Warning: Exhaust valves for 6-cylinder engines up to 174 hp. filled with sodium to improve heat dissipation. These valves should not be scrapped straight away, as the presence of sodium poses a risk of explosion during remelting. Likewise, these valves must not be used as "special tool", for example, a punch. It is therefore recommended that these valves be taken into the care of an AUDI repair shop. If this is not possible, then the following measures must be taken before scrapping: Saw through the valve stem with a hacksaw and throw both parts into a large tank filled with water. As a result of a rapidly advancing chemical reaction, the sodium filling burns out, while it is necessary to step back and protect the eyes.
Withdrawal
1. Remove the cylinder head.
Warning: If valve actuator parts are reused, they must be reinstalled in their original locations. To avoid rearrangement of parts in places, it is recommended to prepare an appropriate laying board.
2. Remove the camshaft.
3. Poppet pushers mark and pull out.
Warning: Place bucket tappets on a work surface (camshaft side) down.
4. Remove valve springs. In workshops, a special tool is used for this (V.A.G-2037).
5. Crackers, and with them the valves and valve springs, can also be removed using a standard valve spring remover. To do this, the inlet or outlet pipes must first be removed, as the case may be.
6. Compress the valve springs and remove the cotters. Remove the upper valve spring plate and valve springs. Take out the valve.
7. Remove the oil seal.
8. Remove the lower plates of the valve springs - arrow - using the special tool VAG-3047 or HAZET 791-5 / 791-2.
Installation
1. Before installing the valves, check and, if necessary, finish or lap the valve seats.
Warning: New valve spring plates have very sharp edges in places at the bottom edge of the cracker hole. These edges may damage (scratch) valve stems. Replace damaged valves, remove sharp edges from valve springs before installation.
2. Insert the lower valve spring plate.
3. Remove sharp edges from the valve stem contact surface.
4. To improve reliability, be sure to replace the valve stem seals.
5. Lubricate the valve stem lightly and insert the valve.
6. Put on a new oil seal.
Warning: If assembly is carried out without the plastic guide sleeve, the valve stem seals will be damaged! The engine will use a lot of oil.
7. Install the valve springs. If the valve springs are replaced, then both at the same time.
8. Insert the top plate of the valve spring. The upper plates of the valve springs have a wide chamfer on the outside - A - and a chamfer on the inside - B.
9. Compress the valve springs with a valve spring remover and insert the crackers so that they lie in the grooves of the valve stem. Loosen the spring remover and insert the next valve.
10. Check the camshaft end play.
11. Lubricate all bucket tappets with engine oil and, in accordance with the marking, insert into the holes.
12. Install the camshaft.
13. Replace the cylinder head gasket, install the cylinder head.
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