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

A plastic sleeve -A- is included with the new valve stem oil seals. –  Fit 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 onto valve guide using valve stem seal fitting tool -3365-. –  Remove plastic sleeve.

–  If valve cotters have been removed from assembly cartridge -VAS 5161/8-, they need to be put into insertion device for valve cotters -VAS 5161/18- first.   Note Larger diameter of valve cotters faces upwards. –  Insert valve spring and valve spring plate. –  Press assembly cartridge onto insertion device from above and take up valve cotters.

–  Re-insert assembly cartridge into guide plate -VAS 5161/23-. –  Push pressure fork down and pull knurled screw upwards while turning screw in both directions - this will insert the valve cotters. –  Release pressure fork with knurled screw still in pulled position. Installation is carried out in the reverse order; note the following: –  Install glow plugs → Rep. gr.28. –  Install camshafts: cylinder head (left-side) → Chapter, cylinder head (right-side) → Chapter.   Note t  Audi A4 models with a 2.7 or 3.0 ltr. TDI engine are always equipped with steel glow plugs. t  Engine is not to be rotated for approx. 30 minutes after installing camshafts. 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.