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- with guide plate for 2.0 ltr. and 3.0 ltr. FSI engine -VAS 5161/19B-

t	Adapter -T40012-

Procedure –  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 and extension -3122 B-. –  Set piston of appropriate cylinder to „bottom dead centre“.

–  Apply drift -VAS 5161/3- to valve spring plate and use plastic-headed hammer to release sticking valve cotters.

–  Fit guide plate for 2.0 ltr. and 3.0 ltr. FSI engine -VAS 5161/19B- onto cylinder head. –  Secure guide plate with knurled screws -VAS 5161/12-. –  Screw adapter -T40012- with seal hand-tight into the corresponding spark plug thread. –  Connect adapter to compressed air line using a commercially available connection piece, and apply constant air pressure. l  Minimum pressure: 6 bar

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

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

If the 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- of puller using a drift and remove impact extractor attachment.

–  Apply bottom section of puller -3364- to valve stem oil seal. –  Secure puller with a punch or roll-pin drift -1-, as shown in illustration. –  Apply assembly lever to puller and pull out valve stem oil seal -arrow-.

Caution Make sure valve stem oil seals are not damaged when installing. New valve stem oil seals -B- are supplied with plastic sleeve; fit plastic sleeve -A- onto valve stem. –  Lightly oil sealing lip of valve stem oil seal. –  Slide valve stem oil seal onto plastic sleeve. –  Carefully press valve stem oil seal onto valve guide using valve stem seal fitting tool -3365-. –  Take off plastic sleeve.

If valve cotters had been removed from assembly cartridge they must first be inserted in insertion device -VAS 5161/18-. l  Larger diameter of valve cotters faces upwards. –  Press assembly cartridge onto insertion device from above and take up valve cotters. –  Insert valve spring and valve spring plate. l  Installation position of valve spring → Fig..

–  Bolt guide plate for 2.0 ltr. and 3.0 ltr. FSI engine -VAS 5161/19B- onto cylinder head once again. –  Insert assembly cartridge in guide plate. –  Press down pressure fork 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. –  Repeat procedure for each valve. Assembling Installation is carried out in the reverse order; note the following: –  Ensure that all roller rocker fingers make contact with the ends of the valve stems correctly and are clipped onto their respective hydraulic compensation elements. –  Install spark plugs → Booklet811, → Booklet812 or → Booklet818. –  Install camshafts → Chapter.   Caution Avoid damage to valves and piston crowns after working on valve gear. t  The hydraulic tappets have to settle; wait for approx. 30 minutes after installing camshafts before starting engine. t  Turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.