Audi Workshop Service and Repair Manuals

Renewing valve stem oil seals

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 / installing device for valve cotters -VAS 5161-

t	Adapter -T40012-

Procedure –  Remove engine: Vehicles with manual gearbox → Chapter; vehicles with automatic gearbox → Chapter. –  Remove timing chains from camshafts → Chapter. –  Remove camshafts → Chapter. –  Remove spark plugs with spark plug socket -3122 B-.

–  Rotate roller rocker fingers upwards and secure them with a rubber band.

–  Fit guide plate -VAS 5161/7- from removal / installing device for valve cotters -VAS 5161- on cylinder head. –  Secure guide plate -VAS 5161/7- using the knurled screws -VAS 5161/12-.   Note If you cannot screw on the guide plate, drill out securing holes approx. 0.5 mm. –  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 forks -VAS 5161/5- into guide plate -VAS 5161/7-. –  Insert assembly cartridge -VAS 5161/8- into guide plate -VAS 5161/7-. –  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 –  Attach pressure fork -VAS 5161/2- to snap-in device -VAS 5161/6- and push assembly cartridge -VAS 5161/8- down. –  At the same time, turn knurled screw of assembly cartridge -VAS 5161/8- 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 assembly cartridge -VAS 5161/8-. –  Release the pressure fork -VAS 5161/2-. –  Remove assembly cartridge -VAS 5161/8-. –  Unscrew guide plate -VAS 5161/7-. 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

t  To press on the valve stem seals from the current product range, the valve stem seal fitting tool -3365- must be drilled out to Ø 10.5 mm. t  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 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 -VAS 5161/8-, they need to be put into valve insertion device -VAS 5161/18- first.   Note The large diameter of the valve cotters points upwards. –  Insert valve spring and valve spring plate. –  Screw guide plate -VAS 5161/7- back onto cylinder head.

–  Insert assembly cartridge -VAS 5161/8- into guide plate -VAS 5161/7-. –  Press down pressure fork -VAS 5161/2- and pull up knurled screw, thus inserting the valve cotters. –  Release the pressure fork -VAS 5161/2- with knurled screw still in pulled position. –  Install spark plugs → Booklet803 or → Booklet805. –  Install camshafts → Chapter. –  Install camshaft timing chains → Anchor. –  Install engine: vehicles with manual gearbox → Chapter; vehicles with automatic gearbox → Chapter.   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.