Audi Workshop Service and Repair Manuals

Renewing valve stem oil seals with cylinder head installed

Special tools and workshop equipment required

t	Spark plug socket and extension -3122 B-

t	Valve stem seal puller -3364-

t	Valve stem seal fitting tool -3365-

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

t	Adapter -T40012-

Removing l  Engine removed and in position on scissor-type assembly platform -VAS 6131 A- with gearbox attached. –  Remove camshafts → Chapter. –  Mark original positions of roller rocker fingers and hydraulic compensation elements for reinstallation. –  Remove roller rocker fingers together with hydraulic compensation elements and put down on a clean surface. –  Remove spark plugs with spark plug socket -3122 B-.

–  Apply drift -VAS 5161/3- to valve spring plate and knock valve cotters loose using a plastic hammer.

–  Fit guide plate -VAS 5161/19B- onto cylinder head. –  Secure guide plate using the knurled screws -VAS 5161/12-. –  Screw adapter -T40012- with seal hand-tight into the corresponding spark plug thread and apply a steady pressure. l  Air pressure: at least 6 bar

–  Screw snap-in device -VAS 5161/6- with engaging fork -VAS 5161/5- into guide plate. –  Insert assembly cartridge -VAS 5161/8- into guide plate. –  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 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 the pressure fork. –  Remove assembly cartridge. –  Detach guide plate and turn to one side. l  The compressed air hose remains connected. –  Remove valve spring with valve spring plate.

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

–  Install valve spring and valve spring plate. l  The closely spaced spring coils -arrow- face the cylinder head.

–  Screw guide plate back onto cylinder head. –  Insert assembly cartridge 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. –  Repeat procedure for each valve. Assembling Installation is carried out in the reverse order; note the following: –  Ensure that all roller rocker fingers contact the ends of the valve stems correctly and are clipped onto their respective hydraulic compensation elements. –  Install camshafts → Chapter. –  Install spark plugs → Booklet803 or → Booklet805.   Note 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.