4.2L V8 4V Engine Mechanical, Engine Code(s): Bvj: Adjustments Audi A8 D3 facelift 2

Support elements with hydraulic adjustment, checking

Note. The support elements with hydraulic adjustment cannot be serviced. Irregular valve noises are normal while starting the engine.

Special tools, testers and auxiliary items required

1. Socket T40058
2. Feeler gauge

Work procedure

1. Start engine and allow it to run until coolant fan has switched on once.
2. Increase RPM to approx. 2500 for 2 minutes and perform road test if necessary.

Note. If irregular valve noises disappear but return during short drives, oil check valve must be replaced. Oil check valve location --> Oil check valve and spray nozzle valve, assembly overview . If support elements with hydraulic adjustment are still loud, locate faulty support element as follows: Remove cylinder head cover: Left --> Left cylinder head cover, removing and installing , right --> Right cylinder head cover, removing and installing .

1. Insert guide pin of socket T40058 so that large diameter - arrow 1 - points to engine. Small diameter - arrow 2 - points to adapter.

1. Rotate crankshaft until cam lobes on support element to be checked point upward.

Scheme 33

1. To determine play between cam lobes and roller rocker lever, press lever down - arrow -.
2. If a 0.20 mm feeler gauge can slide between cam lobes and roller rocker lever, replace support element --> «Camshafts, removing and installing»(ref-289203-S17414273002008062700000) .

Final procedures

1. Install cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(ref-289203-S30024037292008062700000) , right --> «Right cylinder head cover, removing and installing»(ref-289203-S09330649892008062700000) .

Scheme 34

Special tools, testers and auxiliary items required

1. Spark plug removal tool 3122 B
2. Valve seal removal tool 3364
3. Valve stem seal driver 3365
4. Valve cotter disassembly and assembly device VAS 5161

1. Adapter T40012

Removing

1. Remove camshaft timing chains from camshafts --> «Camshaft timing chains, removing from camshafts»(ref-289203-S36890785792008062700000) .
2. Remove camshafts --> «Camshafts, removing and installing»(ref-289203-S17414273002008062700000) .
3. Using spark plug removal tool 3122 B , remove spark plugs.

Scheme 35

1. Place drift VAS 5161/3 on valve spring plate and loosen stuck valve keepers using a plastic hammer.

Scheme 36

1. Place guide plate VAS 5161/19A from Valve Cotters Asm/Dis-Asm Device VAS 5161 on cylinder head.
2. Secure guide plate with knurled screws VAS 5161/12.
3. Install adapter T40012 with gasket by hand into respective spark plug thread and apply constant pressure.

1. Minimum pressure: 6 bar positive pressure.

Scheme 37

1. Secure engaging device VAS 5161/6 with installation fork VAS 5161/5 to guide plate.
2. Push installation cartridge VAS 5161/8 into guide plate.
3. Engage pressure fork VAS 5161/2 at engaging device and press down installation cartridge.
4. At the same time, turn knurled bolt of installation cartridge to the right, until the points engage in the valve keepers.

1. Lightly move knurled bolt back and forth, causing the valve keepers to be pressed apart and be captured in the installation cartridge.
2. Release pressure fork.
3. Take out installation cartridge.
4. Unfasten guide plate and turn it aside.

1. Pressurized air hose remains connected.

1. Remove valve spring with valve spring plate.

Scheme 38

1. Remove valve stem seal with Valve Seal Removal Tool 3364.

If Valve Seal Removal Tool 3364 cannot be used on some valve stem seals due to restricted clearance, proceed as follows

Scheme 39

1. Using a drift, drive out roll pin - arrow - at puller with a drift and remove the impact puller attachment.
2. Place lower part of puller on valve stem seal.

Scheme 40

1. Secure puller with a drift or cotter pin driver - 1 - , as shown in illustration.
2. Place lever on puller and pull off valve stem seal - arrow -.

Installing

1. Lightly coat sealing lips of valve stem seal with oil.
2. Push valve stem seal onto plastic sleeve.

Scheme 41

1. Carefully press valve stem oil seal onto valve guide using valve stem seal driver 3365.
2. Remove plastic sleeve again.

Scheme 42

If valve keepers were removed from installation cartridge, they must then be inserted into insertion device VAS 5161/18.

1. The large diameter of valve keepers point upward.

1. Install valve spring and valve spring plate.

1. The tight spring coils - arrow - face toward cylinder head.

1. Install guide plate onto cylinder head again.
2. Insert installation cartridge into guide plate.
3. Press down pressure fork and pull knurled bolt upward turning to left and right, valve keepers are inserted in this manner.
4. Release pressure fork with knurled bolt still pulled.

1. Ensure that all roller rocker levers seat properly on valve stem ends and are clipped onto respective support elements.
2. Install sparks plugs 404.
3. Install camshafts --> «Camshafts, removing and installing»(ref-289203-S17414273002008062700000) .
4. Position camshaft timing chains on camshafts --> «Installing»(ref-289203-S13580597632009012200000) .

1. Install left and right timing chain covers --> «Installing»(ref-289203-S13492937052009012200000) .
2. Install cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(ref-289203-S30024037292008062700000) , right --> «Right cylinder head cover, removing and installing»(ref-289203-S09330649892008062700000) .

Scheme 43

Note. Intake and exhaust valves must not be refaced by grinding. Only lapping is permitted.